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

Original Illustrated Factory Workshop Service Manual for Toyota Electric Forklift Truck with OPS (Operator Presence Sensing) Models 7FB10, 7FB14, 7FB15, 7FB18, 7FB20, 7FB25, 7FB30, 7FBJ35, 7FBH10, 7FBH14, 7FBH15, 7FBH18, 7FBH20, 7FBH25 (CE316-2)

Original factory manuals for Toyota Forklift 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
    40-7FB10
40-7FB15
40-7FB20
40-7FB25
7FBH10
7FBH14
7FBH15
7FBH18
7FBH20
7FBH25
7FBJ35

Format: PDF, 765 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 .
OPS (fr.o.m 2006)
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)