Toyota Forklift 8FG35U to 8FGC70U Repair Manual

Description

Contents:
Toyota Forklift 8FG35U to 8FGC70U Repair Manual CE105 Vol.2

Toyota Forklift 8FG35U to 8FGC70U Repair Manual CE104 Vol.1 (674 Pages)
GENERAL
EXTEROR VIEWS
VEHICLE MODEL
FRAME NUMBER
HOW TO USE THIS MANUAL
EXPLANATION METHOD
TERMINOLOGY
ABBREVIATIONS
OPERATIONAL TIPS
HOUR METER START
CIRCUIT TESTER
STANDARD BOLT & NUT TIGHTENING TORQUE
BOLT STRENGTH TYPE IDENTIFICATION METHOD
TIGHTENING TORQUE TABLE
PRECOAT BOLTS
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
HOISTING THE VEHICLE
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
COMPONENTS WEIGHT
RECOMMENDED LUBRICANT QUANTITY & TYPES
LUBRICATION CHART
PERIODIC MAINTENANCE
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
1 ENGINE
ENGINE EXTERIOR VIEWS
MAJOR SPECIFICATIONS
ENGINE PERFORMANCE CURVES
ENGINE ASSY
REMOVAL AND INSTALLATION
AIR BLEEDING OF THE FUEL SYSTEM (DIESEL VEHICLE)
1FS ENGINE INSPECTION AND ADJUSTMENT
Idle Speed Inspection (for both gasoline and LPG)
No-load Maximum Speed Inpsection (for both gasoline and LPG)
Compression Inspection (for both gasoline and LPG)
V-belt Tension Inspection and Adjustment (for both gasoline and LPG)
Oil Pressure Inspection (for both gasoline and LPG)
Ignition Inspection (for both gasoline and LPG)
VF Voltage Inspection and Adjustment (only for LPG)
Fuel Pressure Inspection (only for gasoline)
Injector Inspection and Cleaning (only for gasoline)
Fuel Pump Inspection (only for gasoline)
LPG Injector Inspection (only for LPG)
LPG Resistor Inspection (only for LPG)
Electronic Throttle Inspection and Cleaning (for both gasoline and LPG)
Intake Air Temperature Sensor Inspection (for both gasoline and LPG)
Water Temperature Sensor Inspection (for both gasoline and LPG)
Crank Angle Sensor Inspection (for both gasoline and LPG)
Cam Angle Sensor Inspection (for both gasoline and LPG)
O2 Sensor Inspection (for both gasoline and LPG)
Vacuum Sensor Inspection (for both gasoline and LPG)
1KD ENGINE INSPECTION AND ADJUSTMENT
Idle Speed Inspection
No-load Maximum Speed Inpsection
Compression Inspection
V-ribbed Belt Inspection and Adjustment
Oil Pressure Inspection
Preheating System Inspection
Glow Plug Inspection
Fuel Pressure Inspection
Inlet Air Temperature Sensor Inspection
Crank Position Sensor Inspection
Cam Position Sensor Inspection
Intake Air Flowmeter S/A Inspection
Water Temperature Sensor Inspection
Turbo Charger S/A Inspection
Supply Pump ASSY Inspection
Common Rail ASSY Inspection
Electric EGR Control Valve Inspection
AIR CLEANER
COMPONENTS
SPECIFICATIONS
AIR CLEANER CLEANING AND INSPECTION
CLOGGING WARNING SYSTEM INSPECTION (OPT)
RADIATOR
COMPONENTS
SPECIFICATIONS
COOLANT CAPACITY AND ANTIFREEZE TABLE
FAN DRIVE
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
FAN DRIVE SHAFT
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
MUFFLER & EXHAUST PIPE
COMPONENTS
REMOVAL AND INSTALLATION
LPG REGULATOR
GENERAL
COMPONENTS
SPECIFICATIONS
SSTs FOR LPG REGULATOR OVERHAUL
