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Toyota 8FGU30 User Manual

Toyota 8FGU30
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

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Questions and Answers:

Toyota 8FGU30 Specifications

General IconGeneral
Model8FGU30
CategoryForklifts
Fuel TypeGasoline/LPG
Tire TypePneumatic
Load Capacity6, 000 lbs
Lift Height187 in
Overall Width1220 mm
Turning Radius2400 mm
Engine Power58 hp (43 kW)
Mast Height83 in
Overall Length3200 mm
Overall Height83 inches (with standard mast)
Wheelbase1600 mm
Travel Speed (Full/No Load)12.4 mph

Summary

4Y-E Repair - GENERAL

4Y-E Repair - ENGINE

ENGINE ASSY

Details on engine assembly and its removal/installation.

1DZ-II Repair - GENERAL

BOLT AND NUT TIGHTENING TORQUE

Standard torque values for bolts and nuts.

1DZ-II Repair - TROUBLESHOOTING

ENGINE DOES NOT CRANK NORMALLY

Troubleshooting steps when starter motor does not respond or makes unusual noise.

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

Diagnosis for starting issues related to ignition, fuel, and compression.

ENGINE OVERHAUL (4Y-M) (Section 2)

CYLINDER HEAD

Components and disassembly/assembly procedures for the cylinder head.

CYLINDER BLOCK

Components and disassembly/assembly procedures for the cylinder block.

FUEL SYSTEM (4Y-M) (Section 4)

COOLING SYSTEM (Section 7)

LUBRICATION SYSTEM (Section 8)

OIL PRESSURE INSPECTION

Procedures for checking oil level and measuring oil pressure.

ENGINE OIL AND OIL FILTER REPLACEMENT

Steps for draining engine oil and replacing the oil filter.

IGNITION SYSTEM (Section 9 for 4Y-M)

DISTRIBUTOR

Components, inspection, removal/installation, and disassembly/inspection/reassembly.

STARTING SYSTEM (Section 11 for 4Y-E)

STARTER MOTOR

Components, removal/inspection/installation, and disassembly/inspection/reassembly procedures for the starter motor.

CHARGING SYSTEM (Section 12 for 4Y-E)

ALTERNATOR

Electrical circuit diagram, components, and disassembly/inspection/reassembly.

APPENDIX (Section 13 for 4Y-E)

SERVICE STANDARDS

Detailed service standards and specifications for various engine components.

FUEL SYSTEM (Section 4)

CARBURETOR

Schematic diagram, components, on-vehicle inspection, and adjustment procedures.

LPG Device for 4Y-E Engine - GENERAL

BOLT & NUT TIGHTENING TORQUES

Torque values for bolts and nuts in LPG system.

PERIODIC MAINTENANCE

Schedules for inspection and replacement of LPG system parts.

LPG Device for 4Y-E Engine - OPERATION DESCRIPTION

REGULATOR

Explains the regulator's function in reducing and vaporizing LPG pressure.

LPG Device for 4Y-E Engine - LPG REGULATOR OVERHAUL

PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR

Critical safety precautions for handling LPG systems.

DISASSEMBLY·REASSEMBLY

Detailed steps for disassembling and reassembling the LPG regulator.

LPG LEAK INSPECTION

Methods for checking LPG leaks using soapy water or a gas leak detector.

LPG Device for 4Y-E Engine - ELECTRICAL TROUBLESHOOTING

DIAGNOSIS (SELF DIAGNOSIS FUNCTION)

Explanation of the diagnostic system, error codes, and using the analyzer.

TABLE OF DIAGNOSIS CODES

Lists error codes, their memory, spanner, detection ECU, error mode, and phenomenon.

TROUBLESHOOTING BY SYMPTOMS

Symptom-based troubleshooting guide with page references.

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