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GENERAL
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Page 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
RECOMMENDED LUBRICANT QUANTITY & TYPES ................. 0-20
LUBRICATION CHART................ 0-21
PERIODIC MAINTENANCE........ 0-22
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ..... 0-27
sec00.book 1 ページ ２０１０年４月１４日 水曜日 午後６時２９分
Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
Service Information Bulletin1 SIB MA06-001 - 7FBCU Option Menu Changes2 SIB CC06-001 - A5 Error Code Additional Information3 SIB RA06-002 - Tie Rod Change4 SIB FA06-003 - Front Axle Hub Change5 SIB FA06-002 - Changes to Reamer Bolt Torque6 SIB RA04-001 - New Tie Rod End Design7 SIB MA05-009 7FBEU Option Set Menu Changes8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload Specification)9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust12 SIB DU05-004 - Reduction Gear Change13 SIB ST99-001R - Recommended Special Service Tools14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32)17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55)18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32)19 SIB FA05-001 - Gear Case Change (7FBCU35-55)20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20)21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~2022 SIB CE05-001 Key Switch Change (All Models)23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20)24 SIB CE05-008 7FBEU Voltage Conversion25 SIB CC05-011 Low Battery Voltage / Performance Reduction26 SIB CC05-007 MB Contactor Cover (7FBEU15-20)27 SIB ST06-001 - Recommended Special Service Tools28 SIB CE05-006 Pump Motor Cooling Fan29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit30 SIB MA07-005 - Maintenance Indicator Changes31 SIB RA07-001 Rear Axle Flange Change32 SIB HS07-001 Addition of Back-Tilt Lock Valve33 SIB CE06-005R - Display Battery Replacement34 SIB CE06-005R Display Battery Replacement35 SIB FA07-001R Front Axle Shaft Change36 SIB CC07-004 - Tuning No. 14 Information37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section38 SIB CC08-003R Inching While Braking Option (Tuning Level 13)39 SIB DU08-001R 7BNCU Drive Unit Repair Correction40 SIB ST08-001 Recommended Special Service Tools41 SIB CE08-002R Battery Connector Bracket42 SIB HS08-002 Addition of OPSS Back-tilt Lock Valve
Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
43 SIB CC08-010 7FB10-J35 Programming Changes44 SIB Option Setting and Tuning Modes (7FB Models)45 SIB BR09-001 7FB Repair Manual Corrections 46 CC09-001 7FB Revision of Repair Manual 47 CC09-003 Error Codes 31-1, 31-2 and 31-348 DU09-003 Gear Case Bolt Torque Change49 CC09-004 5F and 5G codes 50 DM09-001 Drive, Pump and Steer Motor through Bolt Torque51 DM09-002 Pump Motor Cable Clearance52 CC10-001 Flashware v4.2 53 HS10-001 7FBEU Steering Circuit Hydraulic Schematics 54 SIB CE10-004 8FBC(H)U Voltage Conversion55 SIB ST10-001 Measuring Parking Brake Force on 8FBC(H)U Trucks56 SIB BR10-001 Stainless Steel Deadman Switch Mounting Screws57 SIB CC10-005 v3.1 Software Update for Auxiliary Functions58 SIB MA10-002 8FBCU Tuning Modes Explained59 SIB CE10-006 7FBEU Motor Sensor Bearing Change60 SIB CE10-007 8FBCU Height Selector Information61 SIB CE10-008 8FBCU Shock Sensor Information62 SIB MA10-003 8FBCU Auto Speed Control Information63 SIB MA10-004 8FBCU Touch Pad Information64 SIB MA10-006 AC Motor Controller Change65 SIB CE11-001 Clamp Release Interlock (Mini Lever Units)66 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin67 SIB FA11-001 7FBEU Front Axle Repair Kits68 SIB CC11-004 8FBCU Tuning No.1 Explained69 SIB CE11-002 8FBCU Horn Wires Breaking70 SIB CE11-003 Clamp Release Interlock (Standard Lever Units)71 SIB DM11-002 7BNCU New Auxiliary Motor and Pump
Technical News Brief1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal
Option, Over Heating Diagnosis, and 7FBCU Voltage Specs2 TNB - 2004-07 - Hydraulic oil change3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump5 TNB - 2006-05 - Plate to Prevent Chain Rollback6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage
Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display10 TNB - 2006-09 - 7-Series Electric ROM Write11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention12 TNB-2006-03 - 7FBEU Counterweight Squeaking13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure14 TNB-2008-10 7BNCU Steer Sensor Alignment Tool15 TNB-2008-16 Dual Contactor (Units with Pump Chopper)16 TNB-2009-04 7FBEU Static Strap Update
Hotline Tech Tips1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels
7FBCU2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU
gradeability; 7FBCU CB1 and CB23 HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on
7FBEU and 7FBCU4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential
Oil Level5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU
Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction Mode and Lift Interrupt Settings
7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 29 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon11
HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures;
7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse Replacement13
HTT-2006-01 - 7 Series Electric Lift Truck Erratic Display; 7FBE Drive Unit Part Numbers14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-316 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption19 HTT-2006-07 - 7FBEU Slow Motor Speed20 HTT-2006-08 - 7FBEU E2-1 Error Code21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes23 HTT-2006-11 - 7FBCU Drive Transistors
Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU28 HTT-2007-04 - Class 1 gear case oil29 HTT-2007-05 - 7FBCU Gear Case Sealing30 HTT-2007-06 - Steer Cylinder change31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting33 HTT-2007-09 - Repair Manual 32234 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors35 HTT-2007-11 - CU322 Repair manual clarification, 7FBEU 31-1, 31-2, 31-336
HTT-2007-12 - Class 1 Alarm with OPSS37 HTT-2008-01 - Class I Gear Noise38 HTT-2008-02 - Drive Unit Part Numbers, EF-1 & EF-2 Error Codes, Flashware Cable for 39 HTT-2008-03 - 7FBE Error Codes 64-2 & H9-2, 7FBCU15-55 A8, A1 & C3 Error Codes, 40 HTT-2008-04 - No Display with EZ Pedal, (30)7FBCU15-32 Complaint of Low Top Speed 41 HTT-2008-05 - 7FBCU20-32 Battery Slide out Field Installation Kit, (30)7FBCU15-55 Drive 42 HTT-2008-06 - 7FBE Front Hub Induction Hardening and Drive Axle Clattering43 HTT-2008-07 - 7FBCU15-25 Inspecting the EHPS Transistor44 HTT-2008-08 - 7FBE Internal Gear Hardened45 HTT-2008-09 - (30)7FBCU15-32 Error Code C0-(1-6)46 HTT-2008-10 - 7FBE Drive Axle Connector Rod Adjustment47 HTT-2008-11 - Using The SST Tools In Diagnosing Board Issues and UL Ratings48 HTT-2008-12 - Diagnostic Tips49 HTT-2009-01 - Slow Lowering or Incorrect Staging During Lowering50 HTT-2009-02 - C2-2 or C2-3 Error Codes and Trouble Shooting Error Codes H9-1,2,3 Or 64-
1,2,351 HTT-2009-03 - Static Strap Mounting and Lift Interrupt Settings52
HTT-2009-04 - Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters53 HTT-2009-05 - Error Codes After Card Replacement54 HTT-2009-06 - Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On55 HTT-2009-07 - Slow Travel Speed56 HTT-2009-08 - Occurrence of Error Code AO-457 HTT-2009-09 - Jerky Travel at Slow Speeds58 HTT-2009-10 - Gear Case Bolt Torque Increase59 HTT-2009-11 - A5 Error Code On 7FBE and 7FBC Forklifts With OPSS, 5F and 5G Codes
for the 7BNCU Model Forklifts60 HTT-2009-12 - 7FBCU Transistor Test Procedure & Speed Sensor Check61 HTT-2010-01 - FE-4, E2-2, E2-4 Error Codes62 HTT-2010-02 - Switch Adjust, RF Interference on AC Trucks
Service Information Bulletins affecting Models (30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
63 HTT-2010-03 - Documenting 7FBCU Brake Inspection and Adjustment During PDI, Flashware v4.2
64 HTT-2010-04 - Class I Brush Warning Option 14, 7BNCU Diode Replace Instructions65 HTT-2010-05 - Class I 7FBEU Front Axle Repair Kits66 HTT-2010-06 - Class I AC Drive Motor Over Current Limit Checks, SAS Manual Lowering
Valve67 HTT-2010-07 - 8FBCU Slow Travel or Surging Hydraulics, Setting Time/Date68 HTT-2010-08 - 8FBCU Display, Main CPU and Changing Voltage69 HTT-2010-09 - 8FBCU Measuring Parking Brake Force, 7BNCU Software v3.170 HTT-2010-10 - 8FBCU Service Information Bulletins71 HTT-2010-11 - 8FBCU Slow Attachment Speeds, Seat Switch Failures 72 HTT-2010-12 - 8FBCU Travel Alarm in Both Forward and Reverse73 HTT-2011-01 - Speed Limit Adjustment on 8FBCU74 HTT-2011-02 - Class I-VI Common Electrical Acronyms, 7FBEU Error Codes 72-1, 72-2 or
