8FG 35U, 40U, 45U, 50U, 60U, 70U, 80U

8FD 35U, 40U, 45U, 50U, 60U, 70U, 80U

8FGC 35U, 45U, 55U, 60U, 70U

VOL. 1

Pub. No. CE104

 FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT 8FG/8FD
35U to 80U series and 8FGC35U to 70U series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of October 2013. 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.

For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with this manual.

(Reference)
Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 8FG/8FD35U to 80U series and

8FGC35U to 70U series VOL.2 REPAIR MANUAL (No. CE105)

TOYOTA INDUSTRIAL EQUIPMENT 1KD ENGINE

REPAIR MANUAL (No. CE302)

TOYOTA INDUSTRIAL EQUIPMENT 1FS ENGINE

REPAIR MANUAL (No. CE303)
 Table of Contents
1 ENGINE............................................................................................................................................................................. 34

2 TORQUE CONVERTER & TRANSMISSION......................................................................................................... 165

3 PROPELLER SHAFT..................................................................................................................................................... 234

4 DIFFERENTIAL............................................................................................................................................................. 242

5 FRONT AXLE................................................................................................................................................................. 263

6 REAR AXLE..................................................................................................................................................................... 296

7 STEERING...................................................................................................................................................................... 342

8 BRAKE............................................................................................................................................................................. 369

9 BODY................................................................................................................................................................................ 405

10 MATERIAL HANDLING SYSTEM........................................................................................................................... 428

11 MAST............................................................................................................................................................................... 446

12 CYLINDER...................................................................................................................................................................... 508

13 OIL PUMP....................................................................................................................................................................... 551

14 OIL CONTOROL VALVE............................................................................................................................................ 560

15 MINI LEVER................................................................................................................................................................... 621

16 SAS/OPS.......................................................................................................................................................................... 630

17 SST LIST AND SERVICE STANDARDS LIST....................................................................................................... 657

 -3

GENERAL
EXTEROR VIEWS
Pneumatic tire model

Cushion tire model

-4

VEHICLE MODEL
Pneumatic Tire

Capacity New Model Previous Model Capacity

( L.C. 24 inch) Engine Model Engine Model (L.C. 600 mm)
lbs.
8000 1FS 8FG35U GM 6-262 7FGU35 3500
1KD 8FD35U 15Z 7FDU35
9000 1FS 8FG40U GM 6-262 7FGKU40 4000
1KD 8FD40U 15Z 7FDKU40
10000 1FS 8FG45U GM 6-262 7FGU45 4500
1KD 8FD45U 15Z 7FDAU45
11000 1FS 8FG50U GM 6-262 7FGAU50 5000
1KD 8FD50U 15Z 7FDAU50
13500 1FS 8FG60U GM 6-262 7FGU60 6000
1KD 8FD60U 15Z 7FDU60
15500 1FS 8FG70U GM 6-262 7FGU70 7000
1KD 8FD70U 15Z 7FDU70
17500 1FS 8FG80U GM 6-262 7FGU80 8000
1KD 8FD80U 15Z 7FDU80
Cushion Tire

Capacity New Model Previous Model Capacity

( L.C. 24 inch) Engine Model Engine Model (L.C. 600 mm)
lbs.
8000 1FS 8FGC35U GM 6-262 7FGCU35 3500
10000 1FS 8FGC45U GM 6-262 7FGCU45 4500
12000 1FS 8FGC55U GM 6-262 7FGCU55 5500
13500 1FS 8FGC60U GM 6-262 7FGCU60 6000
15500 1FS 8FGC70U GM 6-262 7FGCU70 7000
 -5

FRAME NUMBER

Frame number

Pneumatic Tire
Capacity Engine Vehicle model Frame No. Stamping
(L.C. 24 inch) lbs.
8000 to 9000 1FS 8FG35U 8FG40U - 10011
8FG40U
1KD 8FD35U 8FD40U - 10011
8FD40U
10000 to 11000 1FS 8FG45U 8FG50U - 10011
8FG50U
1KD 8FD45U 8FD50U - 10011
8FD50U
13500 to 17500 1FS 8FG60U 8FG80U - 10011
8FG70U
8FG80U
1KD 8FD60U 8FD80U - 10011
8FD70U
8FD80U
Cushion Tire
Capacity Engine Vehicle model Frame No. Stamping
(L.C. 24 inch) lbs.
8000 1FS 8FGC35U 8FGC45U - 10011
10000 8FGC45U ( EEC spec.: 8FGC45U * 10011)
12000 1FS 8FGC55U 8FGC55U - 10011
13500 1FS 8FGC60U 8FGC70U - 10011
15500 8FGC70U ( EEC spec.: 8FGC70U * 10011)

Detail of *
-6

HOW TO USE THIS MANUAL

EXPLANATION METHOD
Operation procedure
The operation procedure is described to explain each operation step with illustration which indicates the step
number.
How to read components figures
The components figure uses the illustration in the parts catalog for the vehicle model. Please refer to the catalog
for checking the part name.
The number in the illustration of each component figure indicates the Fig. number in the parts catalog.

