Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 1 PDF

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Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 1 – PDF DOWNLOAD

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Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 1 – PDF DOWNLOAD

Language : English
Pages : 465
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 1 – PDF DOWNLOAD\

GENERAL 4
EXTERIOR VIEWS 5
VEHICLE MODEL 6
FRAME NUMBER 7
Frame No Punching Position 7
TERMINOLOGY 8
ABBREVIATIONS 8
SI UNITS 9
Meaning of SI 9
New Units Adopted in SI 9
OPERATIONAL TIPS 10
JACK-UP POINT 12
HOISTING THE VEHICLE 13
CAUTION FOR TOWING 13
CIRCUIT TESTER 14
STANDARD BOLT & NUT TIGHTENING TORQUE 16
BOLT STRENGTH CLASS IDENTIFICATION METHOD 16
Identification by Bolt Shape 16
Identification by Part No 17
Tightening Torque Table 17
Identification by Bolt Shape (Hexagon flange bolt) 18
Tightening Torque Table (Hexagon flange bolt) 18
PRECOAT BOLTS 19
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 19
WIRE ROPE SUSPENSION ANGLE LIST 20
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE 20
COMPONENTS WEIGHT 21
Member weight list 21
RECOMMENDED LUBRICANT QUANTITY & TYPES 22
Amounts and Types of Specified Lubricants 22
LUBRICATION CHART 23
PERIODIC MAINTENANCE 24
Inspection Method 24
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS 28
BATTERY 29
BATTERY COMPARTMENT AND REQUIRED WEIGHT 30
SERVICE STANDARDS 31
TROUBLESHOOTING 31
INSPECTION 32
BATTERY SIDE-OUT 35
ROLL OUT 35
SIDE-OUT FOR FORK POCKET 36
CHARGER 37
ON-TRUCK TYPE 38
GENERAL 38
TRANSFORMER ASSY 40
GENERAL 40
SPECIFICATIONS 41
CHARGER PANEL 43
GENERAL 43
SPECIFICATIONS 45
CHARGER LIST 46
COMPONENTS 47
REMOVAL·INSTALLATION 48
Removal Procedure 48
Installation Procedure 49
COOLING FAN 50
COMPONENTS 50
REMOVAL·INSTALLATION 51
Removal Procedure 51
Installation Procedure 51
CHARGER PANEL 52
COMPONENTS 52
REMOVAL·INSTALLATION 53
Removal Procedure 53
Installation Procedure 53
TRANSFORMER ASSY 54
REMOVAL·INSTALLATION 54
Removal Procedure 54
Installation Procedure 55
CHARGER INSPECTION 56
Inspection standard 56
Inspection procedures 56
OFF-TRUCK TYPE 59
CHARGER LIST 59
FRONT MODULE 61
FRONT MODULE ASSY 63
GENERAL 63
REMOVAL·INSTALLATION 64
Removal Procedure 65
Installation Procedure 72
MOTOR 74
GENERAL CONFIGURATION 74
DRIVE MOTOR 78
GENERAL 78
SPECIFICATIONS 78
COMPONENTS 79
REMOVAL·INSTALLATION 81
Removal Procedure 81
Installation Procedure 82
DISASSEMBLY·INSPECTION·REASSEMBLY 84
Disassembly Procedure 84
Reassembly Procedure 86
PUMP MOTOR 87
GENERAL 87
SPECIFICATIONS 87
COMPONENTS 88
REMOVAL·INSTALLATION 90
Removal Procedure 90
Installation Procedure 90
DISASSEMBLY·INSPECTION·REASSEMBLY 91
Disassembly Procedure 91
Reassembly Procedure 93
DRIVE UNIT 94
REMOVAL·INSTALLATION 94
Removal Procedure 95
Installation Procedure 95
DISASSEMBLY·INSPECTION·REASSEMBLY 97
Disassembly Procedure 97
Reassembly Procedure101
DIFFERENTIAL CASE ASSY102
DISASSEMBLY·INSPECTION·REASSEMBLY (1·2 TON SERIES)102
DISASSEMBLY·INSPECTION·REASSEMBLY (3 TON SERIES)103
Disassembly Procedure (1·2 ton series)104
Disassembly Procedure (3 ton series)105
Reassembly Procedure (1·2 ton series)107
Reassembly Procedure (3 ton series)109
FRONT AXLE110
GENERAL110
COMPONENTS111
1 ton series111
2 ton series113
3 ton series115
TIRES·WHEELS117
FRONT AXLE SHAFT·AXLE HUB118
REMOVAL·INSTALLATION118
Removal Procedure119
Installation Procedure120
FRONT AXLE BRACKET·AXLE HOUSING123