Missing Manager's Functions75 HTT-2011-03 - Class I 8FBCU Slow Lowering w/Standard Levers76 HTT-2011-04 - Class I 8FBCU H Power Mode, 7FBEU RPM Sensor Bearing Damage77 HTT-2011-05 - Class I Adding Electrical Devices, 78 HTT-2011-06 - Class I Battery Option/Type79 HTT-2011-07 - Class I 7FBCU35-55 Using SST3 On CN11280 HTT-2011-08 - Class I 8FBCU Tuning No. 1, Back to Basics Troubleshooting81 HTT-2011-09 - Class I Important SIBs82 HTT-2011-10 - Class I 8FBC(H)U Controller Software Change83 HTT-2011-11 - Class I Adding Forward Travel Alarm84 HTT-2011-12 - Class I C1-2 Error Codes, Hyd Oil Maint and Diagnosing Intermittent
Complaints85 HTT-2012-01 - Class I 8FBCU Relief Valve Structure, Using DVOM to Check Voltage Drop
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EXTERIOR VIEWS0
sec00.book 2 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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0
VEHICLE MODELModelCode Load Capacity Vehicle Model Voltage Remarks
20 4000 lbs 8FBCU20 36V/48V
25 5000 lbs8FBCU25 ↑
8FBCHU25 ↑
28 5500lbs 8FBCU28 ↑
30 6000 lbs 8FBCU30 ↑
32 6500 lbs 8FBCU32 ↑ USA·CANADA·MEXICO only
sec00.book 3 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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FRAME NUMBER
Frame No. Punching Position
*: EEC spec.
Vehicle Model Punching format8FBCU20 8FBCU25-60011
* 8FBCU25 600118FBCU258FBCHU25 8FBCHU25-60011
8FBCU288FBCU28-60011
* 8FBCU28 600118FBCU30 8FBCU32-60011
* 8FBCU32 600118FBCU32
Punching position
sec00.book 4 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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0
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
Example of description in pattern B
DISASSEMBLY·INSPECTION·REASSEMBLYTightening torque unit T = N·m (kgf·cm) [ft·lbf]
Disassembly Procedure1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2]
3 Remove the gear.
Point Operations[Point 1]
Disassembly:Put a match mark when removing the pump cover.
[Point 2]
Inspection:Measure the bush inside diameter.
Limit: 19.12 mm (0.7528 in)
• Step Nos. are partially sometimes omitted inillustrations.
• When a part requiring tightening torqueinstruction is not indicated in the illustration,the part name is described in the illustrationframe.
T = 46.1 to 48.1(470 to 490)[34.0 to 35.5]
Operation explained later
Explanation of key point for operation with an illustration
sec00.book 5 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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2. How to read components figures (Example)
3. Matters omitted in this manualThis 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 observethem.
Note:Important items of which negligence may cause breakage or breakdown, or matters in operationprocedure requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONSAbbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly RR Rear
ATT Attachment SAE Society of AutomotiveEngineers (USA)
EHPSElectronically controlledfully hydraulic powersteering
SAS System of active stability
FHPS Fully hydraulic powersteering SOL Solenoid
LH Left hand SST Special service toolFR Front STD Standard
OPS Operator Presence Sensing T= Tightening torque
OPT Option T Number of teeth ( )O/S Oversize U/S UndersizePS Power steering W/ WithRH Right hand L/ Less
3201
FIG number in parts catalog
(1) The components figure uses the illustrationin the parts catalog for the vehicle model.Please refer to the catalog for checking thepart name.The number at the right shoulder of eachcomponents figure indicates the Fig.number in the parts catalog.
(2) Refer to the parts catalog for the latestinformation.
sec00.book 6 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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SI UNITS
Meaning of SIThis manual uses SI units. SI represents the International System of Units, which was established to unify the varioussystems of units used in the past for smoother international technical communication.
