Toyota Forklift 7FBCU15,-18,-20,-25,-30,-32,-35,-45,-55, 7FBCHU25 Workshop Service Manual (CU322)

Original Illustrated Factory Workshop Service Repair Manual for Toyota Electric Forklift Trucks Models 7FBCU15, 7FBCU18, 7FBCU20, 7FBCU25, 7FBCU30, 7FBCU32, 7FBCU35, 7FBCU45, 7FBCU55, 7FBCHU25 and optional OPS

OPS Manual CU335 is Included!!!

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:
7FBCHU25
7FBCU15
7FBCU18
7FBCU20
7FBCU25
7FBCU30
7FBCU32
7FBCU35
7FBCU45
7FBCU55

Format: PDF, 918 Pages
Language: English

Contents:
   GENERAL
    EXTERIOR VIEWS
    VEHICLE MODEL
    FRAME NUMBER
    HOW TO USE THIS MANUAL
    EXPLANATION METHOD
    TERMINOLOGY
    ABBREVIATIONS
    OPERATIONAL TIPS
    JACK-UP POINT
    HOISTING THE VEHICLE
    CAUTION FOR TOWING
    ATTENTIVE POINTS ON SAS
    CIRCUIT TESTER
    STANDARD BOLT & NUT
    TIGHTENING TORQUE
    BOLT STRENGTH TYPE IDENTIFICATION METHOD
    TIGHTENING TORQUE TABLE
    PRECOAT BOLTS
    HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .
    WlRE ROPE SUSPENSION ANGLE LIST .
    SAFE LOAD FOR EACH WlRE
    ROPE SUSPENSION ANGLE
    COMPONENTS WEIGHT .
    RECOMMENDED LUBRICANT QUANTITY & TYPES
    LUBRICATION CHART
    PERIODIC MAINTENANCE
    PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
   BATTERY
    BATTERY COMPARTMENT AND REQUIRED WEIGHT
    SERVICE STANDARD
    DISPLAY
    TROUBLESHOOTING
    BATTERY ASSY
    REMOVAL-INSTALLATION
    INSPECTION
   CONTROLLER
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    CONTROLLER .
    TRAVELINGIMATERIAL HANDLING CONTROLLER ASSY
    REMOVAL-INSTALLATION (15 - 32 MODEL) .
    TRAVELING CONTROLLER ASSY REMOVAL-INSTALLATION (35 - 55 MODEL) .
    MATERIAL HANDLING CONTROLL ASSY REMOVAL-INSTALLATION (35 - 55 MODEL) .
    TRAVELING AND MATERIAL
    HANDLING CONTROLLER
    INSPECTION
    CONTACTOR PANEL ASSY REMOVAL.INSTALLATlON (1 5 - 32 MODEL)
    CONTACTOR PANEL ASSY REMOVAL-INSTALLATION (35 - 55 MODEL)
    CONTACTOR PANEL
    INSPECTION
    PS CONTROLLER ASSY REMOVAL-INSTALLATION (15 - 32 MODEL)
    PS CONTROLLER INSPECTION (15 - 32 MODEL)
    SAS CONTROLLER ASSY REMOVAL-INSTALLATION
    BOARD INSPECTION
    DISASSEMBLY
    REASSEMBLY
    DISPLAY INSPECTION .
    DIRECTION SWITCH
    REMOVAL-INSTALLATION
    DISASSEMBLY-INSPECTION-REASSEMBLY
    ACCELERATOR POTENTIOMETER ADJUSTMENT
    BRAKE SWITCH ADJUSTMENT
    FOOT BRAKE
    PARKING BRAKE
    MATERIAL HANDLING LEVER SWITCH ADJUSTMENT
    EZ PEDAL (OPT)
    COMPONENTS
    INSPECTION
   MULTI-DISPLAY FUNCTIONS
    MULTIPLE DISPLAY
    GENERAL
    GENERAL FUNCTIONS
    DISPLAY INDICATION LIST
    SPECIFICATIONS
    ABBREVIATIONS DISPLAYED ON THE SCREEN
    NORMAL FUNCTION SCREEN
    USA SPECIFICATION MODEL
    EXPORT MODEL
    MASK FUNCTIONS
    GENERAL
    MANAGER`S FUNCTION
    SERVICE FUNCTION
    ANALYZER
    TUNING
    OPTION SET
    MATCHING
    WHEEL DIA
    DIAGNOSIS
    DIAGNOSIS CODE LIST .