(Example)
CN
CN

DU

CR

40A
CU
40
01

AZ

BZ

3701-118

This manual omits description of the following jobs, but perform them in actual operation:
▪ Cleaning and washing of removed parts as required
▪ Visual inspection (partially described)

TERMINOLOGY
"Caution" : Important matters of which negligence may cause hazards on human body. Be sure to ob-
serve 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.
 -7

ABBREVIATIONS
Abbrevia- Meaning Abbrevia- Meaning
tion tion
(code) (code)
ASSY Assembly SAE Society of Automotive Engineers (USA)
Cu Cushion tire models Pn Pneumatic tire models
LH Left hand RH Right hand
LLC Long life coolant SST Special service tool
STD Standard OPT Option
O/S Oversize T= Tightening torque
T/C Torque converter & transmission U/S Undersize
SAS System of active stability OPS Operator presence sensing
PS Power steering **T Number of teeth (** )
NMR No-load maximum speed W/ With
L/ Less
-8

OPERATIONAL TIPS
1. Safe operation
a) After jacking up, always support with wooden blocks or rigid stands.
b) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load ca‐
pacity.
c) Always disconnect the battery terminal before the inspection or servicing of electrical parts.
d) Do not touch the high pressure hoses by bare hands when inspecting them.
2. Tactful operation
a) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge,
etc.) and SSTs before starting operation.
b) Before disconnecting wiring, always check the cable color and wiring state.
c) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neat‐
ly to prevent confusion.
d) When disassembling and inspecting such a precision part as the control valve, use clean tools and oper‐
ate in a clean location.
e) Follow the described procedures for disassembly, inspection and reassembly.
f) Replace, gaskets, packings and O-rings with new ones each time they are disassembled.
g) Use genuine Toyota parts for replacement.
h) 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. Grasping the trouble state
a) When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trou‐
ble requires disassembly or replacement for remedying.
4. Disposal of waste fluid, etc.
a) When draining waste fluid from the vehicle, receive it in a container.
If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped
without permission, it will either adversely affect human health or destroy the environment.
Always sort waste fluids, etc. and treat them properly by requesting disposal by specialized companies.
5. Jack up points
Front side: Jack up the bottom edge of the front plate under the frame.
Rear side: Jack up the under the counterweight.
 -9

HOUR METER START

It is necessary to start the hour meter by con-
UPPER necting the connector which is located under the
left of toe-board.
RH FR

Hour meter connectors

-10

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.

Analog circuit tester

a Forward direction b Reverse direction

Measurent result example

Analog type
(Tester range: kΩ range)
Forward Continuity exists
11 kΩ
Reverse No continuity
∞
 -11

Digital circuit tester

a Forward direction b Reverse direction

Measurement result example

Digital type
(Tester range: MΩ range)
Forward Continuity exists
1
Reverse Continuity exists
2 MΩ
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 di-
ode varies with the circuit tester power supply volt-
age.
The diode characteristics are shown in the figure.
The resistance values of the same semiconductor
measured with two types of circuit testers having
different power supply voltages are different.
This manual describes the results of measure-
ment with a circuit tester whose power supply volt-
age is 3.0 V.
-12

3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the

measurement range switches over the internal cir-
cuit to vary the circuit resistance.
Even when the same diode is measured, the
measurement result varies with the measurement
range.
 -13

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2. The nut tightening torque can be judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

IDENTIFICATION BY BOLT SHAPE
Shape Class
Hexagon head bolt Bolt head No. 4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
No mark 4T

Hexagon flange bolt No mark 4T

Hexagon head bolt Two protruding lines 5T

Hexagon flange bolt Two protruding lines 6T

Hexagon head bolt Three protruding lines 7T

Hexagon head bolt Four protruding lines 8T

Welded bolt 4T

Stud bolt No mark 4T

Grooved 6T
-14

IDENTIFICATION BY PART NO.

Hexagon head bolt Stud bolt
 -15

TIGHTENING TORQUE TABLE

Class Diameter Pitch Specified torque Specified torque
mm mm Hexagon head bolt Hexagon flange bolt

Nm kgf-cm ft-lbf Nm kgf-cm ft-lbf

4T 6 1.0 5.4 55 48 in-lbf 5.9 60 52 in-lbf
8 1.25 13 130 9 14 145 10
10 1.25 25 260 19 28 290 21
12 1.25 47 480 35 53 540 39
14 1.5 75 760 55 83 850 61
16 1.5 113 1150 83 - - -
5T 6 1.0 6.4 65 56 in-lbf 7.5 75 65 in-lbf
8 1.25 16 160 12 18 175 13
10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 137 1400 101 157 1600 116
6T 6 1.0 7.8 80 69 in-lbf 8.8 90 78 in-lbf
8 1.25 19 195 14 21 215 16
10 1.25 38 400 29 43 440 32
12 1.25 72 730 53 79 810 59
14 1.5 110 1100 80 123 1250 90
16 1.5 170 1750 127 191 1950 141
7T 6 1.0 11 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
12 1.25 95 970 70 103 1050 76
14 1.5 147 1500 108 167 1700 123
16 1.5 226 2300 166 - - -
8T 6 1.0 12 125 9 14 145 9
8 1.25 29 300 22 32 330 24
10 1.25 61 620 45 68 690 50
12 1.25 108 1100 80 123 1250 90
14 1.5 172 1750 127 196 2000 145
16 1.5 265 2700 195 299 3050 221
-16

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:
▪ After it is removed.
▪ When the precoat bolt is moved (loosened or tightened) by tightness check, etc.

