Toyota 8FGU15 Operating instructions

8FGU 15, 18, 20, 25, 30, 32
8FDU 15, 18, 20, 25, 30, 32
62-8FDU 15, 18, 20, 25, 30
8FGCU 20, 25, 30, 32
Pub. No. CE118
Supplement

FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT 8FGU/
8FDU15 to 32 series, 62-8FDU15 to 30 series and 8FGCU20 to 32 series. Please
use this manual for providing quick, correct servicing of the corresponding forklift
models.
This manual deals with the above models as of March 2016. Please understand that
disagreement can take place between the descriptions in the manual and actual vehi-
clesdue to change in design and specifications. Any change or modifications thereaf-
ter will beinformed byToyota 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 8FGU/8FDU15 to 32 series and
8FGCU20 to 32 series REPAIR MANUAL VOL.1/VOL.2 (No. CU052/
CU053)
TOYOTA INDUSTRIAL EQUIPMENT 8FGU/8FDU15 to 32 series and
8FGCU20 to 32 series REPAIR MANUAL Supplement
(No. CU066 and CE106)
TOYOTA INDUSTROAL EQUIPMENT 1ZS ENGINE
REPAIR MANUAL (No.CE304-1)
TOYOTA INDUSTROAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (No.CE663)
TOYOTA INDUSTROAL EQUIPMENT 1DZ-II ENGINE
REPAIR MANUAL (No.CE664)
Foreword.fm 1 ページ ２０１４年３月１２日 水曜日 午後１時３９分

i
Table of Contents
1 GENERAL................................................................................................. 2
2 STEERING ................................................................................................ 5
3 MATERIAL HANDLING SYSTEM .......................................................... 17
4 OIL PUMP ............................................................................................... 22
5 OIL CONTROL VALVE........................................................................... 25
6 SAS/OPS ................................................................................................ 52
7 DISPLAY................................................................................................. 55
8 TROUBLESHOOTING.......................................................................... 152
9 WIRING DIAGRAM............................................................................... 203
10 SST LIST AND SERVICE STANDARDS LIST..................................... 217

1-2 1 GENERAL
1 GENERAL
1.1 VEHICLE MODEL
Pneumatic Tire Models (Pn)
Classification Load Capacity Vehicle Model Transmis-
sion Type Engine
Series Model
Pn1 ton series
Pn15 3000 lbs
8FGU15 T/C 4YE
(4YM) Gasoline
8FDU15 T/C 1ZS Diesel
62-8FDU15 T/C 1DZ-II
Pn18 3500 lbs
8FGU18 T/C 4YE
(4YM) Gasoline
8FDU18 T/C 1ZS Diesel
62-8FDU18 T/C 1DZ-II
Pn2 ton series
Pn20 4000 lbs
8FGU20 T/C 4YE
(4YM) Gasoline
8FDU20 T/C 1ZS Diesel
62-8FDU20 T/C 1DZ-II
Pn25 5000 lbs
8FGU25 T/C 4YE
(4YM) Gasoline
8FDU25 T/C 1ZS Diesel
62-8FDU25 T/C 1DZ-II
Pn3 ton series
Pn30 6000 lbs
8FGU30 T/C 4YE
(4YM) Gasoline
8FDU30 T/C 1ZS Diesel
62-8FDU30 T/C 1DZ-II
Pn32 6500 lbs *8FGU32 T/C 4YE Gasoline
*8FDU32 T/C 1ZS Diesel
Cushion Tire Models (Cu)
Classification Load Capacity Vehicle Model Transmission
Type Engine
Series Model
Cu2 ton series Cu20 4000 lbs 8FGCU20 T/C 4YE Gasoline
Cu25 5000 lbs 8FGCU25 T/C 4YE Gasoline
Cu3 ton series Cu30 6000 lbs 8FGCU30 T/C 4YE Gasoline
Cu32 6500 lbs *8FGCU32 T/C 4YE Gasoline
*: For USA, CANADA, MEXICO and HAWAII Only
4YM: Option for South America
1DZ-II: Standard for South America
T/C: Model with torque converter

