Original Illustrated Factory Workshop Service Manual for Toyota Diesel Forklift Truck Type 7FDF.

Original factory manuals for Toyota (BT) Forclift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks

Covered models:
7FDF15
7FDF18
7FDF20
7FDF25
7FDF30
7FDJ35

Format: PDF, 612 Pages
Language: English

Contents:
GENERAL
EXTERIOR VIEWS
VEHICLE MODEL
FRAME NUMBER
HOW TO USE THIS MANUAL
EXPLANATION METHOD
TERMINOLOGY
ABBREVIATIONS
OPERATIONAL TIPS
HOISTING THE VEHICLE
CIRCUIT TESTER
STANDARD BOLT & NUT TIGHTENING TORQUE
BOLT STRENGTH TYPE IDENTIFICATION METHOD
TIGHTENING TORQUE TABLE
PRECOAT BOLTS
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
COMPONENTS WEIGHT
RECOMMENDED LUBRICANT QUANTITY & TYPES
SMÖRJSCHEMA
PERIODISKT UNDERHÅLL
UTBYTE AV SMÖRJMEDEL OCH DELAR
ENGINE
ENGINE SECTIONAL VIEWS
MAJOR SPECIFICATIONS
ENGINE PERFORMANCE CURVES
ENGINE ASSY
REMOVALINSTALLATION
AIR BLEEDING FROM FUEL SYSTEM (DIESEL VEHICLE)
ENGINE SPEED INSPECTION AND ADJUSTMENT
4Y ENGINE
1DZ-II2Z ENGINE
AIR CLEANER
SPECIFICATIONS
COMPONENTS
AIR CLEANER CLEANING INSPECTION
CLOGGING WARNING SYSTEM INSPECTION
RADIATOR
COMPONENTS
SPECIFICATIONS
COOLANT CAPACITY AND ANTIFREEZE TABLE
MUFFLER & EXHAUST PIPE
COMPONENTS
REMOVAL and INSTALLATION
CATALYTIC MUFFLER MAINTENANCE
BATTERY
COMPONENTS
SPECIFICATIONS
INSPECTION
V-BELT TENSION INSPECTION ADJUSTMENT
ACCELERATOR PEDAL
COMPONENTS
INSPECTION and ADJUSTMENT
ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT
VEHICLE SPEED CONTROL SYSTEM (OPT)
COMPONENTS
CONNECTING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
DIAGNOSIS
REMOVAL and INSTALLATION
ACCELERATION AND THROTTLE WIRE ADJUSTMENT
TROUBLESHOOTING
DPF-II SYSTEM (OPT)
COMPONENTS
CONNECTING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
DPF MUFFLER REMOVAL and INSTALLATION
DPF MUFFLER DISASSEMBLY and INSPECTION and REASSEMBLY
CONTROLLER REMOVAL and INSTALLATION
BLOWER REMOVAL and INSTALLATION
INDIVIDUAL FUNCTIONAL PARTS INSPECTION
CONTROLLER ERROR CODE CLEARING METHOD
DPF FILTER MEMORY CLEARING METHOD
REGENERATION METHOD
TROUBLESHOOTING
TRANSMISSION
GENERAL
HYDRAULIC CIRCUIT DIAGRAM
SPECIFICATIONS
COMPONENTS
TROUBLESHOOTING
TRANSMISSION & CONTROL VALVE ASSY
REMOVAL&INSTALLATION
DISASSEMBLY&NSPECTION&REASSEMBLY
TORQUE CONVERTER&OIL PUMP
REMOVAL&INSTALLATION
TORQUE CONVERTER & TRANSMISSION ASSY
REMOVAL & INSTALLATION
TRANSMISSION ASSY
DISASSEMBLY & INSPECTION&REASSEMBLY
CLUTCH DRUM ASSY
DISASSEMBLY & INSPECTION & REASSEMBLY
DIRECTION SWITCH ASSY
REMOVAL & INSTALLATION
OIL PRESSURE MEASUREMENT AND STALL TEST
2 SPEED TRANSMISSION
PROPELLER SHAFT
GENERAL
SPECIFICATIONS
COMPONENTS
PROPELLER SHAFT
REMOVAL & INSTALLATION
DISASSEMBLY & INSPECTION & REASSEMBLY
DIFFERENTIAL
GENERAL
SPECIFICATIONS
COMPONENTS
DIFFERENTIAL ASSY
REMOVAL & INSTALLATION
DISASSEMBLY & INSPECTION & REASSEMBLY
DIFFERENTIAL CASE ASSY
DISASSEMBLY & INSPECTION & REASSEMBLY
DIFFERENTIAL CARRIER
DISASSEMBLY & INSPECTION & REASSEMBLY.
FRONT AXLE
GENERAL
SPECIFICATIONS
COMPONENTS
TIRES & WHEELS
FRONT AXLE SHAFT&AXLE HUB
REMOVAL & INSTALLATION
FRONT AXLE BRACKET & AXLE HOUSING
REMOVAL & INSTALLATION
REAR AXLE
GENERAL
SPECIFICATIONS
COMPONENTS
TIRES & WHEELS
REAR AXLE ASSY
REMOVAL & INSTALLATION
REAR AXLE HUB & STEERING KNUCKLE
REMOVAL & INSTALLATION
REAR AXLE CYLINDER
REMOVAL & INSTALLATION
DISASSEMBLY & INSPECTION & REASSEMBLY
REAR WHEEL ALIGNMENT.
STEERING
GENERAL
SPECIFICATIONS
COMPONENTS