NOTICE
For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retight-
en it according to the steps below.

2. Method for reuse of precoat bolts

▪ Wash the bolt and threaded hole. (The threaded hole must be
washed even for replacement of the bolt.)
▪ Perfectly dry the washed parts by air blowing.
▪ Coat the specified seal lock agent to the threaded portion of
the bolt.
 -17

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 fit‐
ting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter of Standard tightening torque Hose nominal size
screw N m [ft-lbf] mm (in)
Standard Tightening range
7/16 - 20UNF 25 [18.4] 24 to 26 [17.7 to 19.2] 6 (0.24)
9/16 - 18UNF 34 [25.1] 32 to 36 [23.6 to 26.6] 9 (0.35)
3/4 - 16UNF 59 [43.5] 56 to 62 [41.3 to 45.7] 12 (0.47)
7/8 - 14UNF
7/8 - 14UNF 78 [57.5] 74 to 82 [54.6 to 60.5] 15 (0.59)
1・1/16 - 12UNF 118 [87.1] 112 to 123 [82.6 to 90.7] 19 (0.75)
1・5/16 - 12UNF 137 [101.1] 130 to 144 [95.9 to 106.2] 25 (0.98)
PF1/4 25 [18.4] 24 to 26 [17.7 to 19.2] 6 (0.24)
PF3/8 34 [25.1] 32 to 36[23.6 to 26.6] 9 (0.35)
PF1/2 59 [43.5] 56 to 62 [41.3 to 45.7] 12 (0.47)
PF3/4 118 [87.1] 112 to 123 [82.6 to 90.7] 19 (0.75)
PF1 137 [101.1] 130 to 144 [95.9 to 106.2] 25 (0.98)
-18

HOISTING THE VEHICLE

When hoisting the vehicle, sling with wire rope(s) at the mast
hook holes and the counterweight hook holes.

CAUTION
Use wire ropes having sufficient strength.
Never hoist the forklift by the weight hook holes.
 -19

WIRE ROPE SUSPENSION ANGLE LIST

Lifting angle Tension Compression Suspension method
0° 1.00 time 0 time

30° 1.04 time 0.27 time

60° 1.16 time 0.58 time

90° 1.41 time 1.00 time

120° 2.00 time 1.73 time

-20

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]
Rope di- Cutting Single- Two-rope suspension Four-rope suspension
ameter load rope sus-
pension
0° 0° 30° 60° 90° 0° 30° 60° 90°
6mm 21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
(0.24 in) (2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
8 mm 31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
(0.32 in) (3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
10 mm 49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
(0.4 in) (5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
12.5 mm 76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
(0.5 in) (7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
14 mm 96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
(0.56 in) (9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
 -21

Click here for more information

COMPONENTS WEIGHT
Component Weight kg (lb)
Engine 1FS 185 (408)
1KD 218(480)
Torque converter & transmission Pn35 to 50 209(461)
Pn60 to 80 model 218(480)
Cu35 ~ 70 model 190(419)
Counter weight Pn35 model Approx.1675 ( 3695)
Pn40 model Approx. 2025 ( 4465)
Pn45 model Approx. 2215 ( 4885)
Pn50 model Approx. 2505 ( 5525)
Pn60 model Approx. 2610 ( 5755)
Pn70 model Approx. 3265 ( 7200)
Pn80 model Approx. 4060 ( 8950)
Cu35 model Approx.1865 ( 4110)
Cu45 model Approx. 2550 ( 5625)
Cu55 model Approx. 2995 ( 6605)
Cu60 model Approx. 3155 ( 6955)
Cu70 model Approx. 3780 ( 8335)
V mast ASSY L/backrest and fork Pn35/40 model Approx. 850 (1870)
(with lift cylinder, max. lifting height: 3000 mm Pn45 model Approx. 1000 (2210)
(118 in)) Pn50 model Approx. 1110 (2450)
Pn60/70 model Approx. 1360 (3000)
Pn80 model Approx. 1440 (3180)
Cu35 model Approx. 820 (1810)
Cu45 model Approx. 860 (1900)
Cu55 model Approx. 960 (2120)
Cu60/70 model Approx. 1270 (2800)
-22

