Toyota (BT) Diesel Forklift Truck 7FDF15, 7FDF18, 7FDF20, 7FDF25, 7FDF30, 7FDJ35 Service Manual

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
        REMOVAL•INSTALLATION 
        AIR BLEEDING FROM FUEL SYSTEM (DIESEL VEHICLE)
        ENGINE SPEED INSPECTION AND ADJUSTMENT
        4Y ENGINE
        1DZ-II•2Z 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 (FV•FSV)
        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 REMOVAL•INSTALLATION
        TIRE ANGLE SENSOR REMOVAL•INSTALLATION 
        SWING LOCK CYLINDER REMOVAL•INSTALLATION
        STEERING KNOB POSITION CORRECTING VALVE
        REMOVAL•INSTALLATION 
        TILT ANGLE SENSOR REMOVAL•INSTALLATION 
        LOAD SENSOR REMOVAL•
        INSTALLATION 
        SPEED SENSOR REMOVAL•INSTALLATION 
        FORK HEIGHT SWITCH REMOVAL•INSTALLATION
        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
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