8FBCU 20, 25, 28, 30, 32

8FBCHU 25

VOL. 1

Pub. No. CU346

Sec Index.fm 1 ページ ２０１０年３月３１日　水曜日　午後４時２１分

SECTION INDEX
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
Sections indicated by solid characters are included in this manual.
Sections indicated by half-tone characters: See vol. 2.
sec00.book 1 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-1

GENERAL
0

Page Page
EXTERIOR VIEWS .......................... 0-2 RECOMMENDED LUBRICANT
QUANTITY & TYPES ................. 0-20 0
VEHICLE MODEL............................ 0-3
FRAME NUMBER ............................ 0-4 LUBRICATION CHART ................ 0-21
HOW TO USE THIS MANUAL ..... 0-5 PERIODIC MAINTENANCE ........ 0-22
EXPLANATION METHOD ................ 0-5 PERIODIC REPLACEMENT OF
PARTS AND LUBRICANTS ..... 0-27
TERMINOLOGY................................ 0-6
ABBREVIATIONS ............................. 0-6
SI UNITS ........................................... 0-7
OPERATIONAL TIPS ..................... 0-8
JACK-UP POINT ........................... 0-10
HOISTING THE VEHICLE ........... 0-11
CAUTION FOR TOWING ............. 0-11
ATTENTIVE POINTS 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
sec00.book 2 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-2

EXTERIOR VIEWS
0
sec00.book 3 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-3

VEHICLE MODEL
Model
Load Capacity Vehicle Model Voltage Remarks
Code
20 4000 lbs 8FBCU20 36V/48V
8FBCU25 ↑
25 5000 lbs
8FBCHU25 ↑
0
28 5500lbs 8FBCU28 ↑
30 6000 lbs 8FBCU30 ↑
32 6500 lbs 8FBCU32 ↑ USA·CANADA·MEXICO only
sec00.book 4 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-4

FRAME NUMBER
Frame No. Punching Position

Punching position

Vehicle Model Punching format

8FBCU20 8FBCU25-60011
8FBCU25 * 8FBCU25 60011
8FBCHU25 8FBCHU25-60011
8FBCU28-60011
8FBCU28
* 8FBCU28 60011
8FBCU30 8FBCU32-60011
8FBCU32 * 8FBCU32 60011

*: EEC spec.
sec00.book 5 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-5

HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operation procedure
Example of description in pattern B

DISASSEMBLY·INSPECTION·REASSEMBLY 0
Tightening torque unit T = N·m (kgf·cm) [ft·lbf]

• 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]

Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2] Ã Operation explained later
3 Remove the gear.

Point Operations
[Point 1] Explanation of key point for operation with an illustration
Disassembly:
Ã

Put a match mark when removing the pump cover.

[Point 2]
Inspection:
Measure the bush inside diameter.
Limit: 19.12 mm (0.7528 in)
sec00.book 6 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-6

2. How to read components figures (Example)

(1) The components figure uses the illustration
in the parts catalog for the vehicle model. 3201
Please refer to the catalog for checking the
part name. FIG number in parts catalog

The number at the right shoulder of each

components figure indicates the Fig.
number in the parts catalog.
(2) Refer to the parts catalog for the latest
information.
3. Matters omitted in this manual
This manual omits description of the following jobs, but perform them in actual operation:
(1) Cleaning and washing of removed parts as required
(2) Visual inspection (partially described)

TERMINOLOGY
Caution:
Important matters of which negligence may cause hazards on human body. Be sure to observe
them.

Note:
Important items of which negligence may cause breakage or breakdown, or matters in operation
procedure requiring special attention.

Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly RR Rear
Society of Automotive
ATT Attachment SAE
Engineers (USA)
Electronically controlled
EHPS fully hydraulic power SAS System of active stability
steering
Fully hydraulic power
FHPS SOL Solenoid
steering
LH Left hand SST Special service tool
FR Front STD Standard
Operator Presence
OPS T= Tightening torque
Sensing
OPT Option {{T Number of teeth ({{)
O/S Oversize U/S Undersize
PS Power steering W/ With
RH Right hand L/ Less
sec00.book 7 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-7