New Units Adopted in SI
<Reference>* 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as therate for conversion between conventional and SI units.* 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], whichshould be used as the unit of force.
Conversion between Conventional and SI UnitsEquation for conversion
When converting, change the unit of the value in conventional or SI units to the one in the conversion ratecolumn in the table above before calculation. For example, when converting 100 W to the value inconventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.
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
(Moment)N·m kgf·cm 1 kgf·cm = 9.80665 N·m
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 consumption g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding to X in the conversion rate column in the table aboveValue in conventional unit = Value in SI unit ÷ Conversion rate
sec00.book 7 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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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 tighteningtorque 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, maydamage elements inside the controllers.
4. Confirming defect statusDo not start immediate disassembly or replacement, but first confirm if such disassembly orreplacement 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 otherharmful substance may cause adverse affect to people or environmental destruction, sort each wasteand 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.
sec00.book 8 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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7. Disconnect the battery plugWhen unplugging the battery plug, use the grip. Do not pull up the cable.
For example:
sec00.book 9 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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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
sec00.book 10 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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HOISTING THE VEHICLE
When hoisting the vehicle, use the mast hook on the front ofthe 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 awayfrom the ground.
2. The traveling speed in towing must not exceed themaximum traveling speed of the forklift.
3. Always set the key switch to OFF and the directionswitch to the neutral position before starting towing.In case of towing by connection with a wire rope with theoperator on the forklift, however, set the key switch toON (PS operation) and always set the direction switch tothe neutral position.
4. Before towing, either remove the fork or take an actionto prevent fork contact with the ground due to bounding.
sec00.book 11 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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ATTENTIVE POINTS ON SAS1. Reference should be made to seperate manual “New Model Feature 8FBCU20 to 32 Pub. No.PU319”
for the explanations of SAS functions and operations. 2. Read Section 17 “SAS Precautions for Repair” on Page 17-9 in this repair manual in advance. 3. Whenever the repair or replacement is performed to the place where relative to SAS function, maching
procedure by which the SAS regain proper function must be performed. (See 17-18) 4. The warning on the SAS caution label must be confirmed when the modification or change is such as
to change the original specification.If improper, change the label. (See Page 17-22)
5. Care should always be exercised for safety operation whenever you operate the truck.Make distinction between the SAS featured trucks and those of none, because the control features aredifferent.
6. The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oilwill adversely affect the functions of these valves, always wash the parts clean at the time ofinstallation after disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodicreplacement of the hydraulic oil is very important.
7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may causefaults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliaryequipment, optional parts, etc.)
sec00.book 12 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively accordingto the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured valueshould only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.
1. Difference in measurement results with the digital type and analog type* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual.Cautions when the polarities are different between the analog type and digital type are describedbelow.
(1) Analog circuit testerMeasurement result exampleTester range: kΩ range
(2) Digital circuit testerMeasurement result exampleTester range: MΩ range
Forward direction Reverse direction
Analog type
ForwardContinuity exists
11 kΩ
ReverseNo continuity
∞
Forward direction Reverse direction
Digital type
ForwardNo continuity
1
ReverseContinuity exists
2 MΩ
sec00.book 13 ページ ２０１０年４月１４日 水曜日 午後６時２９分
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2. Difference in result of measurement with circuit testerThe circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.The diode characteristics are shown in the figure below.
The resistance values of the same semiconductor measuredwith two types of circuit testers having different power supplyvoltages are different.
This manual describes the results of measurement with acircuit tester whose power supply voltage is 3.0 V.
3. Difference in measurement result by measurement range (analog type)In the analog type circuit tester, changing the measurement range switches over the internal circuit tovary the circuit resistance. Even when the same diode is measured, the measurement result varieswith the measurement range.
Always use the range described in the repair manual formeasurement.
0
1
2
3
4
5
6
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8(V)Forward voltage
Germanium diode
(mA)
Forw
ard
curre
nt
Silicon diode
Resistor Meter
0ΩVariable resistor
Resistor
Resistor
Range:×10
Range:×1
Power source: 1.5V
Red Black
(SW1)
Cur
rent
flow
sec00.book 14 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-15
STANDARD BOLT & NUT TIGHTENING TORQUEStandard bolt and nut tightening torques are not indicated.Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identifybolt class based on the below chart and then determine using the tightening torque table.
2. For tightening torque of hexagon flange bolts, identify bolt class based on the below chart and then determineusing the tightening torque table.
