Toyota 8FGCU25 Forklift Service & Repair Manual

PRINTED IN USA Pub. No. CU066 Pub. No. CU066 Pub. No. CU066 8FGU 15, 18, 20, 25, 30, 32 8FDU 15, 18, 20, 25, 30, 32 8FGCU 20, 25, 30, 32 Supplement Supplement 8FGCU 20-32 8FGU/8FDU 15-32

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 8FGU/ 8FDU15~32 series and 8FGCU20~32 series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. For the portion not covered herein, please refer to the repair manuals shown below. This manual deals with the above models as of April 2010. 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. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 8FGU/8FDU15~32, 8FGCU20~32 REPAIR MANUAL VOL.1/VOL.2 (No. CU052/CU053) TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE REPAIR MANUAL (No. CE663) TOYOTA INDUSTRIAL EQUIPMENT 1DZ-III ENGINE REPAIR MANUAL (No. CE670) TOYOTA INDUSTRIAL EQUIPMENT LPG DEVICE for 4Y-E ENGINE REPAIR MANUAL (No. CU666-1) PARTS & SERVICE NEWS (REF No. EN-8002)

NAME SECTION SECTION INDEX GENERAL 0 ENGINE 1 FRONT AXLE 2 MAST 3 CYLINDER 4 OTHER MODIFICATIONS 5 SST LIST·SERVICE STANDARDS LIST 6 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 VEHICLE MODEL................................................... 0-2 FRAME NUMBER................................................... 0-3 COMPONENTS WEIGHT ....................................... 0-4 RECOMMENDED LUBRICANT QUANTITY & TYPES ........................................... 0-5

0-2 0-2 VEHICLE MODEL Pneumatic Tire Models (Pn) (2008.1~) Cushion Tire Models (Cu) (no change) *: USA, CANADA, MEXICO and HAWAII Only Classification Load Capacity Vehicle Model Transmission Type Engine Series Model Pn1 ton series Pn15 3000 lbs 8FGU15 T/C 4Y Gasoline 8FDU15 T/C 1DZ-III Diesel Pn18 3500 lbs 8FGU18 T/C 4Y Gasoline 8FDU18 T/C 1DZ-III Diesel Pn2 ton series Pn20 4000 lbs 8FGU20 T/C 4Y Gasoline 8FDU20 T/C 1DZ-III Diesel Pn25 5000 lbs 8FGU25 T/C 4Y Gasoline 8FDU25 T/C 1DZ-III Diesel Pn3 ton series Pn30 6000 lbs 8FGU30 T/C 4Y Gasoline 8FDU30 T/C 1DZ-III Diesel Pn32 6500 lbs *8FGU32 T/C 4Y Gasoline *8FDU32 T/C 1DZ-III Diesel Classification Load Capacity Vehicle Model Transmission Type Engine Series Model Cu2 ton series Cu20 4000 lbs 8FGCU20 T/C 4Y Gasoline Cu25 5000 lbs 8FGCU25 T/C 4Y Gasoline Cu3 ton series Cu30 6000 lbs 8FGCU30 T/C 4Y Gasoline Cu32 6500 lbs *8FGCU32 T/C 4Y Gasoline

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 FRAME NUMBER Frame No. Punching Position Series Engine Vehicle model Punching format Pneumatic tire 1 ton series 4Y 8FGU15 8FGU18-30011 8FGU18 1DZ-III 8FDU15 8FDU18-30011 8FDU18 2 ton series 4Y 8FGU20 8FGU25-30011 8FGU25 1DZ-III 8FDU20 8FDU25-30011 8FDU25 3 ton series 4Y 8FGU30 8FGU32-30011 8FGU32 1DZ-III 8FDU30 8FDU32-30011 8FDU32 Cushion tire 2 ton series 4Y 8FGCU20 8FGCU25-10011 8FGCU25 10011* 8FGCU25 3 ton series 8FGCU30 8FGCU32-10011 8FGCU32 10011* 8FGCU32 *: EEC spec Punching position

0-4 0-4 COMPONENTS WEIGHT Component Weight kg (lb) Engine 4Y 134 (295) 1DZ-III 182 (401) Transmission T/C (1 speed) 62 (137) T/C (2 stator T/C) 130 (287) Counter weight Pn15 model Approx. 770 (1700) Pn18 model Approx. 905 (1995) Pn20 model Approx. 1170 (2580) Pn25 model Approx. 1510 (3330) Pn30 model Approx. 1860 (4100) Pn32 model Approx. 1985 (4375) Cu20 model Approx. 1095 (2410) Cu25 model Approx. 1485 (3270) Cu30 model Approx. 1900 (4190) Cu32 model Approx. 2085 (4600) V mast ASSY L/backrest and fork (with lift cylinder, max. lifting height: 3300 mm (131 in)) Pn1 ton series Approx. 400 (870) Pn2 ton series Approx. 510 (1120) Pn3 ton series Approx. 580 (1280) Cu2 ton series Approx. 460 (1020) Cu3 ton series Approx. 570 (1260)

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 RECOMMENDED LUBRICANT QUANTITY & TYPES Note: Since the hydraulic oil volume varies with the mast specification, be sure to check finally with the level gauge. Attached Table 1 Coolant volume Unit: l (US gal) Description Application Quantity l (US gal) Classification Type Engine Gasoline 4Y 4.0 (1.06) API SH, SJ, SL, SM Motor oil SAE30 SAE10W-30 Diesel 1DZ-III 7.9 (2.09) API CE, CF, CF-4 Diesel engine oil SAE30 SAE10W-30 Transmission T/C (1 speed) 6.0 (1.58) ATF GM Dexron ® II T/C (2 stator T/C) 10.0 (2.64) Differential Pn1 ton series 5.8 (1.53) API GL-4 Hypoid gear oil SAE85W-90 Pn2 ton series 6.1 (1.61) Cu2·3 ton series 6.1 (1.61) Pn3 ton series 8.2 (2.16) Hydraulic oil (V mast, max. lifting height 3300 mm (131 in)) Pn1 ton series 31 (8.2) ISO VG32 Hydraulic oil Pn2 ton series 35 (9.2) Cu2·3 ton series 33 (8.7) Pn3 ton series 38 (10.0) Fuel tank Pn1 ton series 45 (11.9) —— ———— Cu2·3 ton series 45 (11.9) Pn2·3 ton series 60 (15.8) Brake line All models Proper quantity Reservoir Tank 0.2 (0.05) —— SAE J-1703 DOT-3 Chassis parts All models Proper quantity —— • MP grease • Molybdenum disulfide grease Coolant (excluding reservoir tank) Attached Table 1 Coolant volume LLC • LLC 30-50% mixture (for winter or allseason) • Coolant with rustinhibitor (for spring, summer and autumn) Coolant (Reservoir Tank) All models 0.47 (0.124) (at Full level) ↑ ↑ Engine Pn1 ton series Pn2 ton series Pn3 ton series Cu2·3 ton series 4Y 8.1 (2.14) 9.3 (2.46) 9.3 (2.46) 8.1 (2.14) 1DZ-III 6.8 (1.80) 7.9 (2.09) 7.9 (2.09) —

Toyota 8FGCU25 Forklift Service & Repair Manual

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