Toyota LPG Forklift 8-Series: 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32 Workshop Service Manual
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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) —
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Print one or all pages of your manual
$46.99
- Illustrated Factory Workshop Service Manual for Toyota LPG Forklift 8-Series is an original factory manual for Toyota (BT) Forklift Trucks.
- It contains high-quality images, circuit diagrams, and instructions for operating, maintaining, and repairing the truck.
- All manuals are printable, contain searchable text, and navigation bookmarks.
- Language: English
- These manuals are useful for both professional mechanics and DIY enthusiasts.
- It covers models: 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32.
- The manual is divided into sections with a total of 1907 pages.
- Sections include: General, Engine-Chassis, Repair, Transmission, 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, SST List, Multifunction Display DX, Electrical System Troubleshooting, Wiring Diagram E, and Service Information Bulletins SIB.
This manual provides detailed information on various aspects including operational tips, hoisting the vehicle, engine exterior view, engine performance curves, fuel system, cooling system, ignition system, transmission, differential, steering, brake, material handling system, mast, cylinder, oil pump, oil control valve, mini lever-joystick, SAS/OPS, SST list, multifunction display DX, electrical system troubleshooting, and wiring diagram E.