REMOVAL·INSTALLATION123
Removal Procedure124
Installation Procedure124
FRONT BRAKE126
GENERAL126
FRONT BRAKE126
Parking brake127
Master cylinder128
SPECIFICATIONS128
COMPONENTS129
Brake pipe129
Brake master cylinder130
Reservoir tank131
Brake pedal132
Potentiometer type, limit switch type133
DISASSEMBLY·INSPECTION·REASSEMBLY134
1 ton series134
2 · 3 ton series134
Disassembly Procedure135
Reassembly Procedure139
BRAKE AIR BLEEDING144
BRAKING FORCE INSPECTION·ADJUSTMENT145
BRAKE MASTER CYLINDER146
REMOVAL·INSTALLATION146
Removal Procedure146
Installation Procedure148
DISASSEMBLY·INSPECTION·REASSEMBLY149
Disassembly Procedure149
Reassembly Procedure149
PARKING BRAKE LEVER151
GENERAL151
How to Operate the Parking Brake Lever151
PARKING BRAKE WIRE REMOVAL152
PARKING BRAKE INSPECTION·ADJUSTMENT153
BRAKE SWITCH INSPECTION·ADJUSTMENT154
Potentiometer type (8FBN15,16,18,20,25,30)154
Limit switch type (50-8FBN15,18,20)155
Stop lamp switch155
BRAKE PEDAL INSPECTION·ADJUSTMENT156
OIL PUMP158
GENERAL158
Single Gear Pump158
COMPONENTS159
REMOVAL·INSTALLATION160
Removal Procedure160
Installation Procedure164
Caution for installation165
DISASSEMBLY·INSPECTION·REASSEMBLY167
Disassembly Procedure168
Reassembly Procedure169
TEST METHOD171
OIL CONTROL VALVE ASSY172
GENERAL (2-WAY)172
X1-X1 section174
X2-X2 section175
X3-X3 section176
X4-X4 section177
Y1-Y1 section (Inlet Side)177
Y2-Y2 section (Lift Side)178
Y3-Y3 section (Tilt Side)178
Solenoid Connector Diagram179
Parts List180
Tightening Torque List181
Hydraulic Circuit Diagram182
GENERAL (4-WAY STANDARD)183
X1-X1 section185
X2-X2 section186
X3-X3 section187
X4-X4 section188
X5-X5 section189
Y1-Y1 section (Inlet Side)189
Y2-Y2 section (Lift Side)190
Y3-Y3 section (Tilt & Attachment Side)190
Solenoid Connector Diagram191
Parts List192
Tightening Torque List193
Hydraulic Circuit Diagram194
GENERAL (4-WAY PR)195
X1-X1 section197
X2-X2 section198
X3-X3 section199
X4-X4 section200
X5-X5 section201
X6-X6 section201
Y1-Y1 section (Inlet Side)202
Y2-Y2 section (Lift Side)202
Y3-Y3 section (TILT & Attachment Side)203
Solenoid Connector Diagram204
Parts List205
Tightening Torque List206
Hydraulic Circuit Diagram207
SPECIFICATIONS208
2-WAY208
4-WAY STANDARD208
4-WAY PR208
I-Q PLATE209
REMOVAL·INSTALLATION210
Removal Procedure211
Installation Procedure211
RELIEF PRESSURE ADJUSTMENT212
MANUAL DOWN VALVE214
TROUBLESHOOTING215
INLET SECTION (X1-X1)232
LIFT SECTION (X2-X2)233
TILT SECTION (X3-X3)234
ATT SECTION (X4-X4)235
Hydraulic Circuit Diagram236
I-Q PLATE237
REAR AXLE238
GENERAL239
Rear Axle Cylinder241
COMPONENTS242
REAR AXLE SUPPORT242
STEERING KNUCKLE·KING PIN·TIE-ROD·HUB·REAR AXLE CYLINDER243
TIRE ANGLE SENSOR245
REAR AXLE CYLINDER246
TIRES·WHEELS247
REAR AXLE ASSY248
REMOVAL·INSTALLATION248
Removal Procedure248
Installation Procedure249
REAR AXLE HUB·STEERING KNUCKLE250
REMOVAL·INSTALLATION250
Removal Procedure250
Installation Procedure251
REAR AXLE CYLINDER256
REMOVAL·INSTALLATION256
Removal Procedure256
Installation Procedure257
DISASSEMBLY·INSPECTION·REASSEMBLY258
Disassembly Procedure258
Reassembly Procedure259
TIRE ANGLE SENSOR (SAS/ SYNCHRONIZED STEERING SPECIFICATION)260
REMOVAL·INSTALLATION260
Removal Procedure260
Installation Procedure260
OPTIONS262
Rear Axle Cylinder Boots262
Rear axle cylinder for the cold storage specification262
Rust proof bolt263
STEERING264
GENERAL265
Hydrostatic Steering Valve266
SPECIFICATIONS267
STEERING WHEEL·MAST JACKET268
REMOVAL·INSTALLATION268
