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Toyota 8FGU25 User Manual

Toyota 8FGU25
618 pages
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SECTION INDEX
NAME
SECTION
GENERAL
0
ENGINE - CHASSIS
1
4Y-E REPAIR
1.1
1DZ-II REPAIR
1.2
4Y-E LPG DEVICE REPAIR
1.3
TRANSMISSION (Pn1•2•3 / Cu2•3)
2
TRANSMISSION (Cu1 Ton Series)
2.1
PROPELLER SHAFT
3
DIFFERENTIAL
4
FRONT AXLE
5
REAR AXLE
6
STEERING
7
BRAKE
8
BODY
9
MATERIAL HANDLING SYSTEM
10
MAST
11
CYLINDER
12
OIL PUMP
13
OIL CONTROL VALVE
14
MINI LEVER - JOYSTICK
15
SAS / OPS
16
SSTLIST - SERVICE STANDARDS LIST
17
MULTIFUNCTION DISPLAY DX (OPTIONAL)
18
ELECTRICAL SYSTEM TROUBLESHOOTING [except Cu1]
19
ELECTRICAL SYSTEM TROUBLESHOOTING [Cu1 ton series]
19.1
WIRING DIAGRAM
E
SERVICE INFORMATION BULLETINS SIB

Table of Contents

Other manuals for Toyota 8FGU25

Questions and Answers:

Toyota 8FGU25 Specifications

General IconGeneral
Model8FGU25
Lift Height189 inches
Tire TypePneumatic
TransmissionAutomatic
Engine TypeInternal Combustion
Load Capacity5000 lbs
Fuel TypeGasoline or LPG
Mast Type2-Stage
Overall Width45.3 in (1150 mm)
Wheelbase63 in (1600 mm)

Summary

GENERAL

VEHICLE MODEL

Details classification, load capacity, vehicle model, transmission, and engine.

OPERATIONAL TIPS

Provides guidance on safe operation, handling troubles, and disposal.

STANDARD BOLT & NUT TIGHTENING TORQUE

Details bolt strength identification and tightening torque tables.

RECOMMENDED LUBRICANT QUANTITY & TYPES

Lists recommended lubricants, quantities, and types for various components.

BOLT & NUT TIGHTENING TORQUES

Provides bolt and nut tightening torques.

LUBRICATION CHART

Provides a diagram and table for lubrication points and inspection intervals.

PERIODIC MAINTENANCE

Outlines periodic maintenance for LPG system.

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Specifies replacement intervals for parts and lubricants.

BOLT AND NUT TIGHTENING TORQUE

Provides standard bolt and nut tightening torques.

BOLT STRENGTH TYPE IDENTIFICATION METHOD AND TIGHTENING TORQUE

Explains bolt strength identification and torque.

PERIODIC REPLACEMENT PARTS

Specifies replacement intervals for LPG parts.

ENGINE

ENGINE MAIN PARAMETERS

Lists key parameters for Gasoline and Diesel engines.

ENGINE ASSY

Illustrates engine assembly components and provides torque specifications.

ENGINE INSPECTION·ADJUSTMENT

Explains inspection and adjustment procedures for engine idle and maximum speed.

Battery Removal

Provides steps for safely removing the battery.

V-BELT TENSION ADJUSTMENT

Explains how to inspect and adjust V-belt tension.

INSPECTION·ADJUSTMENT

Details inspection and adjustment of the accelerator pedal and sensor.

THROTTLE OPENING DEGREE ADJUSTMENT

Details adjustment procedures for idle and NMR switches.

TROUBLESHOOTING

Provides troubleshooting advice for the travel and load handling control device.

4Y-E Repair

GENERAL

Lists general specifications for the 4Y-E engine.

OPERATING TIPS

Provides general instructions for safe operation and preparation.

ELECTRICAL PARTS INSPECTION

Details procedures for inspecting electrical parts.