HOW TO DEAL WITH TAMPER PROOF RING
TROUBLESHOOTING
REMOVAL AND INSTALLATION
LPG MAIN SOLENOID & FILTER
COMPONENTS
LPG MAIN SOLENOID INSPECTION
FILTER INSPECTION AND CLEANING
1FS FUEL PUMP
REMOVAL AND INSTALLATION
FUEL SENDER GAUGE
1KD FUEL FILTER
COMPONENTS
REMOVAL, INSPECTION AND INSTALLATION
TROUBLESHOOTING
STARTER ASSY
COMPONENTS
REMOVAL, INSPECTION AND INSTALLATION
BATTERY
COMPONENTS
SPECIFICATIONS
BATTERY
ACCELERATOR PEDAL
COMPONENTS
INSPECTION AND ADJUSTMENT
EZ PEDAL (OPT)
COMPONENTS
DISASSEMBLY, INSPECTION AND REASSEMBLY
ADJUSTMENT
2 TORQUE CONVERTER & TRANSMISSION
GENERAL
HYDRAULIC CIRCUIT DIAGRAM
SPECIFICATIONS
COMPONENTS
TROUBLESHOOTING
TORQUE CONVERTER
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
TORQUE CONVERTER & TRANSMISSION ASSY
REMOVAL AND INSTALLATION
TRANSMISSION ASSY
DISASSEMBLY, INSPECTION AND REASSEMBLY
STATOR SHAFT NO.2 & OIL PUMP ASSY
DISASSEMBLY, INSPECTION AND REASSEMBLY
CLUTCH DRUM ASSY
DISASSEMBLY, INSPECTION AND REASSEMBLY
DIRECTION SWITCH ASSY
REMOVAL, INSPECTION AND INSTALLATION
OIL PRESSURE MEASUREMENT AND STALL TEST
3 PROPELLER SHAFT
GENERAL
SPECIFICATION
COMPONENTS
PROPELLER SHAFT
REMOVAL AND INSTALLATION
DISASSEMBLY AND INSPECTION AND REASSEMBLY(Pn35 to 45,Cu35 to 50 MODEL)
4 DIFFERENTIAL
GENERAL
SPECIFICATION
COMPONENTS
DIFFERENTIAL ASSY
REMOVAL AND INSTALLATION (Pn35 to 50 MODEL)
REMOVAL AND INSTALLATION(Pn60 to 80, Cu35 to 70 MODEL)
DISASSEMBLY, INSPECTION AND REASSEMBLY
DIFFERENTIAL CASE ASSY
DISASSEMBLY, INSPECTION AND REASSEMBLY
5 FRONT AXLE
GENERAL
SPECIFICATION
COMPONENTS
TIRES and WHEELS (PNEUMATIC TIRE)
FRONT AXLE ASSY (Pn35 to 50 MODEL)
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
FRONT AXLE ASSY (Pn 60 to 80, Cu35 to 70)
REMOVAL AND INSTALLTION
FRONT AXLE HOUSING AND DIFFERENTIAL HOUSING (Pn60 to 80, Cu35 to 70 MODEL)
REMOVAL AND INSTALLATION (Pn60 to 80 MODEL)
REMOVAL AND INSTALLATION (Cu35 to 70 MODEL)
6 REAR AXLE
GENERAL
REAR AXLE
REAR AXLE CYLINDER
SPECIFICATIONS
COMPONENTS
TIRES AND WHEELS (PNEUMATIC TIRE)
REAR AXLE ASSY (Pn 35 to 80 MODEL)
REMOVAL AND INSTALLATION
REAR AXLE ASSY (Cu 35 to 70 MODEL)
REMOVAL AND INSTALLATION
REAR AXLE HUB AND STEERING KNUCKLE (Pn 35 to 80 MODEL)
REMOVAL AND INSTALLATION (Pn 35 to 50 model)
REMOVAL AND INSTALLATION (Pn 60 to 80 model)
STEERING KNUCKLE (Cu 35 to 70 MODEL)
REAR AXLE CYLINDER
REMOVAL AND INSTALLATION (Pn 35 to 80 MODEL)
REMOVAL AND INSTALLATION (Cu 35 to 70 MODEL)
DISASSEMBLY AND INSPECTION AND REASSEMBLY
7 STEERING
GENERAL
SPECIFICATIONS
COMPONENTS
STEERING WHEEL AND MAST JACKET
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
POWER STEERING VALVE ASSY
TROUBLESHOOTING
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
RELIEF PRESSURE INSPECTION AND ADJUSTMENT
KNOB CORRECTION VALVE (Pn60 TO 80, Cu35 TO 70 OPT)
REMOVAL AND INSTALLATION
8 BRAKE
GENERAL
SPECIFICATIONS
COMPONENTS
FRONT BRAKE
DISASSEMBLY, INSPECTION AND REASSEMBLY (Cu35 AND 45 MODEL)
DISASSEMBLY, INSPECTION AND REASSEMBLY (Pn35 TO 80, Cu55 TO 70 MODEL)
BRAKE AIR BLEEDING
