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8FDU20
Repair Manual
Toyota 8FDU20 - Repair Manual
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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
2
Table of Contents
Main Page
Table of Contents
3
Cushion Tire Models (Cu)
4
General Information
4
Pneumatic Tire Models (Pn)
4
Frame No. Punching Position
5
Pneumatic Tire
6
Cushion Tire
6
Hydrostatic Steering Valve - 1ZS and 4YE Engine
7
Steering
7
Hydrostatic Steering Valve - 4YM and 1DZ Engine
8
Hydrostatic Steering Valve - 4YM Engine (L/Synchronized Steering)
9
Specifications
10
Hydrostatic Steering Valve (L/Synchronized Steering) Data
10
Hydrostatic Steering Valve (W/Synchronized Steering) Data
10
Components
11
1ZS and 4YE Engine Components View
11
4YM and 1DZ-II Engine Components View
11
PS Valve Views
12
4YM and 1DZ-II Engine (W/Synchronized Steering) Components View
13
Hydrostatic Steering Valve Assy View
14
Hydrostatic Steering Valve Assy Disassembly
14
Hydrostatic Steering Valve Assy Reassembly
15
Relief Pressure Inspection (1ZS and 4YE)
18
Hydraulic Circuit Diagram - 4YE and 1ZS Engine Without Oil Cooler
19
Material Handling System
19
Hydraulic Circuit Diagram - 4YE and 1ZS Engine with Oil Cooler
20
Hydraulic Circuit Diagram - 4YM and 1DZ-II Engine Without Oil Cooler
21
Hydraulic Circuit Diagram - 4YM and 1DZ-II Engine with Oil Cooler
22
Material Handling System Components View
23
Oil Pump View
24
Oil Pump Specifications
25
Oil Pump Performance Test
26
Lifting Speed
26
Oil Control Valve
27
Oil Control Valve Assy View - 1ZS and 4YE Engine
28
X1-X1 Inlet View
29
Hydraulic Circuit Diagram (1ZS Engine)
30
Hydraulic Circuit Diagram (4YE Engine)
31
Oil Control Valve Specifications
32
Oil Control Valve Components View - 1ZS and 4YE Engine
33
Oil Control Valve Components View - 1DZ-II and 4YM Engine
33
Oil Control Valve Components View - 1DZ-II and 4YM (Inlet/Outlet/Lift)
34
Oil Control Valve Components View - 1DZ-II and 4YM Engine [ATT]
34
Oil Control Valve Disassembly and Reassembly (1ZS and 4YE Engine)
35
Point Operations
36
Oil Control Valve Assy (Mini/Joystick Lever) View - 1ZS/4YE Engine
41
Oil Control Valve Assy - X1-X1 View
42
Oil Control Valve Assy Hydraulic Circuit Diagram (1ZS Engine)
43
Oil Control Valve Assy Hydraulic Circuit Diagram (4YE Engine)
44
Oil Control Valve Assy Specifications
45
Oil Control Valve Assy Components View - 1ZS and 4YE Engine
46
Oil Control Valve Assy Disassembly and Reassembly (1ZS and 4YE Engine)
47
Oil Control Valve Assy - Point Operations
48
Relief Pressure Adjustment
52
SAS Function
54
SAS Components View - Load Sensor (4Y Engine)
54
Sas/Ops
54
SAS Components View - Load Sensor (1ZS Engine)
55
SAS Components View - Load Sensor (1DZ-II Engine)
56
Multi-Function Display DX
57
Display
57
Multi-Function Display DX Function List
58
Screen
59
Initial Screen after Key-On
59
Status Screen
59
Speedometer
60
Torque Converter Oil Temperature Indicator
60
Function Activation Indicator
60
Low Speed Setting Indicator/Auto Speed Control Indicator
60
Menu Lock Indicator
61
Eco-Mode Indicator
61
Maintenance Indicator
61
Odometer
62
Trip Meter
62
Planned Maintenance Hour Meter
62
Meter
62
Torque Converter Oil Temperature Overheat Warning
63
Over Speed Alarm/Diagnostic Code Display
63
Parking Brake on Warning/Parking Brake off Warning
63
Warning
63
Setting Functions
64
Setting Menu for Operator
64
Low Speed Level Setting Screen
64
Over Speed Alarm Setting Screen
64