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Description Application Quantity l Classification Type
(US gal)
Engine Gasoline 1FS 8.8 (2.32) API SM or better SAE 10W - 30
class
Diesel 1KD 7.8 (2.06) API CF4 or better 10W - 30 or 5W -
class 30
Transmission T/C Pn35 to 80: 15.5 ATF GM Dexron Ⅱ or
Click here for more (4.10) Castle Autofluid
information Cu35 to 79: 10.4 DII KAI or Exxon
2034K
(2.75)
Differential Pn35 to 50 9.5 (2.51) API GL-4, GL-5 Hypoid gear oil
Pn60 to 80 10.5 (2.77) SAE85W-90
Cu35 to 70 6.5 (1.72)
Planetary gear Pn35 to 50 - (Included in Dif-
ferential)
Pn60 to 80 0.8 (0.21) for
each side
Cu35 to 70 0.5 (0.13) for
each side
Hydraulic oil Pn35 to 40 57.6 (15.2) ISO VG32 Hydraulic oil
(V mast, max. lifting height 3000mm Pn45 to 50 64.4 (17.0)
(118in)) Cu60 to 70
Pn60 to 80 69.7 (18.4)
Cu35 to 45 37.5 (9.9)
Cu55 model 46.6 (12.3)
Fuel tank Pn35/40 90 (23.8) - -
Pn45/50 120 (31.7)
Pn60 to 80 130 (34.3)
Cu35 to 70 -
(LPG only)
Chassis parts All models Proper quantity - • MP grease
• Molybdenum di-
sulfide greas
Coolant (excluding reservoir tank) 1FS Proper quantity LLC • LLC 30-50%
1KD Proper quantity mixture (for win-
ter or allseason)
Coolant (Reservoir Tank) All models Proper quantity
• Coolant with
rustinhibitor (for
spring, summer
and autumn)
* Underline portion has been added.

Revised April 30, 2014

0 GENERAL 0-23

0.16 LUBRICATION CHART

Pneumatic Tire Model (Pn35 to 80)
0
1 b b 1

13 a c c 2

12 f a 13
(3.5 to 5.0 ton) 3 a
f 12
(6.0 to 8.0 ton) 3 c a 3 (3.5 to 5.0 ton)
c 3 (6.0 to 8.0 ton)
4 e e a 11

8 b b a 14

9 f d d 7

15 f

6 a f 18

5 a a 6

16 a a 5

17 a a 16

10 f a 17
I

II

III

IV

Inspection parts (Number from "1" to "18")

1 Chain 2 Differential 3 3.5 to 5.0 ton: 4 Torque converter
Front wheel bearing case
6.0 to 8.0 ton:
Planetary gear
5 Rear wheel bearing 6 Steering knuckle king 7 Oil tank 8 Engine crank case
pin
9 Rear axle beam front 10 Rear axle beam rear 11 Tilt steering locking 12 Mast support bushing
pin pin mechanism
13 Tilt cylinder front pin 14 Propeller shaft 15 Swing lock cylinder 16 Tie rod end pin
lower pin
17 Rear axle cylinder 18 Fan drive shaft spline
end pin

Revised October 31, 2015

0-24 0 GENERAL

Inspection or replacement oil

Inspection: "a" to "f" in white circle
Replacement: "a" to "f" in black circle
a MP grease b Engine oil c Hypoid gear oil d Hydraulic oil
e Automatic transmis- f Molybdenum disulfide
sion fluid grease

Inspection cycle ("Ⅰ" to "Ⅴ")

Ⅰ Inspect every 8 hours Ⅱ Inspect every 40 Ⅲ Inspect every 500 Ⅳ Inspect every 1000
(daily) hours (weekly) hours (3 monthly) hours (6 monthly)
Ⅴ Inspect every 2000
hours (annual)

Revised October 31, 2015

0 GENERAL 0-25

Cushion Tire Model (Cu35 to 70)

0
1 b b 1

13 a c c 2

12 f a 13

3 c f 12

c 3

4 e e a 11

8 b b a 14

9 f d d 7

15 f

6 a f 18
Click here for
Fan Drive shaft
5 a a 6 inspection
16 a a 5 information
17 a a 16

10 f a 17
I

II

III

IV

Inspection parts (Number from "1" to "18")

1 Chain 2 Differential 3 Planetary gear 4 Torque converter
case
5 Rear wheel bearing 6 King pin 7 Oil tank 8 Engine crank case
9 Rear axle beam front 10 Rear axle beam rear 11 Tilt steering locking 12 Mast support bushing
pin pin mechanism
13 Tilt cylinder front pin 14 Propeller shaft 15 Swing lock cylinder 16 Tie rod end pin
lower pin
17 Rear axle cylinder 18 Fan drive shaft spline
end pin

Revised October 31, 2015

0-26 0 GENERAL

Inspection or replacement oil

Inspection: "a" to "f" in white circle
Replacement: "a" to "f" in black circle
a MP grease b Engine oil c Hypoid gear oil d Hydraulic oil
e Automatic transmis- f Molybdenum disulfide
sion fluid grease

Inspection cycle ("Ⅰ" to "Ⅴ")