SI UNITS
Meaning of SI
This manual uses SI units. SI represents the International System of Units, which was established to unify the various
systems of units used in the past for smoother international technical communication.
New Units Adopted in SI
Item New unit Conventional unit Conversion rate*1 (1 [conventional unit] = X [SI unit])
Force*2 N (newton) kgf 1 kgf = 9.80665 N
*2
Torque N·m kgf·cm 1 kgf·cm = 9.80665 N·m
(Moment)
Pressure*2 Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
↑ ↑ mmHg 1 mmHg = 0.133322 kPa
Revolving speed rpm rpm 1 rpm = 1 r/min
2 N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Spring constant*
Volume l cc 1 cc = 1 ml
Power W PS system 1 PS = 0.735499 kW
Heat quantity W·h cal 1 kcal = 1.16279 W·h
Specific fuel
g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
consumption

<Reference>
* 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the
rate for conversion between conventional and SI units.
* 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which
should be used as the unit of force.
Conversion between Conventional and SI Units
Equation for conversion
Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding to X in the
Value in conventional unit = Value in SI unit ÷ Conversion rate conversion rate column in the table above

When converting, change the unit of the value in conventional or SI units to the one in the conversion rate
column 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.
sec00.book 8 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-8

OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure
gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and
operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packing and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of 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 related to controllers, especially, may
damage elements inside the controllers.
4. Confirming defect status
Do not start immediate disassembly or replacement, but first confirm if such disassembly or
replacement is actually needed.
5. Handling of waste fluid, etc.
When draining waste fluid from the vehicle, always receive it with an appropriate container.
Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other
harmful substance may cause adverse affect to people or environmental destruction, sort each waste
and always ask an authorized contractor for appropriate disposal.
6. Handling of electronic parts
(1) Never apply impacts to electronic parts such as a
microcomputer or relay.
(2) Never let electronic parts be exposed to a high
temperature or humidity.
(3) Do not touch connector pins since they may be
deformed or be damaged due to static electricity.
sec00.book 9 ページ ２０１０年４月１４日　水曜日　午後６時２９分

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 10 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-10

JACK-UP POINT
Strictly observe the following instructions when jacking up the vehicle.
• When a load is on the fork, unload it and park the vehicle on a flat floor. Be sure to avoid an inclined or
rugged place.
• Use a jack with 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 11 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-11

HOISTING THE VEHICLE

When hoisting the vehicle, use the mast hook on the front of
the vehicle and a wire net on the rear wheel.

Caution:
• Use wire ropes having sufficient strength.
• Never hoist the forklift by the weight hook holes or
head guard.

CAUTION FOR TOWING

1. When towing the forklift, always lift the rear wheels away
from the ground.
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 towing, either remove the fork or take an action
to prevent fork contact with the ground due to bounding.
sec00.book 12 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-12

ATTENTIVE POINTS ON SAS

1. Reference should be made to seperate manual “New Model Feature 8FBCU20 to 32 Pub. No.PU319”
for the explanations of SAS functions and operations.
2. Read Section 17 “SAS Precautions for Repair” on Page 17-9 in this repair manual in advance.
3. Whenever the repair or replacement is performed to the place where relative to SAS function, maching
procedure by which the SAS regain proper function must be performed. (See 17-18)
4. The warning on the SAS caution label must be confirmed when the modification or change is such as
to change the original specification.
If improper, change the label. (See Page 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 of
installation after disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic
replacement of the hydraulic oil is very important.
7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause
faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary
equipment, optional parts, etc.)
sec00.book 13 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-13

CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according
to the purpose of measurement.

Analog type: This type is convenient for observing movement during operation, but the measured value
should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.

1. Difference in measurement results with the digital 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
Forward direction Reverse direction Measurement result example
Tester range: kΩ range
Analog type
Continuity exists
Forward
11 kΩ
No continuity
Reverse
∞

(2) Digital circuit tester

Forward direction Reverse direction
Measurement result example
Tester range: MΩ range
Digital type
No continuity
Forward
1
Continuity exists
Reverse
2 MΩ
sec00.book 14 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-14

2. Difference in result of measurement with circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.
The diode characteristics are shown in the figure below.
(mA) The resistance values of the same semiconductor measured
6
with two types of circuit testers having different power supply
5
voltages are different.
Forward current

4 Germanium
diode
This manual describes the results of measurement with a
3
circuit tester whose power supply voltage is 3.0 V.
2 Silicon
diode
1
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (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 repair manual for
measurement.
Resistor Meter

0Ω
Variable resistor
Current flow

Resistor

Range:×10 (SW1)

Resistor

Range:×1

Power source: 1.5V

Red Black
sec00.book 15 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-15

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identify
bolt class based on the below chart and then determine using the tightening torque 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
4 = 4T
5 = 5T
Bolt head No. 6 = 6T
7 = 7T
8 = 8T

No mark 4T

Hexagon head bolt

Two protruding lines 5T

Three protruding lines 7T

Four protruding lines 8T

Welded bolt 4T

No mark 4T

Stud bolt

Grooved 6T
sec00.book 16 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-16

Identification by Part No.