   TROUBLESHOOTING
    BEFORE TROUBLESHOOTlNG
    CONNECTOR HANDLING
    WIRE HARNESS AND CONNECTOR
    INSPECTION PROCEDURE
    TROUBLESHOOTING
    METHOD
    EXPLANATION OF BOXES
    SST SETTING METHODS (15 - 32 MODEL)
    CPU BOARD CONNECTOR
    DClMD BOARD CONNECTOR
    ST BOARD CONNECTOR
    EHPS BOARD CONNECTOR
    TRAVELINGIMATERIAL HANDLING CONTROLLER (CHOPPER-LESS) CONNECTOR-COMPONENT .
    TRAVELINGIMATERIAL HANDLING CONTROLLER (CHOPPER) CONNECTOR*COMPONENT .
    SAS CONTROLLER CONNECTOR*COMPONENT .
    EHPS CONTROLLER CONNECTOR*COMPONENT .
    EHPS CONTROLLER CONNECTOR*COMPONENT .
    CONTACTOR PANEL CONNECTOR*COMPONENT
    TROUBLESHOOTING (15-32 MODEL)
    COMPOSITION LIST .
    TRAVELlNGlMATERlAL HANDLING SYSTEMS
    WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED .
    WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED .
    STEERING SYSTEM .
    WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
    WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED
    MULTI-DISPLAY - MCS COMMUNICATION SYSTEM .
    WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
    WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED
    SAS SYSTEM WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
    WHEN NO ERROR CODE IS DISPLAYED .
   MOTOR
    DRIVE MOTOR
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL-INSTALLATION (15 - 32 MODEL)
    REMOVAL-INSTALLATION (35 - 55 MODEL)
    DISASSEMBLY.INSPECTI0N REASSEMBLY (15 - 32 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
    PUMP MOTOR
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL-INSTALLATION (15 - 32 MODEL)
    REMOVAL-INSTALLATION (35 - 55 MODEL. NO.l)
    REMOVAL-INSTALLATION (35 - 55 MODEL. N0.2)
    DISASSEMBLY.INSPECTION REASSEMBLY
    POWER STEERING MOTOR (15- 32 MODEL)
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL, INSTALLATION, DISASSEMBLY, INSPECTION , REASSEMBLY
    MOTOR BRUSH WEAR AND OVERHEAT WARNING
    INSPECTION
   DRIVE UNIT
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    DRIVE UNIT ASSY (15 - 32 MODEL)
    REMOVAL-INSTALLATION
    DISASSEMBLY-INSPECTION-REASSEMBLY (15-18 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY (15-18 MODEL (DEAD-MAN BRAKE) 20 - 32 MODEL)
    DRIVE UNIT ASSY (35 - 55 MODEL)
    REMOVAL.INSTALLATION
    DISASSEMBLY-INSPECTION-REASSEMBLY
    DIFFERENTIAL CASE ASSY
    DISASSEMBLY-INSPECTION-REASSEMBLY (15 - 32 MODEL)
    DISASSEMBLY-1NSPECTION.REASSEMBLY (35 - 55 MODEL)
   FRONT AXLE
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    FRONT AXLE SHAFT-AXLE HUB (15 - 32 MODEL)
    REMOVAL.INSTALLATION
    FRONT AXLE SHAFTaAXLE HUB (35 - 55 MODEL)
    REMOVAL-INSTALLATION
    FRONT AXLE BRACKETmAXLE HOUSING (15 - 32 MODEL)
    REMOVAL-INSTALLATION
    DIFFERENTIAL HOUSING (35 - 55 MODEL)
    REMOVAL-INSTALLATION .
   REAR AXLE
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REAR AXLE ASSY (15 - 32 MODEL)
    REMOVAL-INSTALLATION
    REAR AXLE ASSY (35- 55 MODEL)
    REMOVAL.INSTALLATION
    STEERING KNUCKLE (15 - 32 MODEL)
    REMOVAL-INSTALLATION
    STEERING KNUCKLE (35 - 55 MODEL)
    REMOVAL-INSTALLATION
    REAR AXLE CYLINDER
    REMOVAL.INSTALLATION (15 - 32 MODEL)
    REMOVAL-INSTALLATION (35 - 55 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY .
   STEERING
    GENERAL
    SPECIFICATIONS
    COMPONENTS .
    STEERING WHEEL-MAST JACKET
    REMOVAL-INSTALLATION
    DISASSEMBLY-INSPECTION-REASSEMBLY
    HYDROSTATIC STEERING VALVE ASSY
    TROUBLESHOOTING
    REMOVAL.INSTALLATION
    DISASSEMBLY.INSPECTl0N.REASSEMBLY
    RELIEF PRESSURE
    INSPECTlON.ADJUSTMENT
    POWER STEERING PUMP ASSY (15 - 32 MODEL)
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL-INSTALLATION
   BRAKE
    GENERAL
    SPEClFlCATlONS
    COMPONENTS
    FRONT BRAKE .
    DISASSEMBLY-INSPECTION.
    REASSEMBLY (15 - 32 MODEL) .
    DISASSEMBLY.INSPECTION
    REASSEMBLY (35-45 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY (55 MODEL)
    DEAD-MAN BRAKE (OPT)
    DISASSEMBLY.INSPECTION. REASSEMBLY
    BRAKE AIR BLEEDING (15 - 32 MODEL)
    BRAKE AIR BLEEDING (35 - 55 MODEL)
    BRAKING FORCE INSPECTION ADJUSTMENT
    DEAD-MAN BRAKE ADJUSTMENT
    BRAKE MASTER CYLINDER (15 - 32 MODEL)
    REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
    BRAKE BOOSTER
    TROUBLESHOOTING
    REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
    DEAD-MAN BRAKE
    CYLINDER .
    COMPONENTS
    REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
    DEAD-MAN BRAKE
    SOLENOID
    REMOVAL-INSTALLATION- DISASSEMBLY-INSPECTION-REASSEMBLY
    DEAD-MAN BRAKE RELIEF VALVE (15 - 32 MODEL)
    REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION- REASSEMBLY
    PARKING BRAKE INSPECTION
    ADJUSTMENT
    DEAD-MAN BRAKE WIRE
    INSPECTION-ADJUSTMENT (15 - 32 MODEL)
    DEAD-MAN BRAKE WlRE
    INSPECTION-ADJUSTMENT (35 - 55 MODEL)
    BRAKE PEDAL INSPECTION ADJUSTMENT (15 - 32 MODEL)
    BRAKE PEDAL INSPECTION ADJUSTMENT (35 - 55 MODEL)
   BODY
    COMPONENTS
    BATTERY HOOD ASSY
    REMOVAL-INSTALLATION
    COUNTERWEIGHT
    REMOVAL-INSTALLATION
    DRIVER`S SEAT
    REMOVAL-INSTALLATION
    FUSE (1 5 - 32 MODEL)
    FUSE MOUNTING POSITION
    NAMES (APPLICABLE PORTIONS) AND CAPACITIES
    FUSE (35 - 55 MODEL)
    FUSE MOUNTING POSITION
    NAMES (APPLICABLE PORTIONS) AND CAPACITIES .
   MATERIAL HANDLING SYSTEM
    HYDRAULIC SYSTEM DIAGRAM
    COMPONENTS
    RETURN FILTER-SUCTION FILTER
    REMOVAL-INSTALLATION (1 5 - 32 MODEL)
    REMOVAL-INSTALLATION (35 - 55 MODEL)
    NATURAL DROP TEST
    NATURAL FORWARD TILT TEST
    OIL LEAK TEST
    LIFT CYLINDER
    TILT CYLINDER .
