Toyota 8FBCU20, 8FBCU25, 8FBCHU25, 8FBCU28, 8FBCU30, and 8FBCU32 Forklift 2010–2015 Repair Manual (P/N CU346 - CU347)

• Covers Toyota 8FBCU20, 8FBCU25, 8FBCHU25, 8FBCU28, 8FBCU30, and 8FBCU32 forklifts, with model, voltage, and frame-number identification tables.
• 654 PDF pages total — Volume 1, P/N CU346: 275 pages; Volume 2, Electrical System & Troubleshooting, P/N CU347: 379 pages.
• Covers drive and pump motors, drive unit and differential repair, front and rear axles, hydrostatic steering, brake bleeding and adjustment, and battery service.
• Includes V, FV, FSV, and QFV mast work, lift and tilt cylinder repair, oil pump testing, and oil control valve service and pressure adjustment.
• Details controller and contactor panel service, OCL measurement, accelerator sensor checks, display analyzer and tuning functions, and Conventional Lever, Mini Lever, and Joystick Lever configurations.
• Provides diagnostic-code and no-code troubleshooting, connector and pin-location drawings, separate connecting and wiring diagrams, and Toyota SST references.
• Factory data includes torque tables, hydraulic test specifications, fluid capacities, inspection limits, electrical test values, and variant-specific service standards.

Component and System Documentation

This two-volume set contains Toyota factory repair publications. Volume 1 covers the chassis, body, material-handling system, mast, cylinders, hydraulics, battery, motors, and SAS hardware. Volume 2 covers the controller, multi-function display, setup functions, and fault diagnosis. The model table identifies both 36V and 48V configurations; the frame-number pages provide punching locations and formats. Toyota states that Volume 2 reflects the listed models as of May 2010; later production changes may differ.

The drive motor and pump motor chapters include removal, installation, disassembly, inspection, and reassembly. The drive-unit section continues through reduction gearing and differential case service, with bearing, seal, thrust-washer, and wear checks. Front and rear axle coverage includes the axle shaft, hub, bracket, housing, rear axle assembly, steering knuckle, center support, and rear axle cylinder. Steering procedures cover the steering wheel and mast jacket, hydrostatic steering valve troubleshooting and overhaul, and relief pressure inspection and adjustment.

Brake service includes front brake disassembly, inspection, and reassembly; hydraulic bleeding; braking force checks; master cylinder repair; parking brake service; and pedal, cable, and release lever adjustments. Battery documentation covers compartment requirements, charge display, troubleshooting, assembly handling, insulation inspection, and stopper adjustment. Body sections add battery hood, counterweight, seat, and fuse-location work.

The material-handling chapters separate V, FV, FSV, and QFV mast configurations. Procedures cover mast and lift bracket removal, disassembly and inspection, roller replacement, chain work, oversize-roller selection, mast setup, lift cylinder rod shimming for uneven lifting, and tilt angle correction. Hydraulic coverage includes natural drop, natural forward tilt, and cylinder oil-leak tests; lift and tilt cylinder repair; the safety down valve; oil pump disassembly and testing; and separate oil control valve circuit layouts for Conventional Lever and Mini Lever/Joystick Lever trucks.

Electrical Controls, Display Functions, and Troubleshooting

Volume 2 documents the traveling and load-handling AC drivers, main controller, contactor panel, display, lamp switch, accelerator potentiometer, and electronic control levers. The multi-function display section explains administrator functions, password access, analyzer screens, tuning, option setting, matching, and setup menus. The manual identifies matching routines required after controller or display replacement; sensor, lever, mast, tilt-cylinder, or attachment work; and tire size or type changes.

The troubleshooting section begins with connector handling, harness inspection, SST use, and a diagnosis code list, then follows with code-specific test charts and a symptom section for failures that do not set a code. Fault coverage spans traveling, load handling, power steering, SAS, OPS, swing lock, fork leveling, lift and tilt control, attachments, and auxiliary equipment. Visual references include the Hydraulic System Diagram, SAS system configuration drawings, drive unit and differential exploded views, V/FV/FSV/QFV mast component views, the Connector Drawing section, and separate Connecting Diagrams and Wiring Diagrams for Conventional Lever and Mini Lever/Joystick Lever layouts.

SAS Scope, Factory Tools, and Repair Cautions

The SAS chapter maps Active Control Rear Stabilizer and Active Mast Function Control inputs and actuators. It covers removal and installation of the yaw rate sensor, swing lock cylinder, tilt angle sensor, load sensor, speed sensor, and mast lifting height switch, followed by matching requirements and the vehicle condition used for calibration. Toyota directs readers to the separate New Model Feature 8FBCU20 to 32 publication P/N PU319 for full SAS function and operation explanations and the battery recommendation; this repair set focuses on precautions, component work, matching, and diagnostics.

Toyota SST references are tied to the jobs. Electrical diagnosis calls out the clamp-on AC/DC high tester P/N 09140-13130-71, AC controller diagnosis kit P/N 09230-13130-71, IC check pin, and dedicated sub-harnesses. The mechanical SST list covers battery lifting, axle and drive-unit bearings, brake springs, mast support, cylinder-cap and piston-rod service, and puller/replacer work.

Several repair traps are stated plainly. The swing lock cylinder must not be disassembled because air entry makes the assembly unusable. The two-stage hydraulic relief valve must be adjusted in the specified order; rushed adjustment can create damaging pressure and harm the oil pump or other hydraulic devices. The electrical section also warns that an imperfect controller connection can damage internal controller elements when the battery is reconnected.

Work on high-current battery circuits, raised or suspended mast components, heavy counterweights, brakes, and pressurized hydraulics requires isolation, secure lifting support, and qualified powered-industrial-truck service practice.