TROUBLESHOOTING

MECHANICAL TROUBLE

Classifies engine fault causes into fuel, compression, and ignition.

TECHNICAL TROUBLE

Classifies engine malfunctions by fuel injection, compression, and preheating.

ENGINE DOES NOT CRANK NORMALLY

Lists symptoms and inspection areas for starter issues.

ENGINE DOES NOT START EASILY, OR DOES NOT START AT ALL

Details inspection areas for starting problems.

ENGINE DOES NOT START EASILY OR DOES NOT START AT ALL

Details inspection areas for starting problems.

ENGINE IS ROUGH, OR STOPS, DURING IDLING

Lists phenomena and inspection areas for idling issues.

CANNOT ACCELERATE SMOOTHLY (INCLUDING HESITATION)

Lists inspection areas for acceleration problems.

INSUFFICIENT POWER OUTPUT (INCLUDING HUNTING)

Lists inspection areas for insufficient power output.

ENGINE OVERHEATS

Lists inspection areas for engine overheating.

ENGINE OVERHEATING

Lists inspection areas for engine overheating.

EXCESSIVE FUEL CONSUMPTION

Lists factors and inspection areas for high fuel consumption.

ABNORMAL COMBUSTION

Classifies abnormal noises like knocking and run-on.

ABNORMAL ENGINE NOISE, OR NOISY ENGINE

Details abnormal noises by operation and cause.

EXCESSIVE ENGINE OIL CONSUMPTION

Classifies oil consumption symptoms and inspection areas.

HIGH ENGINE OIL CONSUMPTION

Classifies oil consumption symptoms and inspection areas.

ENGINE OVERHAUL

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Explains valve clearance check and adjustment.

INJECTION TIMING INSPECTION AND ADJUSTMENT

Explains ignition timing inspection and adjustment.

COMPRESSION INSPECTION

Outlines compression inspection procedure.

ENGINE OVERHAUL (4Y-E)

DISASSEMBLY·INSPECTION·REASSEMBLY

Details procedures for cylinder head disassembly.

INSPECTION·ADJUSTMENT OF IGNITION TIMING

Details ignition timing inspection and adjustment.

FUEL SYSTEM (4Y-M)

LUBRICATION SYSTEM

OIL PRESSURE INSPECTION

Details engine oil pressure inspection.

ENGINE OIL AND OIL FILTER REPLACEMENT

Outlines engine oil and filter replacement.

IGNITION SYSTEM (4Y-M)

IGNITION SYSTEM (4Y-E)

STARTING SYSTEM

STARTER ASSEMBLY INDIVIDUAL INSPECTION

Describes individual inspection tests for the starter assembly.

CHARGING SYSTEM

DISASSEMBLY-INSPECTION-REASSEMBLY

Outlines alternator disassembly, inspection, and reassembly.

DISASSEMBLY, INSPECTION AND REASSEMBLY

Outlines alternator disassembly, inspection, and reassembly.

APPENDIX

SERVICE STANDARDS

Lists service standards for engine overhaul components.

ENGINE BODY

Provides service standards for cylinder block.

TIGHTENING TORQUE FOR EACH PART

Lists tightening torques for various engine components.

FUEL SYSTEM

OPERATION DESCRIPTION

LPG REGULATOR OVERHAUL

PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR

Provides safety precautions for LPG forklift operation and repair.

LPG LEAK INSPECTION

Explains how to check for LPG leaks.

ELECTRICAL TROUBLESHOOTING

BEFORE BEGINNING TROUBLESHOOTING

Provides a diagnostic procedure checklist.

DIAGNOSIS (SELF DIAGNOSIS FUNCTION)

Explains diagnosis system and error code display.

ABOUT TROUBLE SHOOTING BY ERROR CODES

Guides on troubleshooting by error codes.

TABLE OF DIAGNOSIS CODES

Lists diagnosis codes and their meanings.

TROUBLESHOOTING BY SYMPTOMS

Provides a symptom chart for troubleshooting.

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