Ⅰ Inspect every 8 hours Ⅱ Inspect every 40 Ⅲ Inspect every 500 Ⅳ Inspect every 1000
(daily) hours (weekly) hours (3 monthly) hours (6 monthly)
Ⅴ Inspect every 2000
hours (annual)

Revised October 31, 2015

0 GENERAL 0-27

PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or replacement if required.
0
M : Measurement. Repair or adjustment if required.
T : Retightening
C : Cleaning
L : Lubrication
*: Same as the left column
*1: For new vehicle, *2: Except 1KD Engine
Every Every Every Every
6 weeks 3 months 6 months 12 months
Item Inspection Period
Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
ENGINE
Main body Proper starting and abnor- I *1 I * *
mal noise
Rotating condition at idling M *1 M * *
Rotating condition during M *1 M * *
acceleration
Exhaust gas condition I *1 I * *
Air cleaner element C *1 C * *
Valve clearance M *1*2 M
Muffler rubber mount I
Engine Ancillary drive belt I *1 I * *
tension, looseness and
damage
PCV system Clogging and damage in I *1 I * *
PCV valve and piping
Lubrication Oil leak I *1 I * *
system Oil level I *1 I * *
Clogging and dirt of oil fil- I *1 I * *
ter
Fuel system Fuel leak I *1 I * *
Dirt and clogging of fuel I *1 I * *
filter and element
Draining of sedimenter I *
Cooling sys- Coolant level in radiator I *1 I * *
tem and leak
Rubber hose degradation I *1 I * *
Radiator cap condition I *1 I * *
Fan belt tension, loose- I *1 I * *
ness and damage
Radiator rubber mount I
POWER TRANSMISSION SYSTEM
Differential Leak I *1 I * *
Oil level I *1 I * *
Bolt loosening T
Planetary gear Leak I *1 I * *
Oil level I *1 I * *
Bolt loosening T

Revised October 31, 2015

0-28 0 GENERAL

Every Every Every Every

6 weeks 3 months 6 months 12 months
Item Inspection Period
Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Torque con- Leak I *1 I * *
verter & trans- Fluid level I *1 I * *
mission
Operating mechanism I *1 I * *
function and looseness
Control valve and clutch I *1 I * *
functions
Inching valve function I *1 I * *
Stall and hydraulic pres- M *
sure measurement
Propeller shaft Loose joint T * *
and axle shaft Looseness at spline con- I
nections
Looseness of universal I
joint
Twisting and cracks of I
axle shaft
DRIVE SYSTEM
Wheels Tire inflation pressure M *1 M * *
Tire cuts, damage and un- I *1 I * *
even wearing
Loose rim and hub nuts T *1 T * *
Tire groove depth M *1 M * *
Metal chips, pebbles and I *1 I * *
other foreign matter trap-
ped in tire grooves
Rim, side bearing and I *1 I * *
disc wheel damage
Abnormal sound and I *1 I * *
looseness of front wheel
bearing
Abnormal sound and I *1 I * *
looseness of rear wheel
bearing
Front axle Cracks, damage and de- I
formation of housing
Rear axle Cracks, damage and de- I
formation of beam
Looseness of axle beam M *1 M
in vehicle longitudinal di-
rection
STEERING SYSTEM
Steering wheel Play and looseness I *1 I * *
Function I *1 I * *
Steering valve Oil leak I *1 I * *
Looseness of mounting T *1 T * *
Power Steer- Oil leak I *1 I * *
ing Mounting and linkage I *1 I * *
looseness
Damage of power steering I
hose

Revised October 31, 2015

0 GENERAL 0-29

Every Every Every Every

6 weeks 3 months 6 months 12 months
Item Inspection Period
Every Every Every Every 0
250 hours 500 hours 1000 hours 2000 hours
Knuckle King pin looseness I *1 I * *
Cracks and deformation I
BRAKING SYSTEM
Brake pedal Play and reserve M *1 M * *
Braking effect I *1 I * *
Parking brake Operating force I *1 I * *
Braking effect I *1 I * *
Rod and cable looseness I *1 I * *
and damage
Brake pipe Leak, damage and mount- I *1 I * *
ing condition
Brake booster Function, wear, damage, I
and wheel cyl- leak and mounting loose-
inder ness
Brake drum Clearance between drum M *1 M * *
and brake and lining
shoe Wear of shoe sliding por- I
tion and lining
Drum wear and damage I
Shoe operating condition I
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster func- I
tion
Backing plate Deformation, cracks and I
damage
Loose mounting T
MATERIAL HANDLING SYSTEM
Forks Abnormality of fork and I *1 I * *
stopper pin
Misalignment between left I *1 I * *
and right fork fingers
Cracks at fork root and I
welded part
Mast and lift Deformation and damage I *1 I * *
bracket of each part and crack at
welded part
Mast and lift bracket I *1 I * *
looseness
Wear and damage of I
mast support bushing
Wear, damage and rotat- I *1 I * *
ing condition of rollers
Wear and damage of roll- I
er pins
Wear and damage of I *1 I * *
mast trip
Chain and Tension, deformation and I *1 I * *
chain wheel damage of chain