1-31 GENERAL
1.2 FRAME NUMBER
Frame No. Punching Position
Punching position
1

1-4 1 GENERAL
Pneumatic tire
Series
Capacity
(L.C.24inch)
lbs.
Engine Vehicle model Punching format
Pn1 ton series
3000 4YE
(4YM)
8FGU15 8FGU18-60011
3500 8FGU18
3000 1ZS 8FDU15 8FDU18-60011
3500 8FDU18
3000 1DZ-II 62-8FDU15 608FDU18-60011
3500 62-8FDU18
Pn2 ton series
4000 4YE
(4YM)
8FGU20 8FGU25-60011
5000 8FGU25
4000 1ZS 8FDU20 8FDU25-60011
5000 8FDU25
4000 1DZ-II 62-8FDU20 608FDU25-60011
5000 62-8FDU25
Pn3 ton series
6000 4YE
(4YM)
8FGU30 8FGU32-60011
6500 8FGU32
6000 1ZS 8FDU30 8FDU32-60011
6500 8FDU32
6000 1DZ-II 62-8FDU30 608FDU30-60011
Cushion tire
Series
Capacity
(L.C.24inch)
lbs.
Engine Vehicle model Punching format
Detail of *
Cu2 ton series
4000
4YE
8FGCU20 8FGCU25-60011
(EEC spec :
8FGCU25*60011)
5000 8FGCU25
Cu3 ton series
6000
4YE
8FGCU30 8FGCU32-60011
(EEC spec :
8FGCU32*60011)
6500 8FGCU32

2-52 STEERING
2 STEERING
2.1 GENERAL
Hydrostatic Steering Valve
1ZS and 4YE engine
A - A
C - C
B - B
D - D
D
A
A
D
B
B
LS
C
C
2

2-6 2 STEERING
4YM and 1DZ engine (W/synchronized steering)
B-B
A
A
B
B
C-C
C
C

2-72 STEERING
4YM engine (L/synchronized steering)
8
3
1. Neutral position spring
2. Housing
3. Check valve
4. Spool
5. Sleeve
6. Cardan shaft
7. Gear rim
8. Gear wheel (rotor)
9. Relief valve
1
Shock valve (No used)
9
2 5 4 67
2