Part No. Shape

Length (mm) Diameter

Hexagon head bolt
Diameter (mm)
Length
Class

Diameter
Length (mm)
Stud bolt
Diameter (mm)
Length
Class

Tightening Torque Table

Diameter Pitch Specified torque

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 4
8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 1.0 6.5 65 5
8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 1.5 265 2700 195
sec00.book 17 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-17

Identification by Bolt Shape (Hexagon flange bolt)

Class 4.8T 6.8T 8.8T 10.9T 11.9T

No mark

Hexagon flange bolt

— —
No mark

Tightening Torque Table (Hexagon flange bolt)

Diameter Pitch Specified torque

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T
12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88
6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T
12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8.8T
12 1.25 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199
6 1.0 15.5 160 12
8 1.25 38 390 28
10 1.25 80 820 59
10.9T
12 1.25 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266
6 1.0 17.5 180 13
8 1.25 42 430 31
10 1.25 89 910 66
11.9T
12 1.25 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295
sec00.book 18 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-18

PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the following
cases:
(1) After it is removed.
(2) When the precoat bolt is moved (loosened or tightened)
Seal lock agent
by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable
tightening torque range. If the bolt moves, retighten it
according to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded portion
of the bolt.

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth
to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before
installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N·m (kgf·cm) [ft·lbf] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16 — 20UNF 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
9/16 — 18UNF 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [29.3 ~ 26.8] 9 (0.35)
3/4 — 16UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 78 (800) [57.9] 74 ~ 82 (740 ~ 840) [53.5 ~ 60.8] 15 (0.59)
1·1/16 — 12UNF 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
1·5/16 — 12UNF 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
PF3/8 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [23.9 ~ 26.8] 9 (0.35)
PF1/2 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
sec00.book 19 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-19

WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension
Lifting angle Tension Compression Lifting angle Tension Compression
method method

0° 1.00 time 0 time 90° 1.41 time 1.00 time

90°
1.0 tf

tf
41
1.
2t 2t

30°

30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
tf

120°
1.04

f
2t
2t 2t

60° 1.16 time 0.58 time

60°
f
6t
1.1

2t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
sec00.book 20 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-20

COMPONENTS WEIGHT
Member Models Weight kg (lbs)
Battery ASSY See page 1-2
20~25 Approx. 127 (280)
Drive motor ASSY
28~32 Approx. 145 (320)
Pump motor ASSY 20~32 Approx. 47 (104)
20·H25 Approx. 756 (1667)
25 Approx. 1070 (2359)
Counterweight 28 Approx. 1375 (3031)
30 Approx. 1182 (2606)
32 Approx. 1375 (3031)
V mast ASSY L/fork and backrest 20·25 Approx. 460 (1014)
(with lift cylinder, max. lifting
height: 3300 (130 in)) 30·32 Approx. 570 (1257)

RECOMMENDED LUBRICANT QUANTITY & TYPES

Description Quantity l (US gal) Classification Type
API Hypoid gear oil
Drive unit 6.0 (1.58)
GL-4 SAE75W-80W
Hydraulic oil
(V⋅FV⋅FSV mast: ISO
22.0 (5.81) Hydraulic oil
lifting height VG32
3300 mm (130 in))
Proper quantity
SAE J-1703
Brake Reservoir Tank 
DOT-3
0.2 (0.05)
• MP grease
Chassis parts Proper quantity  • Molybdenum
disulfide grease
Battery Proper quantity  Distilled water

Note:
Since the hydraulic oil volume varies with the mast specification, be sure to check finally with the
level gauge.
sec00.book 21 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-21

