Toyota Diesel Forklift Truck 7FDAU50, 7FDKU40, 7FDU35, 7FDU45, 7FDU60, 7FDU70, 7FDU80 Workshop Service Manual

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 7FGU17FDU35 - 80 series and 7FGCU35 - 70 series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of December 2000. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equip- ment Parts & Service News. For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows: TOYOTA G4 (GM6-262) ENGINE REPAIR MANUAL (No. C4630) TOYOTA 11Z,12Z,13Z,14Z ENGINE REPAIR MANUAL (No. C4615) TOYOTA MOTOR CORPORATION

Service Information Bulletins affecting Models 7FG(D)U35-80 and 7FGCU35-70 REV: 2/29/08 Title File File Size Modified On 1 SIB MA04-001 Revision of Repair Manual for 7FG/DU35-80 & 7FGCU35-70 ma04-001.pdf 2739 KB 4/26/2006 2 SIB MA02-001 GM 6-262 Timing & Idle Adjustment Procedure Change ma02-001.pdf 237 KB 5/3/2006 3 SIB FS06-001 13Z Updated Fuel System Components fs06-001.pdf 278 KB 5/8/2006 4 SIB FS06-002 LPG Pre-Filter Service Parts fs06-002.pdf 62 KB 5/8/2006 5 SIB CE05-004 Starter Motor Engagement Delay (All I.C. Units) ce05-004.pdf 1018 KB 5/25/2006 6 SIB BR06-001 Stiffer Inching Pedal Spring br06-001.pdf 77 KB 6/1/2006 7 SIB EN04-004 13Z Injection Pump Changes en04-004.pdf 505 KB 6/7/2006 8 SIB MA05-003 Change to Periodic Replacement Parts (4Y & GM6-262) ma05-003.pdf 45 KB 6/7/2006 9 SIB EN04-001 EPA Compliant Three Way Catalyst System Identification & New SST en04-001.pdf 210 KB 6/7/2006 10 SIB EN03-004 Exhaust Y-Pipe Cracking en03-004.pdf 323 KB 6/7/2006 11 SIB CE01-005 Combination Meter Membrane Grease ce01-005.pdf 385 KB 6/8/2006 12 SIB FA06-001 Changes to Reamer Bolt Torque Specification fa06-001.pdf 82 KB 10/18/2006 13 SIB MA07-001 Caution During Oil Filling ma07-001.pdf 126 KB 1/31/2007 14 SIB FS07-001 New Fuel System for GM6-262 fs07-001.pdf 175 KB 1/31/2007 15 SIB MA07-001R Caution During Oil Filling ma07-001r.pdf 190 KB 6/27/2007 16 SIB FS07-002 MIL Strategy Change fs07-002.pdf 75 KB 6/27/2007 17 SIB FS07-003 ECM calibration revisions and DTC updates fs07-003.pdf 163 KB 7/12/2007 18 SIB CE07-002 Wiring Diagrams for Spectrum Fuel System ce07-002.pdf 3247 KB 9/25/2007 19 SIB ST07-002 Recommended Service Tools for a Field Service Technician st07-002.pdf 84 KB 9/25/2007 20 SIB FS07-004 New Spectrum DTC 652 and 653 fs07-004.pdf 87 KB 10/26/2007 21 SIB FS07-008 New Spectrum DTC 9999 and 1151 fs07-008.pdf 53 KB 10/26/2007 22 SIB FS07-005 New Spectrum DTC 627, 628, and 629 fs07-005.pdf 141 KB 10/26/2007 23 SIB CE07-006 Introduction of VSCS Vehicle Speed Control System ce07-006.pdf 741 KB 10/26/2007 24 SIB FS07-006 Spectrum Fuel System Relay Change fs07-006.pdf 77 KB 11/16/2007 25 SIB BF08-002 Product Improvement for 7FGU/7FDU35-80, 7FGCU35-70 bf08-002.pdf 2504 KB 2/12/2008 Technical New Briefs affecting Models 7FG(D)U35-80 and 7FGCU35-70 1 TNB-2007-08 Troubleshooting 13Z Diesel Exhaust Smoke tnb-2007-08.pdf 71 KB 10/26/2007 2 TNB-2005-04R2 Guidelines for Cleaning a Contaminated Hydraulic System tnb-2005-04-r2.pdf 77 KB 10/26/2007 3 TNB-2007-02 Chassis Lubrication Clarification tnb-2007-02.pdf 71 KB 4/9/2007 4 TNB-2007-01 Use of Torque Adapter for SSC FL06-007 tnb-2007-01.pdf 88 KB 4/9/2007 5 TNB-2003-03 7FGU35 – 80, 7FGCU35 – 70 Poor Engine Performance When Cold tnb-2003-03.pdf 156 KB 11/29/2005 6 TNB-2005-03 Quick Reference Sheet for 13Z Diesel Pump Timing tnb-2005-03.pdf 294 KB 11/29/2005

