Toyota 8FGU 15 Operating instructions

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)
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Foreword.fm 3 ページ ２０１０年３月２３日 火曜日 午後８時１５分

NAME SECTION
SECTION INDEX
GENERAL 0
ENGINE 1
FRONT AXLE 2
MAST 3
CYLINDER 4
OTHER MODIFICATIONS 5
SST LIST·SERVICE STANDARDS LIST 6
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WIRING DIAGRAM E

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GENERAL
Page
VEHICLE MODEL...................................................0-2
FRAME NUMBER...................................................0-3
COMPONENTS WEIGHT .......................................0-4
RECOMMENDED LUBRICANT
QUANTITY & TYPES ...........................................0-5
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0-20-2
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
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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
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0-40-4
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)
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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 ——
•MPgrease
• 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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0-60-6
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ENGINE
Page
ENGINE EXTERIOR VIEW.....................................1-2
ENGINE MAIN PARAMETERS ..............................1-3
ENGINE PERFORMANCE CURVES .....................1-5
ENGINE INSPECTION·ADJUSTMENT..................1-7
1DZ-III ENGINE (2008.1~) .........................................1-7
V-BELT TENSION ADJUSTMENT .........................1-9
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1-21-2
ENGINE EXTERIOR VIEW
1DZ-III Engine (2008.1~)
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ENGINE MAIN PARAMETERS
Gasoline Engine (2010.1~)
Vehicle model
Item
All (STD)
4Y-HIGH POWER (OPT):
8FGU20~32
8FGCU20~32
Engine model 4Y ←
Engine type Gasoline · 4 cycle ←
Number and arrangement of cylinders In-line 4 cylinder,
longitudinally mounted ←
Combustion chamber type Wedge ←
Valve mechanism OHV·chain drive ←
Bore x stroke mm (in) 91.0 × 86.0
(3.583 × 3.386) ←
Total displacement cm3(in3)2237 (136.51) ←
Compression ratio 8.8 ←
Maximum output Gasoline exclusive 38 (51)/2570 44 (59)/2570
kW (PS)/rpm LPG convertible/Gasoline 38 (51)/2570 43 (58)/2570
LPG convertible/LPG 38 (51)/2570 42 (57)/2570
LPG exclusive 38 (51)/2570 42 (57)/2570
Maximum torque Gasoline exclusive 160 (16.3)/2100 165 (16.8)/2570
N·m (kgf·m)/rpm LPG convertible/Gasoline 160 (16.3)/2100 162 (16.5)/2570
LPG convertible/LPG 160 (16.3)/2100 160 (16.3)/2200
LPG exclusive 160 (16.3)/2100 160 (16.3)/2200
Minimum fuel consumption Gasoline exclusive 298 (219)/2000 310 (228)/1600
g/kW·h (g/PS·h)/rpm LPG convertible/Gasoline 298 (219)/2000 310 (228)/1600
LPG convertible/LPG 233 (171)/2000 ←
LPG exclusive 233 (171)/2000 ←
Service weight kg (lb) 135 (298) ←
No-load maximum speed rpm 2570 ←
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1-41-4
Diesel Engine (2008.1~)
Vehicle model
Item 8FDU15·18 8FDU20~32
Engine model 1DZ-III ←
Engine type Diesel · 4 cycle ←
Number and arrangement of cylinders In-line 4 cylinder,
longitudinally mounted ←
Combustion chamber type Whirl chamber ←
Valve mechanism OHV·gear drive ←
Bore x stroke mm (in) 86.0 × 107.0
(3.386 × 4.213) ←
Total displacement cm3(in3)2486 (151.71) ←
Compression ratio 21.5 ←
Maximum output kW (PS)/rpm 38 (52)/2400 41 (55)/2500
Maximum torque N·m (kgf·m)/rpm 157 (16.0)/2300 157 (16.0)/2500
Minimum fuel
conspumption g/kW·h (g/PS·h)/rpm 250 (184)/1400 ←
Service weight kg (lb) 182 (401) ←
No-load maximum speed rpm 2600 2800