LUBRICATION CHART

1 B B 1

3 A C C 2

4 F A 3

5 A F 4

A 5

11 E E A 6

12 D D

13 F

15 F

7 A A 7

8 A A 8

9 A A 9

10 A A 10

14 F
I

II

III

IV

{ Inspection and addition I. Inspect every 8 hours (daily)

z Replacement II. Inspect every 40 hours (weekly)
A MP grease III. Inspect every 250 hours (6 weeks)
B Engine oil IV. Inspect every 1000 hours (6 monthly)
C Hypoid gear oil V. Inspect every 2000 hours (annual)
D Hydraulic oil
E Brake fluid
F Molybdenum disulfide greass

1 Chain 9 Tie rod end pin

2 Drive unit 10 Rear axle cylinder end pin
3 Tilt cylinder front pin 11 Brake master cylinder
4 Mast support bushing 12 Oil tank
5 Front wheel bearing 13 Rear axle beam front pin
6 Tilt steering locking mechanism 14 Rear axle beam rear pin
7 Steering knuckle king pin 15 Swing lock cylinder crank and rod pin
8 Rear wheel bearing
sec00.book 22 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-22

PERIODIC MAINTENANCE
Inspection Method

I : Inspection⋅Repair or replacement if required.

M : Measurement⋅Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Rotation sound I ← ← ←
Motor Looseness in the connecting parts T ← ← ←
Insulation resistance M ← ←
Charging level I ← ← ←
Electrolyte level I ← ← ←
Electrolyte specific gravity M ← ← ←
Looseness in the connecting parts I ← ← ←
Battery Abnormality in the upper portion of the
I ← ← ←
battery case
Insulation resistance M ← ←
Voltage measurement of each battery cell after
M
charging
Contact looseness, damage, abrasion I ← ← ←
Operating condition of the auxiliary contact,
I ← ← ←
contamination, abrasion
Magnet Mounting condition of the arc shooter I
contactor Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead wire,
I
looseness
Operating condition and timing I ← ← ←
Micro switch
Damage and looseness of installing parts I ← ← ←
Direction switch Operation condition, damage I ← ← ←
Operation condition I ← ← ←
Controller Interior contamination, damage C ← ← ←
Motor input voltage M
Fuse Looseness I ← ← ←
sec00.book 23 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-23

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Harness deterioration, clamp damage and
I ← ← ←
Wiring looseness
(including Looseness in connecting parts, taping condition I ← ← ←
charging cord) Connecting condition and damage of the
I ← ← ←
battery connector
POWER TRANSFER SYSTEM
Oil leakage I ← ← ←
Drive unit Oil level I ← ← ←
Bolt or nut looseness T
DRIVE SYSTEM
Tire cuts, damage and uneven wearing I ← ← ←
Loose rim and hub nuts T ← ← ←
Tire groove depth M ← ← ←
Metal chips, pebbles and other foreign matter
I ← ← ←
trapped in tire grooves
Wheels
Rim, side bearing and disc wheel damage I ← ← ←
Abnormal sound and looseness of front wheel
I ← ← ←
bearing
Abnormal sound and looseness of rear wheel
I ← ← ←
bearing
Front axle Cracks, damage and deformation of housing I
Cracks, damage and deformation of beam I
Abnormal noise looseness of rear axle bearing I
Rear axle
Looseness of axle beam in vehicle longitudinal
M* M
direction
STEERING SYSTEM
Play and looseness I ← ← ←
Steering wheel
Function I ← ← ←
Oil leak I ← ← ←
Steering valve
Looseness of mounting T ← ← ←
Oil leake I ← ← ←
Power steering Mounting and linkage looseness I ← ← ←
Damage of power steering hose I
King pin looseness I ← ← ←
Knuckle
Cranks and deformation I
sec00.book 24 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-24

