Toyota 7FBCU15/18/20/25/30, 7FBCU32, 7FBCU35, 7FBCU45, 7FBCU55, 7FBCHU25 Service Manual

Toyota 7FBCU15/18/20/25/30, 7FBCU32, 7FBCU35, 7FBCU45, 7FBCU55, 7FBCHU25 Service Manual

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

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) .
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