Removal Procedure268
Installation Procedure270
DISASSEMBLY·INSPECTION·REASSEMBLY271
Disassembly Procedure271
Installation Procedure271
STEERING VALVE ASSY272
REMOVAL·INSTALLATION272
Removal Procedure272
Installation Procedure272
DISASSEMBLY·INSPECTION·REASSEMBLY273
Disassembly Procedure273
Reassembly Procedure274
RELIEF PRESSURE INSPECTION278
BODY279
EXTERIOR VIEWS280
FRAME281
GENERAL281
Rear frame282
VEHICLE SPECIFCATIONS283
DRIVER’S SEAT (Operating levers and switches)285
HYDRAULIC OIL TANK286
STRUCTURAL SUMMARY286
1 · 2 ton series286
3 ton series286
COMPONENTS287
1 · 2 ton series287
3 ton series288
REMOVAL·INSTALLATION (1 · 2 ton series)289
Removal Procedure289
Installation Procedure291
REMOVAL·INSTALLATION (3 ton series)293
Removal Procedure293
Installation Procedure295
HYDRAULIC OIL296
ACCELERATOR PEDAL298
Installation Procedure298
Adjustment298
ELECTRICAL PARTS LAYOUT299
F1 Fuse302
Accessory fuse (1 · 2 ton series)302
Accessory fuse (3 ton series)302
Relay303
Power supply (3 ton series)303
PTC thermistor304
Accelerator sensor304
Resistor304
MATERIAL HANDLING SYSTEM305
HYDRAULIC CIRCUIT DIAGRAM306
COMPONENTS307
RETURN FILTER307
RETURN FILTER HOSE308
IDENTIFICATION AND POSITIONING MARKING308
DIRECTION OF OIL FLOW309
RETURN FILTER310
REMOVAL·INSTALLATION310
Removal Procedure310
Installation Procedure311
SUCTION FILTER (3 ton series)312
REMOVAL·INSTALLATION312
Removal Procedure313
Installation Procedure313
CONVENTIONAL LEVER ASSY315
GENERAL315
COMPONENTS316
4-WAY LEVER, ROD ASSYÅESENSOR ASSY316
REMOVAL·INSTALLATION317
Removal Procedure317
Installation Procedure318
NOTES ON CONVENTIONAL LEVER REPLACEMENT318
MINI LEVER·JOY STICK LEVER (OPT)320
GENERAL320
Mini lever (Direction shift lever located on the armrest)320
Joy stick lever (Direction shift lever located on the armrest)322
COMPONENTS324
REMOVAL·INSTALLATION328
Removal Procedure328
Installation Procedure329
DISASSEMBLY·REASSEMBLY331
Disassembly Procedure331
Reassembly Procedure331
NATURAL DROP TEST332
NATURAL FORWARD TILT TEST332
OIL LEAK TEST333
LIFT CYLINDER333
TILT CYLINDER333
MAST334
COMPONENTS335
V MAST335
Mast335
Lift Bracket (1 ton series)336
Lift Bracket (2 ton series)337
Lift Bracket (3 ton series)338
Chain339
FSV MAST340
Mast340
Lift Bracket (1 ton series)341
Lift Bracket (2 ton series)342
Lift Bracket (3 ton series)343
Chain344
FV MAST345
Mast345
Lift Bracket (1 ton series)346
Lift Bracket (2 ton series)347
Lift Bracket (3 ton series)348
Chain349
MAST ASSY350
REMOVAL·INSTALLATION (L/ LIFT BRACKET)350
Removal Procedure351
Installation Procedure352
REMOVAL·INSTALLATION (W/ LIFT BRACKET)353
Removal Procedure353
Installation Procedure354
DISASSEMBLY·INSPECTION·REASSEMBLY355
Disassembly Procedure355
Reassembly Procedure356
MAST ROLLER REMOVAL·INSTALLATION357
LIFT BRACKET358
DISASSEMBLY·REASSEMBLY358
Disassembly Procedure359
Reassembly Procedure359
CHAIN360
INSPECTION360
REASSEMBLY361
ADJUSTMENT362
FORK363
REMOVAL·INSTALLATION363
Removal Procedure363
Installation Procedure363
MAST ADJUSTMENT364
LIFT ROLLER ADJUSTMENT AT MAST364
Inner Mast Roller (V·FSV·FV) and Middle Mast Lower Roller (FSV) Clearance Adjustment364
Outer Mast Roller (V·FSV·FV) and Middle Mast Upper Roller (FSV) Clearance Adjustment366
ROLLER ADJUSTMENT AT LIFT BRACKET367
V Mast (1·3 ton series)367
V Mast (2 ton series)370
FSV Mast371
FV Mast373
MAST STRIP ADJUSTMENT374
Mast Strip Clearance Adjustment374
STANDARD FOR SELECTING AN OVERSIZE ROLLER375
LIFT CYLINDER ADJUSTMENT376
V·FSV MAST376
FV MAST377