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
BRAKING SYSTEM
Play and reserve M ← ← ←
Brake pedal
Braking effect I ← ← ←
Operating force I ← ← ←
Parking brake Braking effect I ← ← ←
Rod and cable looseness and damage I ← ← ←
Brake pipe Leak, damage and mounting condition I ← ← ←
Reservoir tank Leak and fluid level I ← ← ←
Master
Function, wear, damage, leak and mounting
cylinder and I
looseness
wheel cylinder
Clearance between drum and lining M ← ← ←
Wear of shoe sliding portion and lining I
Drum wear and damage I
Brake drum and
Shoe operating condition I
brake shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Deformation, cracks and damage I
Backing plate
Loose mounting T
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I ← ← ←
Forks Misalignment between left and right fork fingers I ← ← ←
Cracks at fork root and welded part I*1
Deformation and damage of each part and
I ← ← ←
crack at welded part
Mast and lift bracket looseness I ← ← ←
Mast and lift Wear and damage of mast support bushing I
bracket
Wear, damage and rotating condition of rollers I ← ← ←
Wear and damage of roller pins I
Wear and damage of mast strip I ← ← ←
Tension, deformation and damage of chain I ← ← ←
Chain lubrication I ← ← ←
Chain and chain Elongation of chain I
wheel Abnormality of chain anchor bolt I ← ← ←
Wear, damage and rotating condition of chain
I ← ← ←
wheel
Various Abnormality and mounting condition of each
I ← ← ←
attachments part
sec00.book 25 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-25

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
HYDRAULIC SYSTEM
Loosening and damage of cylinder mounting T ← ← ←
Deformation and damage of rod and rod end I ← ← ←
Cylinder operation I ← ← ←
Natural drop and natural forward tilt
M ← ← ←
Cylinder (hydraulic drift)
Oil leak and damage I ← ← ←
Wear and damage of pin and pin support I ← ← ←
Lifting speed M ← ← ←
Uneven movement I ← ← ←
Oil pump Oil leak and abnormal sound I ← ← ←
Oil level and contamination I ← ← ←
Hydraulic oil
Tank and oil strainer C ←
tank
Oil leak I ← ← ←
Loose linkage I ← ← ←
Control lever
Operation I ← ← ←
Oil leak I ← ← ←
Oil control valve Relief pressure measurement M
Relief valve and tilt lock valve functions I ← ← ←
Oil leak I ← ← ←
Hydraulic piping Deformation and damage I ← ← ←
Loose joint T ← ← ←
SAFETY DEVICES, ETC.
Cracks at welded portion I ← ← ←
Head guard
Deformation and damage I ← ← ←
Loosening of mounting T ← ← ←
Back-rest
Deformation, crack and damage I ← ← ←
Lighting system Function and mounting condition I ← ← ←
Horn Function and mounting condition I ← ← ←
Direction
Function and mounting condition I ← ← ←
indicator
Instruments Functions I ← ← ←
Backup buzzer Function and mounting condition I ← ← ←
Rear-view Dirt, damage I ← ← ←
mirror Rear reflection status I ← ← ←
Loosening and damage of mounting I ← ← ←
Seat
Seat belt damage and function I ← ← ←
sec00.book 26 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-26

Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Damage and cracks of frame, cross members,
I
Body etc.
Bolts and nuts looseness T
Functions I ← ← ←
Loosening and damage at sensor mounting
I ← ← ←
portion
Damage, deformation, oil leakage and loosen-
SAS I ← ← ←
ing of the mounting of functional parts
Loosening and damage of wire harnesses I ← ← ←
Lock cylinder accumulator performance I
Rusting and corrosion of load sensor I
Others Grease up L ← ← ←
sec00.book 27 ページ ２０１０年４月１４日　水曜日　午後６時２９分

0-27

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

z : Replacement
Replacement timing Every Every Every Every
6 weeks 3 months 6 months 12 months
Remarks
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Drive unit oil z
Hydraulic oil *1 z ←
Hydraulic oil filter z z ←
Wheel bearing grease z
Brake fluid z ←
Brake master cylinder rubber parts z
Wheel cylinder cup seals z
Brake fluid reservoir hose *2
Power steering hose *2
Power steering rubber parts *2
Hydraulic hose *2
Chain *3
Swing lock cylinder *4

*1: For new vehicle

*2: Replace every 2 years
*3: Replace every 3 years
*4: Replace every 10,000 hours

Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
0
sec00.book 28 ページ ２０１０年４月１４日　水曜日　午後６時２９分
sec01.book 1 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-1

BATTERY
1

Page
BATTERY COMPARTMENT AND
REQUIRED WEIGHT ..................................................... 1-2
SERVICE STANDARD .................................................... 1-3 1
DISPLAY ............................................................................. 1-3
TROUBLESHOOTING .................................................... 1-4
BATTERY ASSY ............................................................... 1-5
REMOVAL·INSTALLATION ............................................... 1-5
INSPECTION ..................................................................... 1-6
BATTERY STOPPER......................................................... 1-8
sec01.book 2 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-2

BATTERY COMPARTMENT AND REQUIRED WEIGHT

1

When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
See New Model Features (Pub. No. PU319) for the battery recommendation.

