Toyota 7FDU/7FGU35-80, 7FGCU35-70 Series Forklifts PDF Manual

This manual covers service procedures of Toyota Forklifts 7FGU / 7FDU 35-80 series and 7FGCU 35-70 series. You can use this manual for providing quick, correct servicing of the corresponding forklift models.
Electronic manual provides instructions for troubleshooting and repair of forklift trucks Toyota.
This manual includes detailed descriptions and instructions of repair procedures, photos and drawings, which are intended to implement the proper use and maintenance of forklifts Toyota.
This manual comes in PDF and includes 596 pages, which are printable. We recommend to use Adobe PDF Reader, to be sure all images / graphics will display correctly.

Models covered:
7FGU35
7FDU35
7FGKU40
7FDKU40
7FGU45
7FDU45
7FGAU50
7FDAU50
7FGU60
7FDU60
7FGU70
7FDU70
7FGU80
7FDU80
7FGCU35
7FGCU45
7FGCU55
7FGCU60
7FGCU70

SECTION INDEX:

• GENERAL
  •     EXTERIOR VIEWS
  •     VEHICLE MODEL
  •     FRAME NUMBER
  •     HOW TO USE THIS MANUAL
  •     OPERATIONAL TIPS
  •     HOISTING THE VEHICLE
  •     ATTENTIVE POINTS ON SAS
  •     CIRCUIT TESTER
  •     STANDARD BOLT & NUT TIGHTENING TORQUE
  •     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
  •     LUBRICATION CHART
  •     PERIODIC MAINTENANCE
  •     PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
• ENGINE
  •     ENGINE EXTERIOR VIEWS
  •     MAJOR SPECIFICATIONS
  •     ENGINE PERFORMANCE CURVES
  •     ENGINE ASSY
  •     AIR BLEEDING FROM FUEL SYSTEM
  •     ENGINE SPEED INSPECTION AND ADJUSTMENT
  •     AIR CLEANER
  •     RADIATOR
  •     FAN DRIVE
  •     MUFFLER & EXHAUST PIPE
  •     BATTERY
  •     V BELT TENSION ADJUSTMENT
  •     ACCELERATOR PEDAL
  •     ELECTRONIC GOVERNOR
  •     EZ PEDAL (OPT)
• TORQUE CONVERTER & TRANSMISSION
  •     GENERAL
  •     HYDRAULIC CIRCUIT DIAGRAM
  •     SPECIFICATIONS
  •     COMPONENTS
  •     TROUBLESHOOTING
  •     TORQUE CONVERTER
  •     TORQUE CONVERTER & TRANSMISSION ASSY
  •     TRANSMISSION ASSY
  •     STATOR SHAFT NO. 2 & OIL PUMP ASSY
  •     CLUTCH DRUM ASSY
  •     DIRECTION SWITCH ASSY
  •     OIL PRESSURE MEASUREMENT AND STALL TEST
• PROPELLER SHAFT
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     PROPELLER SHAFT
• DIFFERENTIAL
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     DIFFERENTIAL ASSY
  •     DIFFERENTIAL CASE ASSY
  •     DIFFERNETIAL CARRIER COVER ASSY
• FRONT AXLE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     TIRES-WHEELS
  •     FRONT AXLE ASSY
  •     FRONT AXLE BRACKET
  •     FRONT AXLE HOUSING-DIFFERENTIAL HOUSING
• REAR AXLE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     TIRES-WHEELS
  •     REAR AXLE ASSY
  •     REAR AXLE HUB-STEERING KNUCKLE
  •     STEERING KNUCKLE
  •     REAR AXLE CYLINDER
• STEERING
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     STEERING WHEEL-MAST JACKET
  •     HYDROSTATIC STEERING VALVE ASSY
  •     RELIEF PRESSURE INSPECTION-ADJUSTMENT
• BRAKE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     FRONT BRAKE
  •     BRAKE AIR BLEEDING
  •     BRAKING FORCE INSPECTION-ADJUSTMENT
  •     BRAKE BOOSTER
  •     PARKING BRAKE INSPECTION-ADJUSTMENT
  •     BRAKE PEDAL INSPECTION-ADJUSTMENT
  •     INCHING PEDAL
  •     SINGLE BRAKE PEDAL
• BODY
  •     COMPONENTS
  •     COUNTERWEIGHT
  •     DRIVER'S SEAT
  •     SEATBELT
  •     COMBINATION METER
  •     COMBINATION SWITCH
  •     FUEL SENDER GAUGE
  •     RELAY BLOCK
• MATERIAL HANDLING SYSTEM
  •     HYDRAULIC CIRCUIT DIAGRAM
  •     COMPONENTS
  •     RETURN FILTER-SUCTION FILTER
  •     NATURAL DROP TEST
  •     NATURAL FORWARD TILT TEST
  •     OIL LEAK TEST
• MAST
  •     V MAST ASSY
  •     CHAIN
  •     FORK
  •     FV-FSV MAST ASSY
  •     LIFT CYLINDER ROD SHIM ADJUSTMENT
• CYLINDER
  •     LIFT CYLINDER (V) REAR LIFT CYLINDER
  •     FLOW REGULATOR VALVE
  •     SAFETY DOWN VALVE
  •     FRONT LIFT CYLINDER
  •     TILT CYLINDER
• OIL PUMP
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     OIL PUMP ASSY
  •     PERFORMANCE TEST
  •     OIL PUMP DRIVE SHAFT
• OIL CONTROL VALVE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     OIL CONTROL VALVE ASSY
  •     CONTROL VALVE LEVER ASSY
  •     RELIEF PRESSURE ADJUSTMENT
• SAS
  •     GENERAL
  •     COMPONENTS
  •     PRECAUTIONS FOR REPAIR
  •     RENEWAL OF SAS CAUTION LABEL
  •     FUCNTIONAL PARTS
  •     RE-SETTING
  •     CUSTOMIZE
  •     PLUG-IN ANALYZER
  •     DIAGNOSIS
  •     TROUBLESHOOTING
  •     CONNECTOR LAYOUT
  •     CONNECTOR DIAGRAMS
• APPENDIX
  •     SST LIST
  •     SERVICE STANDARDS LIST
  •     WIRING DIAGRAMS