3. For tightening torque of nuts, check the mating bolt and use the method 1.
BOLT STRENGTH CLASS IDENTIFICATION METHOD
Identification by Bolt Shape
Shape and class Class
Hexagon head bolt
Bolt head No.
4 = 4T5 = 5T6 = 6T7 = 7T8 = 8T
No mark 4T
Two protruding lines 5T
Three protruding lines 7T
Four protruding lines 8T
Welded bolt 4T
Stud bolt
No mark 4T
Grooved 6T
sec00.book 15 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-16
Identification by Part No.
Tightening Torque Table
Part No. Shape
Hexagon head bolt
Stud bolt
Class Diametermm
Pitchmm
Specified torque
N·m kgf·cm ft·lbf
4T
6810121416
1.01.251.251.251.51.5
5.413254775113
551302604807601150
49
19355583
5T
6810121416
1.01.251.251.251.51.5
6.516325991
137
65160330600930
1400
512244367101
6T
6810121416
1.01.251.251.251.51.5
7.8193972
108172
8019040073011001750
614295380127
7T
6810121416
1.01.251.251.251.51.5
11255295
147226
110260530970
15002300
8193870108166
8T
6810121416
1.01.251.251.251.51.5
122961
108172265
120300620110017502700
9224580127195
Length (mm)
Diameter (mm)
Class
Diameter
Length
Length (mm)
Diameter (mm)
Class
Diameter
Length
sec00.book 16 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-17
Identification by Bolt Shape (Hexagon flange bolt)
Tightening Torque Table (Hexagon flange bolt)
Class 4.8T 6.8T 8.8T 10.9T 11.9T
Hexagon flange bolt
— —
Class Diametermm
Pitchmm
Specified torque
N·m kgf·cm ft·lbf
4.8T
6810121416
1.01.251.251.251.51.5
5.513275078
120
56130280510800
1220
49
20375888
6.8T
6810121416
1.01.251.251.251.51.5
7.5193971110170
8019040072011201730
614295281125
8.8T
6810121416
1.01.251.251.251.51.5
122961110175270
120300620112017802750
9224581129199
10.9T
6810121416
1.01.251.251.251.51.5
15.53880
145230360
160390820
148023503670
122859107170266
11.9T
6810121416
1.01.251.251.251.51.5
17.54289
160260400
180430910
163026504080
133166118192295
No mark
No mark
sec00.book 17 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-18
PRECOAT BOLTS(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the followingcases:
(1) After it is removed.
(2) When the precoat bolt is moved (loosened or tightened)by tightness check, etc.
Note:For torque check, use the lower limit of the allowabletightening torque range. If the bolt moves, retighten itaccording to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded holemust be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded portionof the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth
to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces beforeinstallation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Seal lock agent
Nominal diameter of screw
Standard tightening torque N·m (kgf·cm) [ft·lbf] Hose inside diameter mm (in)Standard Tightening range
7/16 — 20UNF 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
9/16 — 18UNF 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [29.3 ~ 26.8] 9 (0.35)
3/4 — 16UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 78 (800) [57.9] 74 ~ 82 (740 ~ 840) [53.5 ~ 60.8] 15 (0.59)
1·1/16 — 12UNF 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
1·5/16 — 12UNF 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
PF3/8 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [23.9 ~ 26.8] 9 (0.35)
PF1/2 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
sec00.book 18 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-19
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLEUnit: N (tf) [lbf]
Lifting angle Tension Compression Suspension method Lifting angle Tension Compression Suspension
method
0° 1.00 time 0 time 90° 1.41 time 1.00 time
30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
60° 1.16 time 0.58 time
Ropediameter
Cuttingload
Single-ropesuspension Two-rope suspension Four-rope suspension
0° 0° 30° 60° 90° 0° 30° 60° 90°
6 mm(0.24 in)
21380(2.18)[4807]
3040(0.31)[683.6]
6080(0.62)[1367]
5880(0.6)
[1323]
5200(0.53)[1169]
4310(0.44)[970]
12160(1.24)[2734]
11770(1.2)
[2646]
10400(1.06)[2337]
8630(0.88)[1940]
8 mm(0.32 in)
31480(3.21)[7078]
4410(0.45)[992.3]
8830(0.9)
[1985]
8530(0.87)[1918]
7650(0.78)[1720]
6280(0.64)[1411]
17650(1.8)
[3969]
17060(1.74)[3937]
15300(1.56)[3440]
12550(1.28)[2322]
10 mm(0.4 in)
49230(5.02)[11.69]
6960(0.71)
[1565.6]
14020(1.43)[3153]
13440(1.37)[3021]
11770(1.2)
[2646]
9810(1.0)
[2205]
27460(2.8)
[6174]
26480(2.7)
[5954]
23540(2.4)
[5292]
19610(2.0)
[4410]
12.5 mm(0.5 in)
76880(7.84)
[17387]
10980(1.12)
[2469.5]
21570(2.2)
[4851]
21280(2.1)
[4631]
18630(1.9)
[4190]
14710(1.5)
[3308]
43150(4.4)
[9702]
41190(4.2)
[9261]
37270(3.8)
[8379]
29420(3.0)
[6615]
14 mm(0.56 in)
96400(9.83)
[21675]
13730(1.4)
[3087]
27460(2.8)
[6174]
26480(2.7)
[5954]
23540(2.4)
[5292]
18630(1.9)
[4190]
54920(5.6)
[12348]
52960(5.4)
[11907]
47070(4.8)
[10584]
37270(3.8)
[8379]
1.0
tf
2t 2t
90°
1.41 t
f
2t
30°1.