Compartment dimensions mm (in.) mm (in.) Battery weight kg (lb)

Height
Height from
Z ground
Models Mast Forward- Necessary Referenced
Width V
Rear minimum maximum
X Y Battery Battery with case with case
STD ROLL-OUT ROLL-OUT
SLIDE-OUT SLIDE-OUT

Except 775 992 605 585 470 1090 1430

8FBCU20 QFV (30.5) (39.1) (23.8) (23.0) (18.5) (2400) (3154)
8FBCU25 1200
QFV ↑ ↑ ↑ ↑ ↑ ↑
(2650)
1090
8FBCU28 ALL ↑ ↑ ↑ ↑ ↑ ↑
(2400)
8FBCHU25
870 1360 1613
8FBCU30 ALL ↑ ↑ ↑ ↑
(34.3) (3000) (3555)
8FBCU32

Forward-rear
Forward-Rear
X
in.)
90 mm 5 mm

Hole for cables

(3.5 in.) (0.2

Hole for cables

Z

Height
Height 50 mm
(2 in.)
130 mm
(5.1 in.)
V

Height from ground

Height from ground
Y
Width
Width
sec01.book 3 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-3

SERVICE STANDARD
Specific gravity upon full charge 1.280 [20°C (68°F)]
Specific gravity upon end of discharge 1.150 [20°C (68°F)]
36 V 32.0 V
Discharge end voltage
48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled (deionized) water
Insulation resistance 1MΩ or more
1
DISPLAY
Battery Charge Indicator

The battery charge indicator indicates 10 levels of battery

charge on the LCD.

Battery Overdischarge Warning Function

When the battery becomes over discharged below the preset

level in active “low battery level warning”, all segments in the
battery level indicator blink and a buzzer sounds to warn the
operator.

Low Remaining Battery Charge Warning

When the battery becomes below the preset level, the

battery level indicator blinks. When the operator turns the key
switch from OFF to ON with this condition, a buzzer will
sound for five seconds to warn the operator.
sec01.book 4 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-4

TROUBLESHOOTING

Plate corrosion Sulfation Plate wargage and active substance freeing

Improper charging
Long storage Repeated overdischarge/
without operation overcharge
End of life Short circuit
between cells
Charging current
Defect of electrolyte excessive
Electrolyte
Defective insufficient
electrolyte
Temperature
capacity

Battery defect
Overdischarge
excessive

Crack or
chipping of cell
Separator Improper
defective water Imperfect
supply connection
Overcharge
of the terminal

Deposition of free Fouled terminal or

active substance connecting plug
at bottom of cell

Short circuit Electrolyte leakage end reduction Loosened or corroded connection

sec01.book 5 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-5

BATTERY ASSY
REMOVAL·INSTALLATION
Always remove or install the battery in no-load state (without any load on the fork).

3
1

Removal Procedure
1 Disconnect the battery plug.
2 Slide the operator’s seat to the front most position, and lift up the armrest. (Mini lever/Joystick lever)
3 Open the battery hood.
4 Remove the rear toe board.
5 Loosen battery stoppers (RH and LH) and the fixing bolts.
6 Remove the battery ASSY. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
[Point 1]
SST
Removal Installation:
SST 25009-13201-71
sec01.book 6 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-6

INSPECTION
1. Electrolyte inspection
Battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity. If it
cannot be checked clearly, put the electrolyte in a
beaker for inspection.

2. Specific gravity inspection

Use a hydrometer and measure the specific gravity of
the electrolyte.
Specific gravity upon full charge:
........................................ 1.280 [20°C (68°F)]
Specific gravity upon end of discharge:
........................................ 1.150 [20°C (68°F)]
The specific gravity of the electrolyte at 20°C (68°F) is
used as the standard.