   MAST
    V MAST ASSY
    COMPONENTS
    REMOVAL-INSTALLATION
    REMOVAL-INSTALLATION (WILIFT BRACKET)
    MAST DISASSEMBLY-INSPECTION-REASSEMBLY
    LIFT BRACKET
    DISASSEMBLY-INSPECTION-REASSEMBLY
    MAST ADJUSTMENT (V MAST. 15 - 32 MODEL)
    MAST ADJUSTMENT (V MAST. 35 - 55 MODEL)
    MAST ROLLER REMOVAL INSTALLATION
    CHAIN (15 - 32 MODEL)
    INSPECTION
    REASSEMBLY (V-FV-FSV)
    REASSEMBLY (QFV)
    ADJUSTMENT
    CHAIN (35 - 55 MODEL)
    INSPECTION
    REASSEMBLY (V-FV-FSV)
    ADJUSTMENT
    FORK
    REMOVAL
    INSTALLATION
    INSPECTION
    FV*FSV MAST ASSY
    COMPONENTS
    MAST ADJUSTMENT (FVmFSV. 15 - 32 MODEL)
    MAST ADJUSTMENT (FV-FSV MAST. 35 - 55 MODEL) .
    QFV MAST ASSY
    COMPONENTS
    MAST ADJUSTMENT (QFV) .
    LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)
   CYLINDER
    LIFT CYLINDER (V)*REAR LIFT CYLINDER (FV*FSV*QFV)
    GENERAL
    SPECIFICATIONS .
    COMPONENTS .
    REMOVAL-INSTALLATION (15 - 32 MODEL) .
    REMOVAL-INSTALLATION (35 - 55 MODEL)
    DISASSEMBLY-INSPECTION -REASSEMBLY (15 - 32 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
    FLOW REGULATOR VALVE
    REMOVAL-INSTALLATION (35 55 MODEL)
    SAFETY DOWN VALVE
    REMOVAL-INSTALLATION (35 - 55 MODEL) .
    FRONT LlFT CYLINDER (FV*FSV-QFV)
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL-INSTALLATION
    DISASSEMBLY-INSPECTION-REASSEMBLY (15 - 32 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
    TILT CYLINDER
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL-INSTALLATION 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 (15 - 32 MODEL)
    REMOVAL-INSTALLATION (35 - 55 MODEL NO.l PUMP)
    REMOVAL-INSTALLATION (35 - 55 MODEL N0.2 PUMP)
    DISASSEMBLY.INSPECTION-REASSEMBLY (15-32 MODEL. 35-55 MODEL N0.2 PUMP)
    DISASSEMBLY.INSPECTI0N.REASSEMBLY (35-55 MODEL NO.l PUMP)
    TEST METHOD
   OIL CONTROL VALVE
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    OIL CONTROL VALVE ASSY
    REMOVAL-INSTALLATION
    DISASSEMBLY-INSPECTION-REASSEMBLY (15 - 32 MODEL)
    DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
    LlFT & TILT LOCK VALVE ASSY (35 - 55 MODEL)
    REMOVAL-INSTALLATION
    DISASSEMBLY.INSPECTI0N.REASSEMBLY
    RELIEF PRESSURE ADJUSTMENT
    LlFT LOCK UNLOCKING BOLT (15 - 32 MODEL)
    CONTROL VALVE LEVER ASSY
    REMOVAL-INSTALLATION
   SAS FUNCTIONS
    GENERAL
    COMPONENTS
    BEFORE STARTING REPAIR WORK
    YAW RATE SENSOR
    REMOVAL.INSTALLATION
    SWING LOCK CYLINDER
    REMOVAL-INSTALLATION
    TILT ANGLE SENSOR
    REMOVAL.INSTALLATION
    LOAD SENSOR
    REMOVAL.INSTALLATION
    SPEED SENSOR
    REMOVAL-INSTALLATION
    MAST LIFTING HEIGHT SWITCH
    REMOVAL-INSTALLATION
    MATCHING
    STANDARD STATE OF VEHICLE
    CAUTIONS ON MODIFYING VEHICLES
    RENEWAL OF SAS CAUTION LABEL .
   APPENDIX
    SST LIST
    SERVICE STANDARDS
    CONNECTOR DRAWING (15 - 32 MODEL)
    CONNECTOR DRAWING (35 - 55 MODEL)
    CONNECTING DIAGRAM (15 - 32 MODEL)
    CONNECTING DIAGRAM (35 - 55 MODEL)
    WIRING DIAGRAM (15 - 32 MODEL)
    WIRING DIAGRAM (35 - 55 MODEL) .