04 tf
2t
120°2 tf
2t
60°
1.16
tf
sec00.book 19 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-20
COMPONENTS WEIGHT
RECOMMENDED LUBRICANT QUANTITY & TYPES
Note:Since the hydraulic oil volume varies with the mast specification, be sure to check finally with thelevel gauge.
Member Models Weight kg (lbs)Battery ASSY See page 1-2
Drive motor ASSY20~25 Approx. 127 (280)28~32 Approx. 145 (320)
Pump motor ASSY 20~32 Approx. 47 (104)
Counterweight
20·H25 Approx. 756 (1667)25 Approx. 1070 (2359)28 Approx. 1375 (3031)30 Approx. 1182 (2606)32 Approx. 1375 (3031)
V mast ASSY L/fork and backrest(with lift cylinder, max. liftingheight: 3300 (130 in))
20·25 Approx. 460 (1014)
30·32 Approx. 570 (1257)
Description Quantity l (US gal) Classification Type
Drive unit 6.0 (1.58) APIGL-4
Hypoid gear oilSAE75W-80W
Hydraulic oil(V⋅FV⋅FSV mast:lifting height3300 mm (130 in))
22.0 (5.81) ISOVG32 Hydraulic oil
BrakeProper quantityReservoir Tank0.2 (0.05)
SAE J-1703DOT-3
Chassis parts Proper quantity • MP grease• Molybdenum
disulfide greaseBattery Proper quantity Distilled water
sec00.book 20 ページ ２０１０年４月１４日 水曜日 午後６時２９分
0-26
Inspection Period
Item
Every6 weeks
Every3 months
Every6 months
Every12 months
Every250 hours
Every500 hours
Every1000 hours
Every2000 hours
BodyDamage and cracks of frame, cross members, etc. I
Bolts and nuts looseness T
SAS
Functions I * I ← ←
Loosening and damage at sensor mounting portion I * I ← ←
Damage, deformation, oil leakage and loosen-ing of the mounting of functional parts I * I ← ←
Loosening and damage of wire harnesses I * I ← ←
Lock cylinder accumulator performance I
Rusting and corrosion of load sensor I
Others Grease up L * L ← ←
0-27
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
Note:• Periodic maintenance is fundamental. Need to replace even before replacement interval if
abnormality is seen in Periodic Maintenance, because deterioration differs from condition.• Have customers conduct weekly maintenance (40hr) as mentioned in Operator's Manual.
: Replacement
*1: Replace without reservation at indicated interval in case of hard operation conditions mentioned below. In case of normal operating condition, the distributors are entrusted with the responsibility for determining whether the parts should be replaced or not. If the replacement is determined to be unnecessary, be sure to inspect at the next periodic maintenance.
Note) Definition of "hard operation" is the following.• Extended heavy duty operations (e.g. multi-shift or continuous use)• High temperature areas (e.g. steel mills or foundries)• Low-temperature operations (e.g. freezer operation)• Sudden temperature changes (e.g. traveling between freezer, room temperature, and oven or furnace
environments)• Dusty or sandy conditions (e.g. cement plants, lumber or flour mills, coal dust or stone-crushing areas)• Corrosive chemical atmosphere (e.g. fish, meat, or poultry processing plants, tanneries, chlorine or
saltsea air environments)• High humidity, wet, damp, or moist conditions*2: The distributors are entrusted with the responsibility for determining whether the parts should be replaced
or not. If the replacement is determined to be unnecessary, be sure to inspect at the next periodic maintenance.