Equation for conversion

S20 = St+0.0007 (t-20)
S20 = Specific gravity at 20°C
St:Specific gravity measured at t°C
t:Electrolyte temperature upon measurement (°C)

* How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the
Hydrometer
electrolyte port and allow the electrolyte to be
sucked into its outer tube.
Rubber (2) Let the hydrometer float correctly without
bulb contact with the outer tube, top or bottom, and
Outer tube read the scale at the highest point of the
electrolyte surface as illustrated at left when
the bubbles in the electrolyte disappear.
Nozzle
(3) After the measurement, wash the inside and
outside of the hydrometer well with clear
water and store it after wiping water off with
clean cloth.
sec01.book 7 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-7

3. Insulation resistance inspection

Use an insulation resistance meter (megohmmeter) and
measure the resistance between the battery and battery
case.
Insulation resistance:1 MΩ or more

Note:
• When the insulation resistance is less than 1 MΩ,
wash the battery with water after removing it from the
vehicle.
• Fully dry the washed battery and measure the
insulation resistance again. Install the battery on the
vehicle after confirming that the insulation resistance
is 1 MΩ or more.

* Battery control table

Prepare a control table for each battery to record and maintain the inspection results.
sec01.book 8 ページ ２０１０年４月２３日　金曜日　午前１１時５３分

1-8

BATTERY STOPPER
The battery stopper adjusts the gap between the battery and battery compartment.
Adjust A and B so that total gap between the battery and battery compartment is under 12.7 mm (1/2 in).
This is the UL Standards requirement.
Install spacer plate if B is larger than 12.7 mm (1/2 in).
Spacer plate has two sets of installation holes.
Change the installion hole and bolt depend on wether B is larger than 30 mm (1.2 in).
Battery stopper 1

Tapped hole M12 × 1.25

A
Battery stopper 1 in detail

B 0 ～ 0.5° 0.5°～ 1°　　1°～ 1.5° 1.5°～ 3.2° 3.2°～ 3.8° 3.8°～ 4.3° 4.3°～ 5.5° 5.5°～ 5.55°

CTR Cross
Plate
sec05.book 1 ページ ２０１０年４月２３日　金曜日　午前１１時５７分

5-1

MOTOR
5

Page
DRIVE MOTOR ................................................................. 5-2
GENERAL.......................................................................... 5-2
SPECIFICATIONS.............................................................. 5-2
COMPONENTS.................................................................. 5-3
REMOVAL·INSTALLATION ............................................... 5-4
DISASSEMBLY·INSPECTION·REASSEMBLY ................. 5-6
PUMP MOTOR .................................................................. 5-9
5
GENERAL.......................................................................... 5-9
SPECIFICATIONS............................................................ 5-10
COMPONENTS................................................................ 5-11
REMOVAL·INSTALLATION ............................................. 5-12
DISASSEMBLY·INSPECTION·REASSEMBLY ............... 5-13
sec05.book 2 ページ ２０１０年４月２３日　金曜日　午前１１時５７分

5-2

DRIVE MOTOR
5

GENERAL

SPECIFICATIONS
Vehicle model 8FBCU20·25
8FBCU28·30·32
Item 8FBCHU20
Type Three phase AC Three phase AC
Nominal voltage V 21/28 22/29
Rated output kW 10.8/14.8 13.2/18.0
Dimensions mm φ276 × 275 φ276 × 315
(outside diameter × length) (in) (10.87 × 10.83) (10.87 × 12.40)
Weight kg (lb) 127 (280) 145 (320)
Insulation class F F
sec05.book 3 ページ ２０１０年４月２３日　金曜日　午前１１時５７分

5-3

COMPONENTS
1401

GP
CL

CL 01

CL

FX
43
GF CL

5
CL

1401-192

1401

AQ
AQ
BD BD

AQ AQ
AT
BD FV
AF
AT AD 60 41 AF
AF
20A AX
CH AX AX
BD
AU HN
ER
EE
BJ
BJ BJ
22
AX
AS 01
20B

20
AT
AW
20C
AT
EW
AT
18
AW AT
AT

49

1401-190
sec05.book 4 ページ ２０１０年４月２３日　金曜日　午前１１時５７分

5-4

REMOVAL·INSTALLATION
T = N⋅m (kgf-cm) [ft-lbf]

T = 29.2 ~ 43.8
(298 ~ 447)
[21.5 ~ 32.3]

Removal Procedure

1 Remove the front axle ASSY W/drive motor ASSY. (See page 6-5)
2 Put match marks between the drive unit case and stator ASSY. [Point 1]
3 Loosen the through bolt and remove the drive motor. [Point 2]

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Thank you very much
for your reading.
Please Click Here
Then Get More
Information.