Toyota Electric Forklift Truck 7FB10/14/15/18/20/25/30, 7FBJ35, 7FBH10/14/15/18/20/25 Service Manual

Original Illustrated Factory Workshop Service Manual for Toyota Electric Forklift Truck Type 7FB.

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:
    7FB10
    7FB14
    7FB15
    7FB18
    7FB20
    7FB25
    7FB30
    7FBH10
    7FBH14
    7FBH15
    7FBH18
    7FBH20
    7FBH25
    7FBJ35

Format: PDF, 669 Pages
Language: English

Contents:
GENERAL 
    EXTERIOR VIEWS 
    VEHICLE MODEL 
    FRAME NUMBER 
    HOW TO USE THIS MANUAL 
    EXPLANATION METHOD 
    TERMINOLOGY 
    ABBREVIATIONS 
    SI UNITS 
    OPERATIONAL TIPS 
    JACK-UP POINT 
    HOISTING THE VEHICLE 
    CAUTION FOR TOWING 
    ATENTIVE 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 
    TERMINOLOGY .  0.6  TORQUE 
    WIRE 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 STANDARDS 
    DISPLAY 
    SERVICE STANDARDS (OPT) 
    DISPLAY (OPT) 
    TROUBLESHOOTING 
    BATTERY ASSY 
    REMOVAL INSTALLATION 
    INSPECTION 
CHARGER 
    GENERAL 
    ON-VEHICLE CHARGER 
        APPLICABLE CHARGER LIST 
        SPECIFICATIONS 
        COMPONENTS 
        WIRING DIAGRAM 
        TAP LAYOUT 
        BEFORE CHARGING 
        SWITCH BOX 
        MAGNET SWITCH ASSY 
        TRANSFORMER ASSY 
        TIMER TEST 
        TROUBLESHOOTING 
    OFF-VEHICLE CHARGER 
        APPLICABLE CHARGER LIST 
        GENERAL (GS) 
        SPECIFICATIONS 
        WIRING DIAGRAM 
        BEFORE CHARGING 
        DISASSEMBLY*INSPECTION*REASSEMBLY 
        SERVICE STANDARDS 
        TIMER TEST 
        TROUBLESHOOTING 
CONTROLLER 
    AC CONTROLLER 
    SPECIFICATIONS 
    COMPONENTS 
    CONTROLLER. 
    CONTROL PANEL ASSY (FOR TRAVELING  AND MATERIAL HANDLING) 
    PS CONTROL PANEL ASSY (FOR STD) 
    PS CONTROL PANEL ASSY (FOR WITH SAS) 
    BOARD INSPECTION  BEFORE REPLACING EACH BOARD 
       DISASSEMBLY 
       REASSEMBLY 
    DISPLAY INSPECTION 
    DIRECTION SWITCH 
    ACCELERATOR POTENTIOMETER ADJUSTMENT 
    BRAKE SWITCH ADJUSTMET 
    FOOT BRAKE 
    PARKING BRAKE 
    MATERIAL HANDLING LEVER SWITCH 
    ADJUSTMENT 
MULTI-DISPLAY FUNCTIONS 
    AC CONTROLLER 
    SPECIFICATIONS 
    COMPONENTS 
    CONTROLLER. 
    CONTROL PANEL ASSY (FOR TRAVELING AND MATERIAL HANDLING) 
    PS CONTROL PANEL ASSY (FOR STD) 
    PS CONTROL PANEL ASSY (FOR WITH SAS) 
    BOARD INSPECTION 
    BEFORE REPLACING EACH BOARD 
       DISASSEMBLY 
       REASSEMBLY 
    DISPLAY INSPECTION 
    DIRECTION SWITCH 
    ACCELERATOR POTENTIOMETER 
    ADJUSTMENT 
    BRAKE SWITCH ADJUSTMET 
    FOOT BRAKE 
    PARKING BRAKE 
    MATERIAL HANDLING LEVER SWITCH 
    ADJUSTMENT .