2-8 2 STEERING
2.2 SPECIFICATIONS
Item All models
Steering wheel diameter
mm (in) 300 (11.81)
Steering wheel play (at idling)
mm (in) 20 to 50 (0.79 to 1.97)
Power steering type Hydrostatic steering
Hydrostatic steering valve (L/synchronized steering)
Pn1 ton
series
Pn2 ton
series
Pn3 ton
series
Cu2 ton
series
Cu3 ton
series
Pn1 ton
series
Pn2 ton
series
Pn3 ton
series
1ZS, 4YE 1ZS, 4YE 1ZS, 4YE 4YE 4YE 4YM 4YM 4YM
Manufacturer IHC IHC IHC IHC IHC Sauer
Danfoss
Sauer
Danfoss
Sauer
Danfoss
Delivery
cm3 (in3)/rev
96
(5.86)
105
(6.41)
115
(7.02)
100
(6.10)
100
(6.10)
100
(6.10)
100
(6.10)
115
(7.02)
Rated flow rate
L (US gal)/min -----13.6 (3.59)
13.6
(3.59)
15.8
(4.17)
Relief set pressure
MPa (kgf/cm2) [psi]
7.2 to 7.7
(73.4 to
78.5)
[1044 to
1117]
7.8 to 8.3
(79.5 to
84.6)
[1131 to
1204]
7.8 to 8.3
(79.5 to
84.6)
[1131 to
1204]
6.4 to 6.9
(65.3 to
70.4)
[928 to
1001]
8.2 to 8.7
(83.6 to
88.7)
[1189 to
1262]
6.4 to 6.9
(65.3 to
70.4)
[928 to
1001]
8.2 to 8.7
(83.6 to
88.7)
[1189 to
1262]
8.2 to 8.7
(83.6 to
88.7)
[1189 to
1262]
Hydrostatic steering valve (W/synchronized steering)
Pn1 ton series Pn2 ton series Pn3 ton series
Cu2
ton
series
Cu3
ton
series
4YM 1ZS,
4YE 1DZ-II 4YM 1ZS, 4YE 1DZ-II 4YM 1ZS, 4YE 1DZ-II 4YE 4YE
Manufacturer IHC
Delivery
cm3 (in3)/rev
96
(5.86)
96
(5.86)
96
(5.86)
105
(6.41)
105
(6.41)
105
(6.41)
115
(7.02)
115
(7.02)
115
(7.02)
96
(5.86)
105
(6.41)
Rated flow rate
L (US gal)/min
13.6
(3.59) -13.6 (3.59)
13.6
(3.59) -13.6 (3.59)
15.8
(4.17) -15.8 (4.17) - -
Relief set pressure
MPa (kgf/cm2) [psi]
7.5 to
8.0
(76.5
to
81.6)
[1088
to
1160]
7.2 to
7.7
(73.4
to
78.5)
[1044
to
1117]
7.5 to
8.0
(76.5
to
81.6)
[1088
to
1160]
8.1 to
8.6
(82.6
to
87.7)
[1175
to
1247]
7.8 to
8.3
(79.5
to
84.6)
[1131
to
1204]
8.1 to
8.6
(82.6
to
87.7)
[1175
to
1247]
8.1 to
8.6
(82.6
to
87.7)
[1175
to
1247]
7.8 to
8.3
(79.5
to
84.6)
[1131
to
1204]
8.1 to
8.6
(82.6
to
87.7)
[1175
to
1247]
7.5 to
8.0
(76.5
to
81.6)
[1088
to
1160]
8.1 to
8.6
(82.6
to
87.7)
[1175
to
1247]

2-92 STEERING
2.3 COMPONENTS
1ZS and 4YE engine [4507]
4YM and 1DZ-II engine [4507]
2

2-10 2 STEERING
PS Valve
1ZS and 4YE engine [4503]
4YM engine (L/synchronized steering) [4503]
4503-036
CM
AT
AS
32
AP
CK
AV
AC
AD
CL
30
CJ
AA
31
01K=(INCL. )
01

2-112 STEERING
4YM and 1DZ-II engine (W/synchronized steering) [4503]
2

2-12 2 STEERING
2.4 HYDROSTATIC STEERING VALVE ASSY
2.4.1 DISASSEMBLY, INSPECTION AND REASSEMBLY (1ZS and
4YE)
NOTICE
Clean dirt off from ports and joints before disassembly and operate in a clean place.
9
2
2
1
1
a
5
b
4
7
1
3
8
6
a: T=23 to 27 N m (235 to 275 kgf-cm) [17.0 to 19.9 ft-lbf]
b: T=60 to 80 N m (612 to 816 kgf-cm) [44.3 to 59.0 ft-lbf]
Disassembly Procedure
Step 1. Remove the set bolt and end cover. [Point 1]
Step 2. Remove the gear wheel set, drive shaft, and distributor plate. [Point 2]
Step 3. Remove the steel ball. [Point 3]
Step 4. Remove the sleeve W/ spool and bearing. [Point 4]
Step 5. Remove the relief valve. [Point 5]
Step 6. Remove the pin from the sleeve W/ spool.
Step 7. Remove the center spring. [Point 6]
Step 8. Remove the packing and ring. [Point 7]
Step 9. Remove the dust seal. [Point 8]

2-132 STEERING
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
a
Point 1 Disassembly:
Make a match mark across the end cover, outer gear,
and valve body.
Reassembly:
Follow the steps below for reassembly.
a: Match mark
1. Align the match marks made at the time of disas-
sembly.
2. Two types of set bolts are used.
• Set bolt with '10' mark on the head
• Set bolt without any mark on the head
Use a rod-tip bolt with no mark on its head at pos-
ition A in the illustration at left.
A
a
b
c
Point 2 Reassembly:
Install the drive shaft and inner gear in the illustrated
relative positions.
The spool pin shall pass the slit in the drive shaft.
a: Drive shaft match mark
b: Pin
c: Inner gear match mark
a
Reassembly:
Install the outer gear with its side having the ∇ mark
facing the end cover side.
a: Mark
2