CYLINDER378
LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV)379
GENERAL379
Lift Cylinder (V/ 1·2 ton series)·Rear Lift Cylinder (FSV/ 1·2 ton series)379
Lift Cylinder (V/ 3 ton series)379
Rear Lift Cylinder (FSV/ 3 ton series)380
Rear Lift Cylinder (FV)380
SPECIFICATIONS381
Lift Cylinder (V)381
Rear Lift Cylinder (FSV)381
Rear Lift Cylinder (FV)381
COMPONENTS382
Lift Cylinder (V)382
Rear Lift Cylinder (FSV)383
Rear Lift Cylinder (FV)384
Installation of Lift Cylinder (V)385
Installation of Rear Lift Cylinder (FSV)386
Installation of Rear Lift Cylinder (FV)387
REMOVAL·INSTALLATION388
Removal Procedure389
Installation Procedure389
DISASSEMBLY·INSPECTION·REASSEMBLY390
Disassembly Procedure390
Reassembly Procedure391
Inspection Procedure391
SAFETY DOWN VALVE393
Safety Down Valve Sectional View (for V) (for FSV·FV Rear Lift Cylinder)393
Safety Down Valve Sectional View (for FSV·FV Front Lift Cylinder)393
REMOVAL·INSTALLATION394
Removal Procedure394
Installation Procedure394
FRONT LIFT CYLINDER (FSV·FV)395
GENERAL395
Front Lift Cylinder (FSV·FV)395
SPECIFICATIONS395
COMPONENTS396
REMOVAL·INSTALLATION397
Removal Procedure397
Installation Procedure397
DISASSEMBLY·INSPECTION·REASSEMBLY399
Disassembly Procedure399
Reassembly Procedure400
TILT CYLINDER401
GENERAL401
SPECIFICATIONS401
COMPONENTS402
TILT CYLINDER HOSE403
REMOVAL·INSTALLATION404
Removal Procedure405
Installation Procedure405
DISASSEMBLY·INSPECTION·REASSEMBLY406
Disassembly Procedure406
Reassembly Procedure407
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (ADJUSTMENT OF UNEVEN TILTING)409
INSPECTION METHOD409
ADJUSTMENT METHOD409
SAS/OPS410
GENERAL411
SAS-å (System of Active Stability-å)411
System configuration412
Name of each component413
OPS414
COMPONENTS415
LIFTING HEIGHT SWITCH (V MAST)415
LIFTING HEIGHT SWITCH (FSV, FV MAST)416
TILT ANGLE SENSOR417
LOAD SENSOR418
HEIGHT REEL SENSOR419
BEFORE STARTING REPAIR WORK420
MATCHING421
GENERAL422
Matching Items and Prerequisite for Implementation (Display)423
Matching Items and Prerequisite for Implementation (Multi-function display)425
Before Starting Matching427
BEFORE STARTING REPAIR WORK428
BEFORE STARTING MATCHING429
Standard Vehicle Condition429
APPENDIX431
SST LIST432
Drive unit tool437
SERVICE STANDARDS LIST439
BATTERY439
DRIVE MOTOR439
PUMP MOTOR439
DRIVE UNIT440
FRONT AXLE441
REAR AXLE442
STEERING442
BRAKE443
MATERIAL HANDLING SYSTEM444
MAST444
CYLINDER445
OIL PUMP447
OIL CONTROL VALVE447
SAS447
CONNECTOR DRAWING448
CONNECTING DIAGRAM461
WIRING DIAGRAM462
WIRING DIAGRAM No 1462
WIRING DIAGRAM No2 WIRING DIAGRAM No3463

DESCRIPTION:

Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 1 – PDF DOWNLOAD

FOREWORD:

• This Manual (Volume 1) contains maintenance, specifications and repair procedure
  for the chassis, body and material handling system of the TOYOTA
  ELECTRICAL POWERED FORKLIFT 8FBN15 to 30, 50-8FBN15·18·20
  series.
• For diagnosis and service procedures of electrical controller and display, refer
  to Volume 2 (Pub. No. CE350).
• Please use these manuals for providing quick, correct servicing of the corresponding
  forklift models.
• This manual deals with the above models as of January, 2012. Please understand
  that disagreement can take place between the descriptions in the manual
  and actual vehicles due to change in design and specifications. Any
  change or modifications thereafter will be informed by Toyota Industrial
  Equipment Parts & Service News.

S.V 27/02/2025