ELECTRICAL SYSTEM TROUBLESHOOTING
    GENERAL 
    HOW TO READ TROUBLESHOOTING CHARTS 
    SST SETING METHOD 
    TRAVELING AND MATERIAL HANDLING 
    SYSTEM TROUBLESHOOTING 
    WHEN AN ERROR CODE IS DISPLAYED 
    WHEN NO ERROR CODE IS DISPLAYED 
    FAILURE IN CONCURRENT TRAVELING AND MATERIAL HANDLING 
    STEERING SYSTEM TROUBLESHOOTING 
    MULTIDISPLAY-MCS COMMUNICATION SYSTEM TROUBLESHOOTING 
    WHEN AN ERROR CODE IS DISPLAYED 
    WHEN NO ERROR CODE IS DISPLAYED 
    SAS TROUBLESHOOTING 
    WHEN AN ERROR CODE IS DISPLAYED 
    WHEN NO ERROR CODE IS DIDPLAYED 
    PLUG-IN ANALYZER . 
MOTOR 
    DRIVE MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
        REMOVAL*INSTALLATION 
        DISASSEMBLY*INSPECTION*REASSEMBLY 
    PUMP MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
        REMOVAL*INSTALLATION 
        DISASSEMBLY*INSPECTION*REASSEMBLY 
    POWER STEERING MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
       REMOVAL*INSTALLATION 
       DISASSEMBLY*INSPECTION*REASSEMBLY 
MOTOR 
    DRIVE MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
       REMOVAL*INSTALLATION 
       DISASSEMBLY*INSPECTION*REASSEMBLY 
    PUMP MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
       REMOVAL*INSTALLATION 
       DISASSEMBLY*INSPECTION*REASSEMBLY 
    POWER STEERING MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    REMOVAL*INSTALLATION 
       DISASSEMBLY*INSPECTION*REASSEMBLY 
FRONT AXLE 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    TIRES *WHEELS 
    FRONT AXLE SHAFTaAXLE 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 and 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  (1999.9 - 2000.8)  
    RELIEF PRESSURE INSPECTION* 
    ADJUSTMENT 
    PowER-sTEERING PUMP AssY . 10-15  m .  GENERAL 
    SPECIFICATIONS 
    COMPONENTS .
BRAKE 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    FRONT BRAKE 
    DISASSEMBLY-INSPECTION-REASSEMBLY (1 TON SERIES (EXCLUDING 40-7FB15 MODEL) J3.5TON) . 
    DISASSEMBLY-lNSPECTlON*REASSEMBLY  (40-7FB15 MODEL. 2 TON SERIES AND 3 TON) 
    BRAKE AIR BLEEDING . 
    BRAKING FORCE lNSPECTlON*ADJUSTMENT  . 
    BRAKE MASTER CYLINDER 
    REMOVAL.INSTALLATION . 
    PARKING BRAKE lNSPECTlON.ADJUSTMENT . 
    BRAKE PEDAL INSPECTIONaADJUSTMENT . 
BODY 
    COMPONENTS 
    SEAT STAND ASSY 
        REMOVAL-INSTALLATION 
    COUNTERWEIGHT 
       REMOVAL-INSTALLATION 
    DRIVER'S SEAT 
        REMOVAL-INSTALLATION 
    FUSE 
        MOUNTING POSITION-NAMES (APPLICABLE PORTIONS) AND CAPACITIES 
MATERIAL HANDLING SYSTEM 
    HYDRAULIC SYSTEM DIAGRAM 
    COMPONENTS 
    RETURN FILTER 
    REMOVAL*INSTALLATION 
    SUCTION FILTER  (FOR 3 TONmJ3.5 TON AND 40.7FB20.25)  
    REMOVAL-INSTALLATION 
    NATURAL DROP TEST 
    NATURAL FORWORD TILT TEST 
    OIL LEAK TEST 
    LIFT CYLINDER 
    TILT CYLINDER .