2-14 2 STEERING
aA
Point 3 Disassembly:
A steel ball is placed in portion A of the valve body.
Keep it so as not to be lost.
Reassembly:
Make sure to put the steel ball in portion A.
a: Steel ball
Point 4 Reassembly:
Install the retaining bearing as illustrated at left.
Install one plate, the thrust bearing, and two plates in
this order from the depth.
Reassembly:
When inserting the sleeve W/ spool into the valve
body, apply MP grease to the packing, ring inner sur-
face (portion in sliding contact with the spool), and
dust seal lip.
a
Point 5 Disassembly:
Measure the screwed-in depth of the adjust plug
(depth to the plug end face), and record it on a
memo.
Reassembly:
Refer to the memo for the adjust plug screwed-in
depth.
Reassembly:
Caulk two places on the circumference of the adjust
plug after hydraulic pressure adjustment.
a: Caulk

2-152 STEERING
a
b
Point 6 Reassembly:
Install the center spring as illustrated at left.
Reassembly:
After spool insertion into the sleeve, the notched por-
tion of the spring shall securely set in the groove on
the sleeve.
a: Center spring
b: Notch
a c
b
Point 7 Reassembly:
The packing and ring shall be installed in the illus-
trated directions.
Reassembly:
Apply MP grease to the ring before assembling with
the packing. Apply MP grease to the outer periphery
of the packing.
Reassembly:
Guide the packing W/ ring to the assembling portion
in the valve body with a finger, and set them for inser-
tion.
a: Bearing side
b: Apply grease
c: Dust seal side
ac
bc
Reassembly:
a: SST 09950-76018-71(Plate with punch mark 37)
b: SST 09950-76018-71(Plate with punch mark 34)
c: SST 09950-76020-71
a
b
Point 8 Reassembly:
a: SST 09950-76018-71
b: SST 09950-76020-71
2

2-16 2 STEERING
2.4.2 RELIEF PRESSURE INSPECTION (1ZS and 4YE)
P port
SST
Step 1. Install an oil pressure gauge.
1. Disconnect the hose from the P port of the steer-
ing valve, and connect the SST (adapter).
SST 09450-23320-71
2. Install the oil pressure gauge.
Plug size: PT1/8
Step 2. Start the engine, rotate the steering wheel slowly
clockwise and counterclockwise, and inspect the re-
lief pressure at each stroke end.
Standard: MPa (kgf/cm2) [psi]
Pn1 ton series
7.2 to 7.7 (73.4 to 78.5) [1044 to 1117]
Pn2/3 ton series
7.8 to 8.3 (79.5 to 84.6) [1131 to 1204]

3-173 MATERIAL HANDLING SYSTEM
3 MATERIAL HANDLING SYSTEM
3.1 HYDRAULIC CIRCUIT DIAGRAM........................................................... 17
3.2 COMPONENTS ....................................................................................... 21
3.1 HYDRAULIC CIRCUIT DIAGRAM
4YE and 1ZS engine
Without oil cooler
(3) (7)
(1)
(8)
(2)
(4)
(5)
(6)
(1) Oil pump
(2) Priority valve
(3) Oil control valve
(4) Steering valve
(5) Solenoid valve (OPT)
(6) Power steering cylinder
(7) Lift, tilt and ATT cylinder
(8) Oil tank
3

3-18 3 MATERIAL HANDLING SYSTEM
With oil cooler
(3) (7)
(1)
(8)
(2)
(4)
(5)
(6)
(10)
(9)
(1) Oil pump
(2) Priority valve
(3) Oil control valve
(4) Steering valve
(5) Solenoid valve (OPT)
(6) Power steering cylinder
(7) Lift, tilt and ATT cylinder
(8) Oil tank
(9) Oil cooler
(10) Relief valve