Administrator Functions List
65
Administrator Password
65
Password Entry Procedure
65
Setting Menu for Administrator
67
Administrator Functions
68
Travel Speed Limiter Setting Screen
68
Planned Maintenance Hour Setting Screen
69
Engine Auto Stop Time Setting Screen
69
Administrator’s Second Password Setting Screen
70
Registration of Password
70
Deletion of Password
71
Menu Lock Setting Screen
71
Menu Lock Setting Screen Description
72
Service Functions "Mask Menu"
73
Mask Function List
73
Password Entry Procedure (Mask Menu)
74
Service Functions "Mask Menu" Screen
76
Analyzer Function
77
Tuning Function
78
Optionset Function
78
Speed Limit Set Function
79
Wheel Radius Function
79
Matching Function
79
Idle Adjustment Function
80
Mask Password
80
Manager Pass CLR
80
Contrast
80
Meter Start
81
End
81
Analyzer
82
Analyzer Screen Menu List
83
Analyzer Menu Screen
87
Diagnosis Memory Function "1 Diag. Memory"
89
"Diag. Memory 2/2"
90
In/Out Monitor Function "I/O MONITOR"
91
In/Out Monitor (1) "2.I/O ENGINE CTRL"
91
"I/O Engine CTRL 1/10"
92
"I/O Engine CTRL 2/10"
92
"I/O Engine CTRL 3/10"
93
"I/O Engine CTRL 4/10"
93
"I/O Engine CTRL 5/10"
94
"I/O Engine CTRL 6/10"
94
"I/O Engine CTRL 7/10"
94
"I/O Engine CTRL 8/10"
95
"I/O Engine CTRL 9/10"
95
"I/O Engine CTRL 10/10"
95
Engine Vehicle
96
"I/O Engine CTRL 1/5"
96
"I/O Engine CTRL 2/5"
97
"I/O Engine CTRL 3/5"
97
"I/O Engine CTRL 4/5"
97
"I/O Engine CTRL 5/5"
97
In/Out Monitor (2) "3.I/O TRAVELING"
98
"I/O Traveling 1/3"
99
"I/O Traveling 2/3"
100
Lifting Height Switch (MH) ON/OFF Combination Table
101
"I/O Traveling 3/3"
101
In/Out Monitor (3) "4.I/O M.HANDLING"
102
"I/O M.handling 1/7"
103
Condition of the Seat/Lever and Detected Values
104
"I/O M.handling 2/7"
104
"I/O M.handling 3/7"
105
"I/O M.handling 4/7"
105
"I/O M.handling 5/7"
106
"I/O M.handling 6/7"
107
In/Out Monitor (4) "5.I/O Steering"
108
"I/O M.handling 7/7"
108
"I/O Steering 1/1"
110
In/Out Monitor (5) "6.I/O Others"
111
"I/O Others 1/2"
111
"I/O Others 2/2"
111
Active Test Menu List
112
"Active Test 2/3"
114
"Active Test 1/3"
114
"Active Test 3/3"
115
Program Version "VERSION"
116
Tuning Item List
117
Tuning Menu Screen
121
Tuning General "Tune Gen."
123
Tuning Lift Lever "Lift Down/Lift Up"
124
Tuning Tilt Lever "Tilt Fwd/Tilt BWD"
125
Tuning ATT1 Lever "ATT1 Push/Att1 Pull"
126
Tuning ATT2 Lever "ATT2 Push/Att2 Pull"
127
Tuning ATT3 Lever "ATT3 Push/Att3 Pull"
128
Option Settings
129
Option Set Menu List
129
Option Set Screen "Optionset"
130
Option Set Screen 1
131
Option Set Screen 2
131
Option Set Screen 3
131
Option Set Screen 4
131
Option Set Screen 5
132
Matching
133
Matching Items and Prerequisite for Implementation
133
Prerequisite Content for Implementation
133
Before Starting Matching
134
Mini Lever
134
Emrv
134
Standard Vehicle Condition
134
Loadmeter 0 Set (0 Set of the Load Gauge) Check
135
Tire Straight Traveling Position Check
135
No-Load Vertical Condition Check
135
Matching Menu Screen
136
Matching SAS "SAS"
138
"Tilt Level" Screen
138
"Tilt FWD Limit" Screen
138
"Tire Position" Screen
139
"Swing Level" Screen
139
"Lever2" Screen
140
"Lever1" Screen
140
Matching Mini Lever "Mini Lever"
140
Matching EMRV "EMRV"
141
"Lever3" Screen
141
"Lever4" Screen
141
"EMRV C01 to EMRV C02" Screen
142
Other Service Function
143
Wheel Radius
143
Speed Setting of Speed Limiter "Speed Limit Set"
145
Idle Adjustment (IDLE ADJUSTMENT)
146
Service Second Password Setting "Mask Password"
147
"Mask Password" Screen
