Toyota 8FBCU20-32, 8FBCHU25 Repair Manual

8FBCU 20, 25, 28, 30, 32 8FBCHU 25

VOL. 1

Pub. No. CU346

SECTION INDEX

NAME	SECTION
GENERAL	0
BATTERY	1
CONTROL SYSTEM	2
MULTI-FUNCTION DISPLAY	3
TROUBLESHOOTING	4
MOTOR	5
DRIVE UNIT	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
SAS FUNCTIONS	17
APPENDIX	18

Sections indicated by solid characters are included in this manual. Sections indicated by half-tone characters: See vol. 2.

0-1

GENERAL

	Page
EXTERIOR VIEWS..........................	0-2
VEHICLE MODEL............................	0-3
FRAME NUMBER............................	0-4
HOW TO USE THIS MANUAL .....	0-5
EXPLANATION METHOD ................	0-5
TERMINOLOGY................................	0-6
ABBREVIATIONS .............................	0-6
SI UNITS ...........................................	0-7
OPERATIONAL TIPS .....................	0-8
JACK-UP POINT ...........................	0-10
HOISTING THE VEHICLE ...........	0-11
CAUTION FOR TOWING.............	0-11
ATTENTIVE POINTS ON SAS ...	0-12
CIRCUIT TESTER .........................	0-13
STANDARD BOLT & NUT
TIGHTENING TORQUE.............	0-15
BOLT STRENGTH CLASS
IDENTIFICATION METHOD .........	0-15
PRECOAT BOLTS.........................	0-18
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE.............	0-18
WIRE ROPE SUSPENSION
ANGLE LIST.................................	0-19
SAFE LOAD FOR EACH
WIRE ROPE SUSPENSION
ANGLE...........................................	0-19
COMPONENTS WEIGHT ............	0-20

		Page
	RECOMMENDED LUBRICANT
			0
	QUANTITY & TYPES .................	0-20
	LUBRICATION CHART................	0-21
	PERIODIC MAINTENANCE........	0-22
	PERIODIC REPLACEMENT OF
	PARTS AND LUBRICANTS .....	0-27

0-2

EXTERIOR VIEWS

0-3

VEHICLE MODEL

Model	Load Capacity	Vehicle Model	Voltage	Remarks
Code
20	4000 lbs	8FBCU20	36V/48V
25	5000 lbs	8FBCU25	↑
		8FBCHU25	↑
						0
28	5500lbs	8FBCU28	↑
30	6000 lbs	8FBCU30	↑
32	6500 lbs	8FBCU32	↑	USA·CANADA·MEXICO only

0-4

FRAME NUMBER

Frame No. Punching Position

Punching position

	Vehicle Model	Punching format
	8FBCU20	8FBCU25-60011
		* 8FBCU25	60011
	8FBCU25
	8FBCHU25	8FBCHU25-60011
	8FBCU28	8FBCU28-60011
		* 8FBCU28	60011
	8FBCU30	8FBCU32-60011
		* 8FBCU32	60011
	8FBCU32

*: EEC spec.

			0-5
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
Example of description in pattern B
		DISASSEMBLY·INSPECTION·REASSEMBLY	Tightening torque unit T = N·m (kgf·cm) [ft·lbf]			0
		• 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 to 48.1 (470 to 490) [34.0 to 35.5]

Disassembly Procedure

1Remove the cover. [Point 1]

2Remove the bushing. [Point 2] Ã Operation explained later

3Remove the gear.

Point Operations

[Point 1]	Explanation of key point for operation with an illustration
Disassembly:	Ã

Put a match mark when removing the pump cover.

[Point 2]

Inspection:

Measure the bush inside diameter.

Limit: 19.12 mm (0.7528 in)

0-6

2. How to read components figures	(Example)
(1) The components figure uses the illustration
in the parts catalog for the vehicle model.			3201
Please refer to the catalog for checking the		FIG number in parts catalog
part name.
The number at the right shoulder of each
components figure indicates the Fig.
number in the parts catalog.

(2)Refer to the parts catalog for the latest information.

3.Matters omitted in this manual

This manual omits description of the following jobs, but perform them in actual operation:

(1)Cleaning and washing of removed parts as required

(2)Visual inspection (partially described)

TERMINOLOGY

Caution:

Important matters of which negligence may cause hazards on human body. Be sure to observe them.

Note:

Important items of which negligence may cause breakage or breakdown, or matters in operation procedure requiring special attention.

Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS

	Abbreviation (code)	Meaning	Abbreviation (code)	Meaning
	ASSY	Assembly	RR	Rear
	ATT	Attachment	SAE	Society of Automotive
				Engineers (USA)
		Electronically controlled
	EHPS	fully hydraulic power	SAS	System of active stability
		steering
	FHPS	Fully hydraulic power	SOL	Solenoid
		steering
	LH	Left hand	SST	Special service tool
	FR	Front	STD	Standard
	OPS	Operator Presence	T=	Tightening torque
		Sensing
	OPT	Option	{{T	Number of teeth ({{)
	O/S	Oversize	U/S	Undersize
	PS	Power steering	W/	With
	RH	Right hand	L/	Less

0-7

SI UNITS

Meaning of SI

This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for smoother international technical communication.

New Units Adopted in SI

	Item	New unit	Conventional unit	Conversion rate*1 (1 [conventional unit] = X [SI unit])
	Force*2	N (newton)	kgf	1 kgf = 9.80665 N
	Torque*2	N·m	kgf·cm	1 kgf·cm = 9.80665 N·m
	(Moment)
	Pressure*2	Pa (pascal)	kgf/cm2	1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
	↑	↑	mmHg	1 mmHg = 0.133322 kPa
	Revolving speed	rpm	rpm	1 rpm = 1 r/min
	Spring constant*2	N/mm	kgf/mm	1 kgf/mm = 9.80665 N/mm
	Volume	l	cc	1 cc = 1 ml
	Power	W	PS system	1 PS = 0.735499 kW
	Heat quantity	W·h	cal	1 kcal = 1.16279 W·h
	Specific fuel	g/W·h	g/PS·h	1 g/PS·h = 1.3596 g/kW·h
	consumption

<Reference>

*1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the rate for conversion between conventional and SI units.

*2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which should be used as the unit of force.

Conversion between Conventional and SI Units

Equation for conversion

Value in SI unit = Conversion rate × Value in conventional unit	Conversion rate: Figure corresponding to X in the
	conversion rate column in the table above
Value in conventional unit = Value in SI unit ÷ Conversion rate

When converting, change the unit of the value in conventional or SI units to the one in the conversion rate column in the table above before calculation. For example, when converting 100 W to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.

0-8

OPERATIONAL TIPS

1.Safe operation

(1)After jacking up, always support with wooden blocks or rigid stands.

(2)When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity.

(3)Always disconnect the battery plug before the inspection or servicing of electrical parts.

2.Tactful operation

(1)Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation.

(2)Before disconnecting wiring, always check the cable color and wiring state.

(3)When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion.

(4)When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location.

(5)Follow the described procedures for disassembly, inspection and reassembly.

(6)Replace, gaskets, packing and O-rings with new ones each time they are disassembled.

(7)Use genuine Toyota parts for replacement.

(8)Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly. (Tighten to the center of the specified tightening torque range.)

If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.

3.Protection of functional parts

(1)Thoroughly check each connector for any failure in or imperfect connection before reconnecting the battery plug after the end of vehicle inspection or maintenance.

Failure in or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers.

4.Confirming defect status

Do not start immediate disassembly or replacement, but first confirm if such disassembly or replacement is actually needed.

5.Handling of waste fluid, etc.

When draining waste fluid from the vehicle, always receive it with an appropriate container.

Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other harmful substance may cause adverse affect to people or environmental destruction, sort each waste and always ask an authorized contractor for appropriate disposal.

6.Handling of electronic parts

(1)Never apply impacts to electronic parts such as a microcomputer or relay.

(2)Never let electronic parts be exposed to a high temperature or humidity.

(3)Do not touch connector pins since they may be deformed or be damaged due to static electricity.

0-9

7.Disconnect the battery plug

When unplugging the battery plug, use the grip. Do not pull up the cable.

For example:

0-10

JACK-UP POINT

Strictly observe the following instructions when jacking up the vehicle.

•When a load is on the fork, unload it and park the vehicle on a flat floor. Be sure to avoid an inclined or rugged place.

•Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point will be dangerous.

•Never operate while the vehicle is held with a jack. Always support the frame with a wooden block after jacking up.

•In any case, never let a part of the body (including hands and feet) be under the jacked-up vehicle.

:

Jack-up point

:

Wooden block or stand setting point

0-11

HOISTING THE VEHICLE

When hoisting the vehicle, use the mast hook on the front of the vehicle and a wire net on the rear wheel.

Caution:

•Use wire ropes having sufficient strength.

•Never hoist the forklift by the weight hook holes or head guard.

CAUTION FOR TOWING

1.When towing the forklift, always lift the rear wheels away from the ground.

2.The traveling speed in towing must not exceed the maximum traveling speed of the forklift.

3.Always set the key switch to OFF and the direction switch to the neutral position before starting towing.

In case of towing by connection with a wire rope with the operator on the forklift, however, set the key switch to ON (PS operation) and always set the direction switch to the neutral position.

4.Before towing, either remove the fork or take an action to prevent fork contact with the ground due to bounding.