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.0
Replacement timing
Item
Every6 weeks
Every3 months
Every6 months
Every12 months
RemarksEvery
250 hoursEvery
500 hoursEvery
1000 hoursEvery
2000 hoursDrive unit oilHydraulic oil
Hydraulic oil filter New
vehicle initial replacement
Wheel bearing greaseBrake fluid Brake master cylinder rubber partsWheel cylinder cup sealsBrake fluid reservoir hose Every 2 years *1Power steering hose Every 2 years *1Power steering rubber parts Every 2 years *1Hydraulic hose Every 2 years *1Chain Every 3 years *2Swing lock cylinder Every 10,000 hours
…..This Page Intentionally Left Blank…..
SERVICE INFORMATION BULLETIN Subject: Lubrication of Horn Contact Rings Page 1 of 1
MODEL APPLICATION: 8FBCU20-32, 8FBCHU25, 8FGCU15-32 and 8FGU15-32 GENERAL INFORMATION:
Maintenance MA12-003 May 31, 2012 Lubrication of Horn Contact Rings 8FBC(H)U20-32, 8FGCU15-32, 8FGU15-32,
Silicone/Rubber Grease 08887-76002-71
SERVICE INFORMATION BULLETIN Subject: Service Hint for Greasing Rear Axle Beam Pivot Pin Page 1 of 2
MODEL APPLICATION: All Models GENERAL INFORMATION: This bulletin announces an updated procedure for greasing of the rear axle pivot pin. This procedure should be followed every time a rear axle bushing requires greasing. Rear Axle Assembly
REPAIR INFORMATION: It is necessary to apply molybdenum disulfide grease to the bushing and center pin of rear axle beam periodically according to the repair manual. In order to obtain sufficient lubrication it is recommend that you follow the procedure below when greasing the rear axle bushing.
Maintenance MA11-001 May 13, 2011 Service Hint for Greasing Rear Axle Beam Pivot Pin All Models
Subject: Service Hint for Greasing Rear Axle Beam Pivot Pin Page 2 of 2
Repair Procedure: 1. Lift the counter-weight in order to secure a space above the pivot pin. See Figure 1. With the weight lifted off of the bushing apply grease until to comes out of the bushing ends. 2. Lower the counter-weight in order to secure a space below the Pin. See Figure 2. With the truck lowered to the ground apply grease until it comes out of the bushing ends.
SERVICE INFORMATION BULLETIN Subject: Hydraulic Oil Pump Spline Lubrication Page 1 of 1
MODEL APPLICATION: 8FBCU20-32, 8FBCHU25, 8FBE15-20U, 8FBES15U, 8FBEH18U, 7FBCU15-55, 30-7FBCU15-55. REPAIR INFORMATION: It is recommended to lubricate the hydraulic oil pump splines every year or 2,000 hours (whichever occurs first). The recommended type of grease is MOLIWHITE TA No.1 manufactured by Kyodo YUSHI Co. LTD. The grease should be applied (heavy/generously) to the oil pump splines (fill grooves). This grease is not compatible with the previous lubricants so the spline areas must be cleaned thoroughly and the new grease applied. When installing the pump it is recommended to torque the bolts evenly so the pump is aligned and not angled. See appropriate repair manuals for proper bolt torque. The new grease is in production as of 4/3/2017. The grease has an amber color and is available in a 5 lbs. (80 ounces) can, part number 90901-U9029-71. This information has been added to the repair manuals CU346 pages 0-21, 0-25 and 15-4, CE205 pages 1-18, 1-21 and 12-188, CU321 pages 0-19, 0-20, 0-24 and 15-5 through 15-7. The updated repair manual pages have been included for your convenience. Please remove and discard bulletin HS16-002. Example of properly lubricated splines Bolt Installation
Maintenance MA14-001R May 31, 2017 Hydraulic Oil Pump Spline Lubrication 8FBC(H)U20-32, 8FBE(H)15-20U, 8FBES15U, 7FBCU15-55, 30-7FBCU15-55
Tighten evenly to prevent pump angling.
Fill grooves with grease (generously)