148
Set Mask Second Password Operation
149
Administrator's Second Password Clear "Manager Pass CLR"
150
Contrast Adjustment "Contrast"
151
Meter Start "Meter Start"
152
Troubleshooting
154
Diagnosis Code List
155
Warning List
156
When no Error Code Is Displayed
157
Engine Is Slow to Rev up
158
The Idle Speed Does Not Rise Even if the Lift Is Raised
158
Speed Limit Applies at High Lifting Height Despite Not Being Loaded
159
Speed Limit Does Not Operate
159
Speed Limit Applies at All Times Regardless of Lifting Height or Load
160
Speed Limit Applies When Loaded Despite Being at a Low Lifting Height
160
Mini Lever or Joystick Troubleshooting
161
STD Lever Troubleshooting
161
Easy to Stall (4YE Engine Model)
162
Buzzer Sounds Constantly
163
OPS Leaving Seat Warning Does Not Sound
163
Traveling OPS Return to Neutral Alarm Does Not Sound
163
Material Handling OPS Return to Neutral Alarm Does Not Sound
164
Parking Brake Reminder Alarm Does Not Sound
166
Parking Brake Reminder Alarm Continues to Sound
167
Parking Brake Return Reminder Alarm Does Not Sound
167
Parking Brake Return Reminder Alarm Sounds on Traveling
167
Torque Converter Oil Temperature Indicator Costantly Displays Overheat
168
Torque Converter Oil Temperature Indicator Does Not Display
168
Torque Converter Oil Temperature Indicator Stays at Level 1
168
Feels Unstable When Traveling
169
Swing Lock Continually Activates While Traveling
170
Forward Tilt Automatic Fork Leveling Does Not Stop
171
Forward Tilt Automatic Fork Leveling Does Not Stop
172
Mast Backward Tilting Speed Is Not Limited/Always Slow
174
Backward Tilt Automatic Fork Leveling Does Not Stop
175
Active Steering Control Knob Moves out of Alignment
177
Active Steering Control Knob Is out of Alignment
178
Hour Meter Is Not Displayed
180
Meter Troubleshooting
180
The Wrench Lamp Does Not Light
180
Wrench Lamp Is Lit Continually
180
Cannot Lower the Lift
181
OPS Troubleshooting
181
Cannot Perform Forward Tilt (OPS)
182
Cannot Perform Backward Tilt (OPS)
183
Cannot Perform Material Handling Except for Lift Lower (OPS)
183
Material Handling OPS Does Not Operate
184
No Material Handling Can be Performed (OPS)
185
Traveling OPS Does Not Operate
186
Cannot Perform Material Handling Except for Lift up and Attachments
187
Cannot Travel (OPS)
187
Cannot Travel (Torque Converter Interlock)
188
The Torque Converter Interlock Does Not Operate
188
Torque Converter Interlock Troubleshooting
188
Power Supply Troubleshooting
189
When Error Code Is Displayed
191
Error Code: 61-3
192
Failure Mode: Pressure Sensor Open Abnormality (P-Port)
192
Error Code: 61-4
195
Failure Mode: Pressure Sensor VCC Short Abnormality (P-Port)
195
Error Code: EC-1
197
Failure Mode: Unload Solenoid Open Circuit or Load Short Abnormality
197
Failure Mode: Electromagnetic Relief Solenoid Open Abnormality
199
Error Code: EC-2
199
Error Code: EC-3
201
Failure Mode: Electromagnetic Relief Solenoid Short Abnormality
201
Error Code: EC-4
203
Electromagnetic Relief Solenoid Drive Circuit Abnormality
203
Wiring Diagram
205
Electrical Wiring Routing - Instrument Panel
206
Relay Locations
209
Engine Room R/B: Engine Room Left
209
System Circuits
210
Body: SAS/OPS System Circuits Diagram
210
Lighting System Diagram
214
Head Lamp Wiring Diagram
214
Clearance Lamp Wiring Diagram
216
Connector List
218
Sst List and Service Standards List
219
Service Standards List
220
Pn3 Ton Series
220
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