Revised October 31, 2015

0-30 0 GENERAL

Every Every Every Every

6 weeks 3 months 6 months 12 months
Item Inspection Period
Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Chain lubrication I *1 I * *
Elongation of chain I
Abnormality of chain an- I *1 I * *
chor bolt
Wear, damage and rotat- I *1 I * *
ing condition of chain
wheel
Various attach- Abnormality and mounting I *1 I * *
ments condition of each part
HYDRAULIC SYSTEM
Cylinder Loosening and damage of T *1 T * *
cylinder mounting
Deformation and damage I *1 I * *
of rod, rod screw and rod
end
Cylinder operation I *1 I * *
Natural drop and natural M *1 M * *
forward tilt (hydraulic drift)
Oil leak and damage I *1 I * *
Wear and damage of pin I *1 I * *
and pin support
Lifting speed M *1 M * *
Uneven movement I *1 I * *
Oil pump Oil leak and abnormal I *1 I * *
sound
Hydraulic oil Oil level and contamina- I *1 I * *
tank tion
Tank and oil strainer C *
Oil leak I *1 I * *
Control lever Loose linkage I *1 I * *
Operation I *1 I * *
Oil control Oil leak I *1 I * *
valve Relief pressure measure- M
ment
Relief valve and tilt lock I *1 I * *
valve functions
Hydraulic pip- Oil leak I *1 I * *
ing Deformation and damage I *1 I * *
Loose joint I *1 I * *

Revised October 31, 2015

 : The new inspection item 0-31

Item Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Ignition timing State of spark plug (car- I *1 I * *
bon, soot)
Starting motor Pinion gear meshing status I *1 I * *
Battery Battery fluid level I *1 I * *
Battery fluid specific gravity M *
Electrical wiring Damage of wiring harness I *1 I * *
Fuses I *1 I * *
Preheater Open-circuit of glow plug I *
SAFETY DEVICES AND OTHERS
Head guard Cracks at welded portion I *1 I * *
Deformation and damage I *1 I * *
Back-rest Loosening of mounting T *1 T * *
Deformation, crack and I *1 I * *
damage
Lighting system Function and mounting I *1 I * *
condition
Horn Function and mounting I *1 I * *
condition
Direction indi- Function and mounting I *1 I * *
cator condition
Instruments Functions I *1 I * *
Backup buzzer Function and mounting I *1 I * *
condition
Rear-view mir- Dirt, damage I *1 I * *
ror Rear reflection status I *1 I * *
Seat Loosening and damage of I *1 I * *
mounting
Seatbelt damage and func- I *1 I * *
tion
Seat switch function I *1 I * *
Body Damage and cracks of I
frame, cross members, etc.
Bolt looseness T
Frame bolt looseness I
*See the caution on the
next page
SAS Functions I *1 I * *
Loosening and damage at I *1 I * *
sensor mounting portion
Damage, deformation, oil I *1 I * *
leakage and loosening of
the mounting of functional
parts

Revised October 31, 2015

0-32

Item Inspection Period Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Loosening and damage of I *1 I * *
wire harnesses
Lock cylinder accumulator I
performance
Rusting and corrosion of I
load sensor
OPS Functions I *1 I * *
Others Grease up L *1 L * *

CAUTION
Do not loosen the frame tightening bolts
The frame structure has factory tightened bolts. These bolts are strictly prohibited to loosen. Heavy maintenance
such as engine/torque converter disassembling/reassembling can be possible without loosening these bolts.
Match mark is painted on the rear frame bolt for each, then check them if they are not out of alignment on annual
inspection maintenance.
If this match mark is faded, paint again.

Frame tightening bolts(10 pcs.)

Revised October 31, 2015

0 GENERAL 0-33

PERIODIC REPLACEMENT OF PARTS AND

LUBRICANTS
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.

NOTICE
• Periodic maintenance is fundamental. Need to replace even before replacement interval if abnor-
mality is seen in Periodic Maintenance, because deterioration differs from condition.
• Have customers conduct weekly maintenance (40hr) as mentioned in Operator's Manual.
● : Replacement

Interval Every Every Every Every

6 weeks 3 months 6 months 12 months
Item Every Every Every Every
250 hours 500 hours 1000 hours 2000 hours
Engine oil ● *1 ● *2 ● ●
Engine oil filter ● *1 ● *2 ● ●
Engine coolant *5 ● ● ●
Every 2 years for LLC
Every 3 years for Super LLC
Fuel filter ●
Fuel hose Every 2 years *3
LPG high pressure hose Every 2 years
LPG fuel filter Every 2 years
LPG regulator gasket Every 2 years
Torque converter oil ●
Torque converter oil filter ●
Differential oil ●
Planetary gear oil ●
Hydraulic oil ●
Hydraulic oil filter ●*1 ●
Wheel bearing grease ●
Spark plugs ● ●
Air cleaner element ●
Cups and seals for brake booster and ●
wheel cylinders
Power steering hoses Every 2 years *3
Power steering rubbers parts Every 2 years *3
Hydraulic hoses Every 2 years *3
Torque converter rubber hoses Every 2 years *3
Chains Every 3 years *4
SAS Swing lock cylinder Every 10000 hours
Timing belt of 1KD Every 4000 hours
*1: For new vehicle.
*2: For the engine oil grades listed below, change oil every 500 hours / 6 months.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above
*3: Replace without reservation at indicated interval in case of hard operation conditions mentioned
below.
In case of normal operating condition, the distributors are entrusted with the responsibility for deter-

Revised October 31, 2015

0-34 0 GENERAL

mining whether the parts should be replaced or not.