BRAKING FORCE INSPECTION AND ADJUSTMENT
BRAKE BOOSTER
TROUBLESHOOTING
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
PARKING BRAKE INSPECTION AND ADJUSTMENT
BRAKE PEDAL INSPECTION AND ADJUSTMENT
INCHING PEDAL INSPECTION AND ADJUSTMENT
SINGLE BRAKE PEDAL INSPECTION AND ADJUSTMENT (1-PEDAL: OPT)
TORQUE AND APPLING GREASE
9 BODY
COMPONENTS
COUNTERWEIGHT
REMOVAL AND INSTALLATION
ENGINE HOOD ASSY
REMOVAL AND INSTALLATION
DRIVER’S SEAT
REMOVAL AND INSTALLATION
SEATBELT
REMOVAL AND INSTALLATION
SEATBELT RETRACTOR INSPECTION
HEADLAMPS
REMOVAL AND INSTALLATION
BULB REPLACEMENT
COMBINATION METER
REMOVAL AND INSTALLATION
COMBINATION SWITCH
INSPECTION
10 MATERIAL HANDLING SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
COMPONENTS
RETURN FILTER AND SUCTION FILTER
REMOVAL AND INSTALLATION
NATURAL DROP TEST
NATURAL FORWARD TILT TEST
OIL LEAK TEST
LIFT CYLINDER
TILT CYLINDER
11 MAST
V MAST ASSY
COMPONENTS (V MAST)
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION(W/LIFT BRACKET)
MAST DISASSEMBLY, INSPECTION AND REASSEMBLY
LIFT BRACKET DISASSEMBLY, INSPECTION AND REASSEMBLY
MAST ADJUSTMENT (V MAST)
MAST ROLLER REMOVAL AND INSTALLATION
CHAIN
INSPECTION
REASSEMBLY
ADJUSTMENT
FORK
REMOVAL
INSTALLATION
INSPECTION
FV AND FSV MAST ASSY
COMPONENTS (FV and FSV MAST)
MAST ADJUSTMENT (FV and FSV MAST)
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVENLIFTING)
12 CYLINDER
LIFT CYLINDER(V) AND REAR LIFT CYLINDER (FV/FSV)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
SAFETY DOWN VALVE
GENERAL
REMOVAL AND INSTALLATION
FRONT LIFT CYLINDER (FV and FSV)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
TILT CYLINDER
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (ADJUSTMENT OF UNEVEN TILTING)
13 OIL PUMP
GENERAL
SPECIFICATIONS
COMPONENTS
OIL PUMP ASSY
REMOVAL and INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
PERFORMANCE TEST
14 OIL CONTOROL VALVE
OIL CONTROL VALVE (Mechanical controlled valve)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
OIL CONTROL VALVE (Solenoid controlled valve)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY, INSPECTION AND REASSEMBLY
I-Q PLATE
CONTROL VALVE LEVER ASSY
REMOVAL AND INSTALLATION
RELIEF PRESSURE ADJUSTMENT
MANUAL DOWN VALVE
TROUBLESHOOTING
15 MINI LEVER
GENERAL
COMPONENTS
REMOVAL AND INSTALLATION
DISASSEMBLY,INSPECTION AND REASSEMBLY
16 SAS/OPS
GENERAL
SAS FUNCTION
COMPONENTS
PRECAUTIONS FOR REPAIR
SAS/OPS CONTROLLER REMOVAL AND INSTALLATION
YAW RATE SENSOR REMOVAL AND INSTALLATION
TIRE ANGLE SENSOR REMOVAL AND INSTALLATION
SWING LOCK CYLINDER REMOVAL AND INSTALLATION
TILT ANGLE SENSOR REMOVAL AND INSTALLATION
SPEED SENSOR REMOVAL AND INSTALLATION
LOAD SENSOR REMOVAL AND INSTALLATION
FORK HEIGHT SWITCH REMOVAL AND INSTALLATION
OPS FUNCTIONS
GENERAL
CONTROL SPECIFICATION
17 SST LIST AND SERVICE STANDARDS LIST
SST LIST
SERVICE STANDARDS LIST
ENGINE
TORQUE CONVERTER & TRANSMISSION ASSY
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
SAS/OPS
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