Toyota 7FDF/FGF 15-35 Series Forklifts Service Manual PDF

The service manual contains general service information, special repair instructions, lots of pictures, and drawings for Toyota Forklifts 7FDF/FGF 15-35. The manual helps to get a detailed description of Toyota forklifts, using which you can determine where to assemble and disassemble details, etc. A service manual helps to troubleshoot and resolve any problems that arise.

This service manual comes in PDF format. We recommend using Adobe PDF Reader to be sure all images/graphics will display correctly. If necessary, you can print pages, pictures, charts, or the entire manual completely.

Vehicle Models:
42-7FGF15
02-7FDF15
42-7FGF18
02-7FDF18
42-7FGF20
62-7FDF20
02-7FDF20
42-7FGF25
62-7FDF25
02-7FDF25
02-7FGF30
62-7FDF30
02-7FDF30
02-7FGJF35
02-7FDJF35

INDEX:

• GENERAL
  •     EXTERIOR VIEWS
  •     VEHICLE MODEL
  •     FRAME NUMBER
  •     HOW TO USE THIS MANUAL
  •     OPERATIONAL TIPS
  •     HOISTING THE VEHICLE
  •     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
  •     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
  •     AIR CLEANER
  •     RADIATOR
  •     MUFFLER & EXHAUST PIPE
  •     BATTERY
  •     V-BELT TENSIONINSPECTION• ADJUSTMENT
  •     ACCELERATOR PEDAL
  •     VEHICLE SPEED CONTROL SYSTEM (OPT)
  •     DPF-II SYSTEM (OPT)
• TORQUE CONVERTER & TRANSMISSION
  •     GENERAL
  •     HYDRAULIC CIRCUIT DIAGRAM
  •     SPECIFICATIONS
  •     COMPONENTS
  •     TROUBLESHOOTING
  •     TRANSMISSION & CONTROL VALVE ASSY
  •     TORQUE CONVERTER•OIL PUMP
  •     TORQUE CONVERTER & TRANSMISSION ASSY
  •     TRANSMISSION ASSY
  •     CLUTCH DRUM ASSY
  •     DIRECTION SWITCH ASSY
  •     OIL PRESSURE MEASUREMENT AND STALL TEST
  •     NEW TRANSMISSION From 2003.10
• PROPELLER SHAFT
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     PROPELLER SHAFT
• DIFFERENTIAL
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     DIFFERENTIAL ASSY
  •     DIFFERENTIAL CASE ASSY
  •     DIFFERENTIAL CARRIER
• FRONT AXLE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS         TIRES•WHEELS
  •     FRONT AXLE SHAFT•AXLE HUB
  •     FRONT AXLE BRACKET•AXLE HOUSING
• REAR AXLE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     TIRES•WHEELS     
  •     REAR AXLE ASSY
  •     REAR AXLE HUB•STEERING KNUCKLE
  •     REAR AXLE CYLINDER
  •     REAR WHEEL ALIGNMENT
• 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 MASTER CYLINDER
  •     PARKING BRAKE INSPECTION•ADJUSTMENT
  •     BRAKE PEDAL INSPECTION•ADJUSTMENT
  •     INCHING PEDAL INSPECTION•ADJUSTMENT (~ Mar. 2000)
  •     INCHING PEDAL INSPECTION•ADJUSTMENT (Mar. 2000 ~)
• BODY
  •     COMPONENTS
  •     ENGINE HOOD ASSY
  •     COUNTERWEIGHT
  •     HEAD LAMPS
  •     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 (PREVENTION OF UNEVEN LIFTING)
• CYLINDER
  •     LIFT CYLINDER (V) REAR LIFT CYLINDER (FV FSV)
  •     FLOW REGULATOR VALVE (V FV FSV)
  •     SAFETY DOWN VALVE (V FV FSV)
  •     FRONT LIFT CYLINDER (FV FSV)
  •     TILT CYLINDER
• OIL PUMP
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     OIL PUMP ASSY
  •     PERFORMANCE TEST
• OIL CONTROL VALVE
  •     GENERAL
  •     SPECIFICATIONS
  •     COMPONENTS
  •     OIL CONTROL VALVE ASSY
  •     CONTROL VALVE LEVER ASSY
  •     JUSTERING AV ÖVERSTRÖMNINGSVENTIL
  •     Hydraulschema T.O.M November 2000
  •     Hydraulschema Fr.O.M November 2000
  •     Teleflex Morse, arbetshydraulik
• SAS
  •     GENERAL
  •     COMPONENTS
  •     PRECAUTIONS FOR REPAIR
  •     FUNCTIONAL PARTS
  •     RE-SETTING
  •     CUSTOMIZE
  •     PLUG-IN ANALYZER
  •     DIAGNOSIS
  •     TROUBLESHOOTING
  •     CONNECTOR LAYOUT
  •     CONTROLLER SEQUENCE
  •     CONNECTOR DIAGRAMS
• APPENDIX
  •     SST LIST
  •     SERVICE STANDARDS LIST
  •     WIRING DIAGRAM
  •     Elschema, FLK hytt
  •     Elschema, Toyota Deluxe hytt
• WIRING DIAGRAM
  •     WIRING DIAGRAM EXPLANATION
  •     WIRE TO WIRE LIST (ROUTE)
  •     WIRE TO WIRE LIST (CONNECTOR)
  •     POWER FUSES (R/B)
  •     ELECTRICAL SHIFT TORQUE CONVERTER
  •     CHARGING
  •     FUEL (1DZ-II 2Z)
  •     FUEL & IGNITION (4Y)
  •     FUEL & IGNITION (LPG & GASOLINE LPG ONLY)
  •     INTAKE HEATER (2Z)
  •     GLOW (1DZ-II)
  •     EMISSION CONTROL (GASOLINE)
  •     EMISSION CONTROL (LPG)
  •     REAR WORK LAMP
  •     HEAD LAMP
  •     CLEARANCE LAMP (ILLUMINATION LAMP)
  •     STOP LAMP
  •     TURN SIGNAL LAMP
  •     ROTARY LIGHT (BEACON)
  •     HORN
  •     T/C HEAT GAUGE
  •     LOW LPG LEVEL ALARM
  •     COMBINATION METER
  •     FR/RR WIPER
  •     D2 pedal
  •     Elschema fr.o.m 2002