If the replacement is determined to be unnecessary, be sure to inspect at the next periodic mainte-
nance.
Note) Definition of "hard operation" is the following.
• Extended heavy duty operations (e.g. multi-shift or continuous use)
• High temperature areas (e.g. steel mills or foundries)
• Low-temperature operations (e.g. freezer operation)
• Sudden temperature changes (e.g. traveling between freezer, room temperature, and oven or furnace envi-
ronments)
• Dusty or sandy conditions (e.g. cement plants, lumber or flour mills, coal dust or stone-crushing areas)
• Corrosive chemical atmosphere (e.g. fish, meat, or poultry processing plants, tanneries, chlorine or salt sea
air environments)
• High humidity, wet, damp, or moist conditions
*4: The distributors are entrusted with the responsibility for determining whether the parts should be
replaced or not.
If the replacement is determined to be unnecessary, be sure to inspect at the next periodic mainte-
nance.
*5: In case the engine coolant other than Toyota Super LLC is used, be sure to drain all the coolant
before the replacement. Never mix the engine coolant of different brands.

Revised October 31, 2015

 Maintenance
MA14-002
January 31, 2014
D800 Repair Manual Update – Addition
of Frame Bolt Inspection
SERVICE INFORMATION BULLETIN 8FD35-80U, 8FG35-80U, 8FGC35-70U

Subject: D800 Repair Manual Update – Addition of Frame Bolt Inspection Page 1 of 1

MODEL APPLICATION:
8FD35-80U, 8FG35-80U and 8FGC35-70U

GENERAL INFORMATION:
This bulletin is being released to inform dealership service personnel of an update to the D800
repair manual. This update includes the addition of a new inspection item to be performed
during periodic maintenance.

Inspection of the 10 frame tightening bolts has been added in the repair manual periodic
maintenance body section page 0-31 of Pub. No. CE104.

• Inspection interval is every 12 months or 2000 hours, whichever occurs first.

Each of the 10 frame bolts has a paint mark. Please make sure the paint mark on the
component and the paint mark on the head of the bolt are in alignment at the inspection
period. If this paint mark is faded, please clean and re-paint accordingly.

See below picture for location of the 10 frame bolts.

(6 on sub weight and 4 on front cross plate)

CAUTION:
• Do not loosen the 10 frame bolts. Heavy maintenance such as
engine/transmission removal can be done without loosening these bolts. If
equipped, the cross plate(s) on the bottom of the forklift can be removed for
heavy maintenance repairs.

This information has been added to the repair manual. The updated repair manual pages have
been included for your convenience.
 Maintenance
MA14-003
April 30, 2014
D800 Repair Manual Update – CE104 and
CE105 Changes
SERVICE INFORMATION BULLETIN 8FD35-80U, 8FG35-80U and 8FGC35-70U

Subject: D800 Repair Manual Update – CE104 and CE105 Changes Page 1 of 1
Note: This only effects the complete repair
MODEL APPLICATION: manual, not the individual sections available on
8FD35-80U, 8FG35-80U and 8FGC35-70U TIS
GENERAL INFORMATION:
This bulletin is being released to inform dealership service personnel of an update to the D800
repair manuals. Repair manuals CE104 Vol. 1 and CE105 Vol. 2 have been slightly re-
organized so information is easier to find. Most changes were applied to CE105 Vol. 2.

These updated manuals are now available for download in the Service Support section on TIS.

The following changes were made to CE104 and CE105:

 “Table of Contents” was added to CE105 Vol. 2.

 Section tabs were repositioned so the start of a new section begins on the next page in
CE105 Vol. 2.

 Section tab numbers and page numbers were corrected in Section 2 Troubleshooting
and Section 3 Wiring Diagram of CE105 Vol. 2 so information is now easier to find.

 Unnecessary space in Section 2 Troubleshooting was removed in CE105 Vol. 2.

 Section tabs numbers were revised in CE104 Vol. 1.

 Maintenance
MA14-004
April 30, 2014
D800 Repair Manual Update – Addition of
Transmission Fluid Type
8FD35-80U, 8FG35-80U and
SERVICE INFORMATION BULLETIN 8FGC35-70U

Subject: D800 Repair Manual Update – Addition of Transmission Fluid Type Page 1 of 1

MODEL APPLICATION:
8FD35-80U, 8FG35-80U and 8FGC35-70U

GENERAL INFORMATION:
This bulletin is being released to inform dealership service personnel of an update to the D800
repair manual CE104 page 0-22. This update includes the addition of the transmission oil type
(GM Dexron II) required for the above models. The updated repair manual page has been
attached to this SIB.