STEERING WHEEL & MAST JACKET
REMOVAL & INSTALLATION
DISASSEMBLY & INSPECTION & REASSEMBLY
HYDROSTATIC STEERING VALVE ASSY
TROUBLESHOOTING
REMOVAL & INSTALLATION
DISASSEMBLY & INSPECTION & REASSEMBLY
RELIEF PRESSURE INSPECTION & ADJUSTMENT.
BRAKE
GENERAL
SPECIFICATIONS
COMPONENTS
FRONT BRAKE
DISASSEMBLY & INSPECTION & REASSEMBLY (1 - 3.5 TON SERIES)
DISASSEMBLY & INSPECTION & REASSEMBLY (2 - 3 TON SERIES)
BRAKE AIR BLEEDING
BRAKING FORCE INSPECTION & ADJUSTMENT
BRAKE MASTER CYLINDER
REMOVAL & INSTALLATION
DISASSEMBLY & INSPECTION & REASSEMBLY
PARKING BRAKE INSPECTION & DJUSTMENT
BRAKE PEDAL INSPECTION & ADJUSTMENT
INCHING PEDAL INSPECTION & ADJUSTMENT ( Mar. 2000)
INCHING PEDAL INSPECTION & ADJUSTMENT (Mar. 2000 ).
BODY
COMPONENTS
ENGINE HOOD ASSY
REMOVAL-INSTALLATION
COUNTERWEIGHT
REMOVAL-INSTALLATION
HEAD LAMPS
REMOVAL-INSTALLATION
BULB REPLACEMENT
COMBINATION METER
REMOVAL-INSTALLATION
COMBINATION SWITCH
INSPECTION
FUEL SENDER GAUGE
INSPECTION
RELAY BLOCK
RELAY INSPECTION
PORTIONS PROTECTED BY FUSES.
MATERIAL HANDLING SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
COMPONENTS
RETURN FILTER & SUCTION FILTER
REMOVAL- INSTALLATION
NATURAL DROP TEST
NATURAL FORWARD TILT TEST
OIL LEAK TEST
LIFT CYLINDER
TILT CYLINDER.
MAST
V MAST ASSY
COMPONENTS
REMOVAL-INSTALLATION
REMOVAL-INSTALLATION (W/LIFT BRACKET)
MAST DISASSEMBLY-INSPECTION-REASSEMBLY
LIFT BRACKET DISASSEMBLY-INSPECTION-REASSEMBLY
MAST ADJUSTMENT (V MAST)
MAST ROLLER REMOVAL-INSTALLATION
CHAIN
INSPECTION
REASSEMBLY
ADJUSTMENT
FORK
REMOVAL
INSTALLATION
INSPECTION
FV-SV MAST ASSY
COMPONENTS
MAST ADJUSTMENT (FV- FSV)
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING).
CYLINDER
LIFT CYLINDER (V) - REAR LIFT CYLINDER (FVFSV)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL - INSTALLATION
DISASSEMBLY - INSPECTION - REASSEMBLY
FLOW REGULATOR VALVE (V-FV-FSV)
REMOVAL-INSTALLATION
SAFETY DOWN VALVE (V-FV-FSV)
REMOVAL-INSTALLATION
FRONT LIFT CYLINDER (FV-FSV)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL-INSTALLATION
DISASSEMBLY-INSPECTION-REASSEMBLY
TILT CYLINDER
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL-INSTALLATION
DISASSEMBLY-INSPECTION-REASSEMBLY
MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING).
OIL PUMP
GENERAL
SPECIFICATIONS
COMPONENTS
OIL PUMP ASSY
REMOVAL-INSTALLATION
DISASSEMBLY-INSPECTION-REASSEMBLY (4Y)
DISASSEMBLY-INSPECTION-REASSEMBLY (1DZ-II)
DISASSEMBLY-INSPECTION-REASSEMBLY (2Z)
PERFORMANCE TEST
OIL CONTROL VALVE
GENERAL
SPECIFICATIONS
COMPONENTS
OIL CONTROL VALVE ASSY
REMOVAL-INSTALLATION
DISASSEMBLY-INSPECTION-REASSEMBLY
CONTROL VALVE LEVER ASSY
REMOVAL-INSTALLATION
JUSTERING AV ÖVERSTRÖMNINGSVENTIL
Hydraulschema T.O.M November 2000
Hydraulschema Fr.O.M November 2000
Morse Controls Elservospakar.
SAS
GENERAL
COMPONENTS
PRECAUTIONS FOR REPAIR
FUNCTIONAL PARTS
SAS CONTROLLER REMOVALINSTALLATION
TIRE ANGLE SENSOR REMOVALINSTALLATION
SWING LOCK CYLINDER REMOVALINSTALLATION
STEERING KNOB POSITION CORRECTING VALVE
REMOVALINSTALLATION
TILT ANGLE SENSOR REMOVALINSTALLATION
LOAD SENSOR REMOVAL
INSTALLATION
SPEED SENSOR REMOVALINSTALLATION
FORK HEIGHT SWITCH REMOVALINSTALLATION
RE-SETTING
CUSTOMIZE
PLUG-IN ANALYZER
BASIC OPERATION
ANALYZER
RE-SETTING
OPTION SET (CUSTOMIZE)
TROUBLESHOOTING
DIAGNOSIS
TROUBLESHOOTING
TROUBLESHOOTING BY ERROR CODE
TROUBLESHOOTING BY PHENOMENON
CONNECTOR LAYOUT
CONTROLLER SEQUENCE
CONNECTOR DIAGRAMS.
APPENDIX