Toyota (BT) Diesel Forklift Truck 7FDF15, 7FDF18, 7FDF20, 7FDF25, 7FDF30, 7FDJ35 Workshop Service Manual

SERVICE MANUAL TOYOTA 7FDF/FGF 15-35 BT Svenska AB NAME SECTION GENERAL ENGINE TRANSMISSION 0 1 2 PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE SAS APPENDIX 3 4 5 6 7 8 9 10 11 12 13 14 15 16 INDEX

0-1 0 GENERAL Page EXTERIOR VIEWS ......................................................... 0-2 VEHICLE MODEL .......................................................... 0-3 FRAME NUMBER ........................................................... 0-4 HOW TO USE THIS MANUAL .................................... 0-5 EXPLANATION METHOD ................................................. 0-5 TERMINOLOGY ................................................................ 0-6 ABBREVIATIONS ............................................................. 0-6 OPERATIONAL TIPS .................................................... 0-7 HOISTING THE VEHICLE ............................................ 0-8 CIRCUIT TESTER .................................................. 0-9 STANDARD BOLT & NUT TIGHTENING TORQUE ....................................................................... 0-11 BOLT STRENGTH TYPE IDENTIFICATION METHOD ...... 0-11 TIGHTENING TORQUE TABLE ........................................ 0-12 PRECOAT BOLTS ......................................................... 0-13 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ............................................ 0-13 WIRE ROPE SUSPENSION ANGLE LIST ............... 0-14 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE ............................................... 0-14 COMPONENTS WEIGHT ............................................. 0-15 RECOMMENDED LUBRICANT QUANTITY & TYPES ................................................. 0-16 SMÖRJSCHEMA ........................................................... 0-18 PERIODISKT UNDERHÅLL ........................................ 0-19 UTBYTE AV SMÖRJMEDEL OCH DELAR ................................................................. 0-25

0-2 EXTERIOR VIEWS

0-3 VEHICLE MODEL 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 1.5 ton model 1.75 ton model 2.0 ton model 2.5 ton model 3.0 ton model J3.5 ton model 1 ton series 2 ton series 3 ton series J3.5 ton series T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C 4Y 1DZ-II 4Y 1DZ-II 4Y 1DZ-II 2Z 4Y 1DZ-II 2Z 4Y 1DZ-II 2Z 4Y 2Z Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Transmission Type Vehicle Model Engine Model Series Classification

0-4 FRAME NUMBER Frame No. Punching Position Punching position Series 1 ton series 2 ton series 3 ton, J3.5 ton series Engine 4Y 1DZ-II 4Y 2Z 1DZ-II 4Y 2Z 1DZ-II Vehicle model 42-7FGF15 42-7FGF18 02-7FDF15 02-7FDF18 42-7FGF20 42-7FGF25 02-7FDF20 02-7FDF25 62-7FDF20 62-7FDF25 02-7FGF30 02-7FGJF35 02-7FDF30 02-7FDJF35 62-7FDF30 Punching format 407FGF18 10011 7FDF18 10011 407FGF25 10011 7FDF25 10011 607FDF25 10011 7FGJF35 10011 7FDJF35 10011 607FDF30 10011

0-5 HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, fol- lowed by explanation of cautions and notes summarized as point operations. Example of description in pattern B DISASSEMBLY·INSPECTION·REASSEMBLY Tightening torque unit T = N·m (kgf-cm) [ft-lbf] Disassembly Procedure 1 Remove the cover. [Point 1] 2 Remove the bushing [Point 2]  Operation explained later 3 Remove the gear. Point Operations Explanation of key point for operation with an illustration [Point 1] Disassembly: Put a match mark when removing the pump cover. [Point 2] Inspection: Measure the bush inside diameter. Limit: 19.12 mm (0.7528 in) • Step Nos. are partially sometimes omitted in illustrations. • When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame.  T = 46.1 ~ 48.1 (470 ~ 490) [34.0 ~ 35.5]

0-6 Abbreviation (code) ASSY LH LLC M/T NMR OPT O/S PS RH SAE 2. How to read components figures (Example) (1) The components figure uses the illustration in the parts catalog for the vehicle model. Please refer to the catalog for checking the part name. The number at the right shoulder of each components figure indicates the Fig. number in the parts catalog. 3. Matters omitted in this manual (1) This manual omits description of the following jobs, but perform them in actual operation: Cleaning and washing of removed parts as required Visual inspection (partially described) TERMINOLOGY Caution: Important matters of which negligence may cause accidents. Be sure to observe them. Note: Important items of which negligence may cause accidents, or matters in operation procedure requiring special attention. Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment. ABBREVIATIONS Meaning System of active stability Special service tool Standard Tightening torque Torque converter & transmission Number of teeth ( ) Undersize With Less Meaning Assembly Left hand Long life coolant Manual transmission No-load maximum speed Option Oversize Power steering Right hand Society of Automotive Engineers (USA) Abbreviation (code) SAS SST STD T = T/C T U/S W/ L/ - FIG number in parts catalog 3201

0-7 OPERATIONAL TIPS 1. Safe operation (1) After jacking up, always support with wooden blocks or rigid stands. (2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity. (3) Always disconnect the battery terminal before the inspection or servicing of electrical parts. 2. Tactful operation (1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation. (2) Before disconnecting wiring, always check the cable color and wiring state. (3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location. (5) Follow the described procedures for disassembly, inspection and reassembly. (6) Replace, gaskets, packings and O-rings with new ones each time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly. Tighten to the center of the specified tightening torque range. If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table. 3. Grasping the trouble state When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for remedying. 4. Disposal of waste fluid, etc. When draining waste fluid from the vehicle, receive it in a container. If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped without permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids, etc. and treat them properly by requesting disposal by specialized companies. 5. Jack up points Jack up points are provided in the front and rear portions of the vehicle. Always apply jacks at the jack up points. Front side: A circular groove to accept a screw jack is provided un- der the front side of the frame. When a garage jack is used, jack up at the bottom surface of the frame. Rear side: A circular groove to accept a screw or garage jack is provided at the bottom surface of the counterweight. For screw jack For screw jack For garage jack

0-8 HOISTING THE VEHICLE When hoisting the vehicle, sling with wire rope(s) at the mast hook holes and the rear side of the head guard. Slinging at the head guard is done in two ways. Method A: Sling after removing the head guard seat. Method B: Carefully sling so as not to damage rear combination lamps. A B

0-9 CIRCUIT TESTER Circuit testers are available in both the analog and digital types. They should be used selectively according to the purpose of measurement. Analog type: This type is convenient for observing movement during operation, but the measured value should only be used for reference or rough judgement. Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement. 1. Difference in measurement results with the digital type and analog type * The result may be different between measurements with the analog type and digital type. Always use a circuit tester according to its operation manual. Cautions when the polarities are different between the analog type and digital type are described below. (1) Analog circuit tester (2) Digital circuit tester Measurement result example Tester range: kΩ range Analog type Continuity exists 11 kΩ No continuity Forward Reverse Measurement result example Tester range: MΩ range Digital type No continuity 1 Continuity exists 2 MΩ Forward Reverse ∞ Forward direction Forward direction Reverse direction Reverse direction

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Toyota (BT) Diesel Forklift Truck 7FDF15, 7FDF18, 7FDF20, 7FDF25, 7FDF30, 7FDJ35 Workshop Service Manual

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