MAST 
    V MAST ASSY 
    COMPONENTS 
        REMOVAL*INSTALLATION 
        REMOVAL*lNSTALLATlON (WILIFT BRACKET) 
    MAST DISASSEMBLY*INSPECTION*REASSEMBLY 
    LlFT BRACKET DISASSEMBLY-INSPECTION* 
    REASSEMBLY 
    MAST ADJUSTMENT (V MAST) 
    MAST ROLLER REMOVAL*lNSTALLATlON 
    CHAl N 
    INSPECTION 
    REASSEMBLY 
    ADJUSTMENT 
    FORK 
    REMOVAL 
    INSTALLATION 
    INSPECTION 
    SV*FV* FSV MAST ASSY 
    COMPONENTS 
    MAST ADJUSTMENT (SV*FV*FSV) 
    LlFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) 
CYLINDER 
    LlFT CYLINDER (VaSV) l 
    REAR LIFT CYLINDER (FVaFSV) 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    FLOW REGULATOR VALVE (VaSVaFVaFSV) 
       REMOVAL*INSTALLATION 
    SAFETY DOWN VALVE (VaSVaFVaFSV) 
       REMOVAL*INSTALLATION (V) 
       REMOVAL*INSTALLATION (SV-FV-FSV) 
    FRONT LIFT CYLINDER (FVaFSV) 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
        REMOVAL-INSTALLATION 
    TILT CYLINDER . 
    GENERAL 
    SPECIFICATIONS . 1 5-23  m .  COMPONENTS 
    MAST FORWARD BACKWARD TILTING ANGLE 
    ADJUSTMENT (PREVENTION OF UNEVEN TILTING) 
OIL PUMP 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    OIL PUMP ASSY 
        REMOVAL*INSTALLATION 
    DISASSEMBLY.INSPECTION-REASSEMBLY  (I AND 2 TON SERIES) 
    DISASSEMBLY-INSPECTION*REASSEMBLY  (3 AND J3.5 TON) 
    TEST METHOD 
OIL CONTROL VALVE 
    VEHICLE WISAS 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    OIL CONTROL VALVE ASSY 
        REMOVAL*INSTALLATION 
        DISASSEMBLY*INSPECTION*REASSEMBLY 
    RELIEF PRESSURE ADJUSTMENT 
    LIFT LOCK UNLOCKING BOLT 
    CONTROL VALVE LEVER ASSY 
        REMOVAL*INSTALLATION 
    VEHICLE WITHOUT SAS 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    OIL CONTROL VALVE ASSY 
        REMOVAL*INSTALLATION 
        DISASSEMBLY-INSPECTION*REASSEMBLY 
    RELIEF PRESSURE ADJUSTMENT .
SAS FUNCTIONS (OPT) 
    GENERAL 
    COMPONENTS 
    BEFORE STARTING REPAIR WORK 
    RENEWAL OF SAS CAUTION LABEL 
    FUNCTIONAL PARTS 
    STEERING KNOB POSITION 
    CORRECTING VALVE 
        REMOVAL*INSTALLATION (1999.9- 2000.8) 
        REMOVAL*INSTALLATION (2000.9 up ) 
    TIRE ANGLE 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 
    REMOVALINSTALLATION 
    MATCHING 
    STANDARD STATE OF VEHICLE 
    CAUTIONS ON MODIFYING VEHICLES .
APPENDIX 
    SST LIST 
    CONNECTOR DRAWING  (FOR VEHICLE WITHOUT SAS) 
    CONNECTOR DRAWING  (FOR VEHICLE WITH SAS) 
    CPU BOARD CONNECTOR DRAWING 
    DC/MD BOARD CONNECTOR DRAWING 
    SCPU BOARD CONNECTOR DRAWING 
    DC/SD BOARD CONNECTOR DRAWING 
    CONNECTING DIAGRAM  (FOR VEHICLE WITHOUT SAS) 
    CONNECTING DIAGRAM  (FOR VEHICLE WITH SAS) 
    WIRING DIAGRAM  (FOR VEHICLE WITHOUT SAS) 
    WIRING DIAGRAM  (FOR VEHICLE WITH SAS)
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