Toyota 8FBCHU 25, Repair Manual

Page 1: ...8FBCU 20 25 28 30 32 8FBCHU 25 VOL 1 Pub No CU346 ...

Page 2: ...ee vol 2 NAME SECTION GENERAL 0 BATTERY 1 CONTROL SYSTEM 2 MULTI FUNCTION DISPLAY 3 TROUBLESHOOTING 4 MOTOR 5 DRIVE UNIT 6 FRONT AXLE 7 REAR AXLE 8 STEERING 9 BRAKE 10 BODY 11 MATERIAL HANDLING SYSTEM 12 MAST 13 CYLINDER 14 OIL PUMP 15 OIL CONTROL VALVE 16 SAS FUNCTIONS 17 APPENDIX 18 Sec Index fm 1 ページ ２０１０年３月３１日 水曜日 午後４時２１分 ...

Page 3: ...TS 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 PERIOD...

Page 4: ...0 2 EXTERIOR VIEWS 0 sec00 book 2 ページ ２０１０年４月１４日 水曜日 午後６時２９分 ...

Page 5: ...Code Load Capacity Vehicle Model Voltage Remarks 20 4000 lbs 8FBCU20 36V 48V 25 5000 lbs 8FBCU25 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 ...

Page 6: ... EEC spec Vehicle Model Punching format 8FBCU20 8FBCU25 60011 8FBCU25 60011 8FBCU25 8FBCHU25 8FBCHU25 60011 8FBCU28 8FBCU28 60011 8FBCU28 60011 8FBCU30 8FBCU32 60011 8FBCU32 60011 8FBCU32 Punching position sec00 book 4 ページ ２０１０年４月１４日 水曜日 午後６時２９分 ...

Page 7: ... 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 in illustrations When a part requiring tightening torque instruction is not indicated in the illustration the part name is described in the illustration frame T 46 1 to 48 1 470 to 490 34 0 to 35 5 Ã Operation explained lat...

Page 8: ... Abbreviation code Meaning Abbreviation code Meaning ASSY Assembly RR Rear ATT Attachment SAE Society of Automotive Engineers USA EHPS Electronically controlled fully hydraulic power steering SAS System of active stability FHPS Fully hydraulic power steering SOL Solenoid LH Left hand SST Special service tool FR Front STD Standard OPS Operator Presence Sensing T Tightening torque OPT Option T Numbe...

Page 9: ...mn in the table above before calculation For example when converting 100 W to the value in conventional 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 0...

Page 10: ...the specified tightening torque range If no tightening torque is specified tighten the bolt or nut according to the standard tightening torque 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 rela...

Page 11: ...0 9 7 Disconnect the battery plug When 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 ...

Page 12: ...ith 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...

Page 13: ...2 The traveling speed in towing must not exceed the maximum traveling speed of the forklift 3 Always set the key switch to OFF and the direction switch to the neutral position before starting towing In case of towing by connection with a wire rope with the operator on the forklift however set the key switch to ON PS operation and always set the direction switch to the neutral position 4 Before tow...

Page 14: ...age 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 are different 6 The SAS oil control valves comprise many precision valves Since dirty or contaminated hydraulic oil will adversely affect the functions of these valves always wash the parts clean at the time ...

Page 15: ...l 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 described below 1 Analog circuit tester Measurement result example Tester range kΩ range 2 Digital circuit tester Measurement result example...

Page 16: ...measurement with a circuit 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 to vary the circuit resistance Even when the same diode is measured the measurement result varies with the measurement range Always use the range described in the...

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Page 18: ... table 2 For tightening torque of hexagon flange bolts identify bolt class based on the below chart and then determine using 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 4T 5 5T 6 6T 7 7T 8 8T No mark 4T Two protrudi...

Page 19: ... 32 59 91 137 65 160 330 600 930 1400 5 12 24 43 67 101 6T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 7 8 19 39 72 108 172 80 190 400 730 1100 1750 6 14 29 53 80 127 7T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 11 25 52 95 147 226 110 260 530 970 1500 2300 8 19 38 70 108 166 8T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 12 29 61 108 172 265 120 300 620 1100 1750 2700 9 22 45 80 127 195 Length mm ...