Product Type:
Forklift Truck Service Manual
Line Name:
8-Series Diesel
Covered Models:
8FD10, 8FD15, 8FD18, 8FD20, 8FD25, 8FD30, 8FDJ35, 8FDK20, 8FDK25, 8FDK30
Target Audience:
Professional forklift technicians, maintenance departments, and serious DIY users.
Advantage:
Provides factory-level, detailed diagrams and procedures often missing in aftermarket manuals.
Illustration Quality:
Features high-quality illustrations and clear circuit diagrams for enhanced understanding.
Breadth Of Coverage:
Covers a wide range of models within the Toyota 8-Series diesel forklift lineup.
Powertrain Engine:
Comprehensive coverage of diesel engine operation, maintenance, and repair.
Powertrain Transmission:
Detailed information on torque converter, manual transmission, and associated components.
Drivetrain:
Includes propeller shaft, differential, front axle, and rear axle systems.
Steering And Braking:
In-depth coverage of steering mechanisms and brake system components and operation.
Material Handling:
Detailed breakdown of mast, cylinders, oil pump, oil control valve, and mini lever/joystick.
Operator Safety Systems:
Includes SAS (System of Active Stability) and OPS (Operator Presence System) diagnostics.
Electrical And Diagnostics:
Extensive electrical system troubleshooting, circuit diagrams, and wiring schematics.
Body And Chassis:
Coverage of the truck's body structure and related components.
Routine Maintenance:
Covers oil changes, filter replacements, lubrication schedules, and inspections.
Component Diagnostics:
Step-by-step procedures for diagnosing engine, transmission, hydraulic, and electrical faults.
Assembly Disassembly:
Detailed instructions for removing, overhauling, and reinstalling major components.
Hydraulic System Service:
Procedures for servicing the hydraulic pump, control valves, and cylinders.
Safety System Calibration:
Guidance on testing and calibrating SAS and OPS features.
Electrical Repairs:
Instructions for diagnosing and repairing wiring harnesses, sensors, and control modules.
Depth Of Information:
Comprehensive factory-level repair and diagnostic information suitable for trained technicians.
Diagnostic Tools:
Includes information on required Special Service Tools (SST).
Service Standards:
Provides critical service standards and specifications for accurate repairs.
Engine Type:
Diesel (Specific engine model varies by forklift capacity, but typically Toyota industrial diesel engines like 1DZ or 4Y variants)
Power Output:
Varies by model (e.g., 8FD10 typically around 30-40 HP, 8FD35 around 50-60 HP).
Torque Output:
Varies by model and engine; crucial for lifting capacity and performance.
Injection System:
Likely indirect injection (IDI) or direct injection (DI) depending on specific engine variant and emission standards of the era.
Cooling Method:
Liquid-cooled via radiator and fan.
Transmission Type:
Automatic (Torque Converter with Power Shift Transmission - PS)
Optional Transmission:
While the manual lists 'Manual Transmission' as a section, the primary transmission for these diesel models is automatic. The manual likely details variations or specific components.
Torque Converter:
Integrated torque converter for smooth power transfer and load handling.
Transmission Fluid Type:
Requires specific Automatic Transmission Fluid (ATF), likely Toyota ATF WS or equivalent, refer to manual for exact specification and capacity.
Model Variations:
Dimensions vary significantly across the model range (8FD10 to 8FD35) due to different load capacities and mast heights. Specific dimensional data (L, W, H) is provided per model within the manual.
Operating Weight:
Varies by model. For example, 8FD10 might be around 2,000-2,500 kg, while 8FD35 could be 4,000-5,000 kg. Exact curb weights provided in manual.
Load Capacity:
Models indicate capacity: 1000 kg (8FD10), 1500 kg (8FD15), 1800 kg (8FD18), 2000 kg (8FD20), 2500 kg (8FD25), 3000 kg (8FD30), 3500 kg (8FD35).
Safety Standards:
Designed to meet industrial safety standards for forklifts. Specific certifications may vary by region.
Sas System:
System of Active Stability (SAS) for enhanced stability during operation, cornering, and mast tilting.
Ops System:
Operator Presence System (OPS) that disengages drive and hydraulic functions when the operator leaves the seat.
Overhead Guard:
Standard overhead guard for operator protection.
Seatbelt:
Operator seatbelt for restraint.
Operator Interface:
Features a 'Multi-function Display (OPT)' for operational status and diagnostics, though not standard on all units.
Stability Control:
SAS (System of Active Stability) is a key advanced stability control technology.
Diagnostic Ports:
Diagnostic information is accessible through the electrical system and diagnostic codes, often requiring specific tools or procedures detailed in the manual.
Engine Oil Change:
Typically every 250-500 operating hours or 6-12 months, refer to manual for precise intervals based on operating conditions.
Transmission Fluid Change:
Typically every 1000-2000 operating hours, with filter changes at similar intervals. Crucial to follow manual recommendations.
Hydraulic Fluid Change:
Intervals vary, often 1000-2000 operating hours. Monitor fluid condition and check for contamination.
Engine Oil Specification:
Typically SAE 15W-40 API CF or higher diesel engine oil. Exact grade and capacity specified in manual.
Coolant Specification:
Ethylene glycol-based antifreeze with a 50/50 mix of coolant and distilled water. Specific coolant type (e.g., Toyota Super Long Life Coolant) will be detailed.
Hydraulic Fluid Type:
Toyota Genuine Hydraulic Oil or equivalent ISO VG 32 or 46. Refer to manual for exact viscosity and type.
Common Wear Items:
Common wear items include mast rollers, fork carriage wear pads, tires, battery terminals, and hydraulic seals.
Diesel Engine Considerations:
Proper glow plug operation, fuel filter maintenance, and air intake system cleanliness are critical for diesel engine reliability.
Toyota Industrial Equipment:
Toyota Industries Corporation is a global leader in material handling equipment, known for reliability and innovation in forklifts.
8 Series Introduction:
The 8-Series represents a significant generation of Toyota forklifts, building on previous designs with improvements in ergonomics, efficiency, and safety.
Production Period:
Specific production years for this manual's coverage are not stated but typically align with models produced from the late 1990s through the 2000s, depending on the specific generation of 8-Series. Consult manual for exact model year applicability.