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ENGINE PERFORMANCE CURVES
4Y All (STD) (2010.1~)
4Y-HIGH POWER (OPT): 8FGU/8FGCU 20~32 (2010.1~)
Torque
Power
Fuel consumption ratio
Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
Gasoline (Exclusive·Convertible)
Torque
Power
Fuel consumption ratio
Gasoline (Exclusive)
LPG (Exclusive·Convertible)
Gasoline (Convertible with LPG)
Gasoline (Exclusive)
LPG (Exclusive·Convertible)
Gasoline (Convertible with LPG)
LPG (Exclusive·Convertible)
Gasoline (Exclusive·Convertible)
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1-61-6
1DZ-III 8FDU15·18 (2008.1~)
1DZ-III 8FDU20~32 (2008.1~)
Torque
Power
Fuel consumption ratio
Torque
Power
Fuel consumption ratio
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1-7
ENGINE INSPECTION·ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above
1DZ-III ENGINE (2008.1~)
Idle Speed Inspection·Adjustment
1. Install the rev counter.
2. Check the return of the accelerator wire, and also check that
the injection pump idle adjusting screw is in contact with the
accelerator lever.
3. Inspect the idle speed.
Standard 750 ± 30 rpm
4. If the standard is not met, loosen the lock nut and adjust with
the idle adjusting screw.
5. Tighten the lock nut, and inspect the idle speed again.
Rev counter
Idle adjusting screw
Accelerator lever
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1-81-8
No-load Maximum Speed Inspection·Adjustment
1. Install the rev counter.
2. Inspect the no-load maximum speed.
(1) While the engine is at standstill, press down the
accelerator fully, and check that the adjusting lever is
touching the maximum adjusting screw.
(2) Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator pedal is fully
pressed down.
Standard
8FDU15·18: 2600 ± 50 rpm
8FDU20~32: 2800 ± 50 rpm
In the case of vehicles equipped with travel and load handling
control, the rpm tolerance is .
3. Adjust the no-load maximum speed.
Remove the sealing of the maximum adjusting screw, and
adjust by turning it.
4. Inspect the relief down amount.
(1) Operate the tilt lever to fully backward at the maximum
engine speed, and measure the engine speed upon full
relief. Measure the decrease (relief down) in the engine
rpm.
Standard: Within 200 rpm
5. Seal the set screw.
Maximum adjusting screw
Accelerator lever
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1-9
V-BELT TENSION ADJUSTMENT
Note:
• 4Y (2007.1~)
• 1DZ-II (2007.1~2007.12)
• 1DZ-III (2008.1~)
1. Inspect the V-belt tension.
Standard
[amount of delfection when pressed with 98 N (10 kgf)]
New belts
4Y·1DZ-II·1DZ-III: 7~9 mm (0.28~0.35 in)
Belts in use
4Y·1DZ-II·1DZ-III: 8~13 mm (0.31~0.51 in)
Standard
[When using a tension gauge (SST)]
SST 09216-76002-71 (09216-00021)
New belts
4Y: 392~588 N (40~60 kgf) [88~132 lbf]
1DZ-II·1DZ-III:
520~760 N (53~77 kgf) [117~171 lbf]
Belts in use
4Y: 294~490 N (30~50 kgf) [66~110 lbf]
1DZ-II·1DZ-III:
320~560 N (33~57 kgf) [72~126 lbf]
2. V-belt deflection adjustment
4Y engine vehicle
(1) Loosen the fixing bolt.
(2) Loosen the set bolt and turn the adjustment bolt to adjust
the tension.
(3) Tighten the fixing bolt and recheck the belt tension.
Note:
Be careful not to apply excessive tension to the belt.
1DZ-II·1DZ-III engine vehicles
(1) Loosen the fixing bolt and adjusting bolt.
(2) Stretch the V-belt using a pry bar with the length of 300 to
400 mm (11.8 to 15.7 in), and tighten the alternator
adjustment bolt.
(3) Tighten the fixing bolt then recheck the belt tension.
Note:
Adjustment of the tension using a pry bar gives rise to
considerable individual differences, and tends to result in
excessive or insufficent tension. Therefore, be sure to inspect
the deflection amount.
Set bolt
Adjustment bolt
Fixing bolt
Adjustment bolt
Fixing bolt
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