The previous versions of the repair manual did not state the recommended transmission oil
type and the operator manual states to use Castle Autofluid DII KAI or Exxon 2034K. However
these 2 oil types may not be readily available.

When servicing the transmission on the above models it is recommended that GM Dexron II be
used.
 -21

COMPONENTS WEIGHT
Component Weight kg (lb)
Engine 1FS 185 (408)
1KD 218(480)
Torque converter & transmission Pn35 to 50 209(461)
Pn60 to 80 model 218(480)
Cu35 ~ 70 model 190(419)
Counter weight Pn35 model Approx.1675 ( 3695)
Pn40 model Approx. 2025 ( 4465)
Pn45 model Approx. 2215 ( 4885)
Pn50 model Approx. 2505 ( 5525)
Pn60 model Approx. 2610 ( 5755)
Pn70 model Approx. 3265 ( 7200)
Pn80 model Approx. 4060 ( 8950)
Cu35 model Approx.1865 ( 4110)
Cu45 model Approx. 2550 ( 5625)
Cu55 model Approx. 2995 ( 6605)
Cu60 model Approx. 3155 ( 6955)
Cu70 model Approx. 3780 ( 8335)
V mast ASSY L/backrest and fork Pn35/40 model Approx. 850 (1870)
(with lift cylinder, max. lifting height: 3000 mm Pn45 model Approx. 1000 (2210)
(118 in)) Pn50 model Approx. 1110 (2450)
Pn60/70 model Approx. 1360 (3000)
Pn80 model Approx. 1440 (3180)
Cu35 model Approx. 820 (1810)
Cu45 model Approx. 860 (1900)
Cu55 model Approx. 960 (2120)
Cu60/70 model Approx. 1270 (2800)
-22

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Description Application Quantity l Classification Type
(US gal)
Engine Gasoline 1FS 8.8 (2.32) API SM or better SAE 10W - 30
class
Diesel 1KD 7.8 (2.06) API CF4 or better 10W - 30 or 5W -
class 30
Transmission T/C Pn35 to 80: 15.5 ATF GM Dexron Ⅱ or
(4.10) Castle Autofluid
Cu35 to 79: 10.4 DII KAI or Exxon
2034K
(2.75)
Differential Pn35 to 50 9.5 (2.51) API GL-4, GL-5 Hypoid gear oil
Pn60 to 80 10.5 (2.77) SAE85W-90
Cu35 to 70 6.5 (1.72)
Planetary gear Pn35 to 50 - (Included in Dif-
ferential)
Pn60 to 80 0.8 (0.21) for
each side
Cu35 to 70 0.5 (0.13) for
each side
Hydraulic oil Pn35 to 40 57.6 (15.2) ISO VG32 Hydraulic oil
(V mast, max. lifting height 3000mm Pn45 to 50 64.4 (17.0)
(118in)) Cu60 to 70
Pn60 to 80 69.7 (18.4)
Cu35 to 45 37.5 (9.9)
Cu55 model 46.6 (12.3)
Fuel tank Pn35/40 90 (23.8) - -
Pn45/50 120 (31.7)
Pn60 to 80 130 (34.3)
Cu35 to 70 -
(LPG only)
Chassis parts All models Proper quantity - • MP grease
• Molybdenum di-
sulfide greas
Coolant (excluding reservoir tank) 1FS Proper quantity LLC • LLC 30-50%
1KD Proper quantity mixture (for win-
ter or allseason)
Coolant (Reservoir Tank) All models Proper quantity
• Coolant with
rustinhibitor (for
spring, summer
and autumn)
* Underline portion has been added.

Revised April 30, 2014

 Maintenance
MA16-019
December 31, 2016
Fan Drive Shaft Inspection
SERVICE INFORMATION BULLETIN 8FGC35-70U, 8FG(D)35-80U

Subject: Fan Drive Shaft Inspection Page 1 of 1

MODEL APPLICATION:
8FGC35U-70U and 8FG(D)35U-80U

GENERAL INFORMATION:
Addition of Fan Drive Shaft inspection to the Periodic Maintenance Inspection Chart.

REPAIR INFORMATION:
Section 0 of Repair Manual CE104, Page 27 does not include a physical inspection of the Fan Drive
Shaft assembly under Cooling System. This inspection should be completed at each 6 Week / 250
Hour interval.

The physical inspection starts with the engine turned off, and the negative battery terminal
disconnected. With the engine completely stopped, grab the driveshaft and check for play in the U-
Joints. If play is detected, replace the drive shaft assembly.

Due to the operating rpm of the driveshaft do not attempt to replace the U-Joints. Instead replace the
drive shaft as an assembly.

Effective Serial Number Break:

This affects all serial numbers.