Hotline Tech Tip Articles affecting Models 7FG(D)U35-80 and 7FGCU35-70 REV: 2/29/08 1 HTT-11-2004 - V-6 hard start; Hydraulic valve sticking: Excessive brake wear & noise; Axle plate mounting bolts loose hotline tech tips-2004-11.pdf 114 KB 2/6/2006 2 HTT-12-2004 - GMV6 Timing; Strobe Light Failures; V6 hard start; Drive Train Noise; Hydraulic pump failures hotline tech tips-2004-12.pdf 130 KB 2/6/2006 3 HTT-1-2005 - Rotten Egg Smell, Retrieving TWC Error Codes, Flame Retardant Hydraulic Oil, GM V-6 Crank Pulley hotline tech tips-2005-01.pdf 119 KB 7/5/2006 4 HTT-2-2005 - LP Pre-filter Parts, Retrieving TWC Error Codes, Hydraulic Pump Change hotline tech tips-2005-02.pdf 153 KB 2/20/2006 5 HTT-3-2005 - “Rotten Egg” Smell; Driveline Vibration; Aisin LPG Regulator Rich/Lean Air/fuel Ratio; Abnormal Brake Noise; Diesel Engine Smoke; Overheating hotline tech tips-2005-03.pdf 121 KB 2/6/2006 6 HTT-4-2005 - Lean LPG Main Path, Engine Compression Check; Key Switch Change hotline tech tips-2005-04.pdf 94 KB 2/6/2006 7 HTT-5-2005 - Seat Switch Testing, Premium GM V-6 Engine; GM V-6 Crankshaft Bolt hotline tech tips-2005-05.pdf 168 KB 7/5/2006 8 HTT-6-2005 - Injector Harness Test Light; Cascade House Valves hotline tech tips-2005-06.pdf 326 KB 2/6/2006 9 HTT-7-2005 - TWC Initial Setting for Injector Period, Improvements to the new key switches, Operator Prescence System hotline tech tips-2005-07.pdf 118 KB 3/13/2006 10 HTT-8-2005 - TWC Initial Setting for Injector Period, Improvements To The New Key Switches, Operator Presence System hotline tech tips-2005-08.pdf 112 KB 3/13/2006 11 HTT-9-2005 - 13Z Diesel Injection Timing hotline tech tips-2005-09.pdf 323 KB 2/6/2006 12 HTT-10-2005 - 13Z Diesel Injection Timing hotline tech tips-2005-10.pdf 97 KB 2/2/2006 13 HTT-11-2005 - TWC Analyzer Tips, GM V6 Hot Soak Engine Shut Down hotline tech tips-2005-11.pdf 74 KB 2/6/2006 14 HTT-12-2005 - OPSS Component Information hotline tech tips-2005-12.pdf 278 KB 4/9/2007 15 HTT-1-2006 - TWC Trouble Shooting Tips, Metal Clad Wiper Seals on Rear Lift Cylinders hotline tech tips-2006-01.pdf 71 KB 2/2/2006 16 HTT-2-2006 - O.P.S.S. Error Code 1, TWC Light Strobing & Adjustments, Hood Vents, Replacement Radiators, GM V-6 Y Pipe Update hotline tech tips-2006-02.pdf 185 KB 3/2/2006 17 HTT-3-2006 - 7Series Starter Delay Circuit hotline tech tips-2006-03.pdf 249 KB 4/3/2006 18 HTT-4-2006 - LPG Regulator Air Testing, Home Depot Options, LPG Pre-Filter Service Parts hotline tech tips-2006-04.pdf 84 KB 4/27/2006 19 HTT-5-2006 -7FDU Oil Filing, Cotton Core Radiator, LPG Oil Contamination hotline tech tips-2006-05.pdf 279 KB 6/20/2006 20 HTT-6-2006 - V-Mast Rear Cylinders, Wire Harness Repair, SAS Code 63, Axle Mount Bolts hotline tech tips-2006-06.pdf 344 KB 7/11/2006 21 HTT-7-2006 - GM6-262 Exhaust Y-Pipe Breaking hotline tech tips-2006-07.pdf 131 KB 4/9/2007 22 HTT-8-2006 -Engine Shutdown Option, Extreme Environment Radiator hotline tech tips-2006-08.pdf 268 KB 9/6/2006 23 HTT-9-2006 - V-Mast Cylinder Spacer, GM6-262 Timing Chain Tensioner, TWC Tamper Resistant Plug hotline tech tips-2006-09.pdf 134 KB 10/3/2006 24 HTT-10-2006 - GM6-262 Hard/Impossible to Start, SAS L-Off hotline tech tips-2006-10.pdf 257 KB 4/9/2007 25 HTT-11-2006 - Ultra-Low Sulfur Diesel, 7FGCU35-45 Brake Noise, TWC Emission Warranty hotline tech tips-2006-11.pdf 99 KB 11/27/2006 26 HTT-12-2006 - Travel Speed Measurement, Clogged LP injector, New Fuel System SST hotline tech tips-2006-12.pdf 308 KB 4/9/2007 27 HTT-1-2007 - GM6-262 Spectrum Fuel System hotline tech tips-2007-01.pdf 136 KB 4/9/2007 28 HTT-2-2007 - Spectrum MIL Strategy change, Chassis Lubrication, USB adapter for Spectrum hotline tech tips-2007-02.pdf 519 KB 4/9/2007 29 HTT-3-2007 - IC Radiator Offerings hotline tech tips-2007-03.pdf 154 KB 4/9/2007 30 HTT-4-2007 - Spectrum Adapter hardware change hotline tech tips-2007-04.pdf 381 KB 5/10/2007 31 HTT-5-2007 - Spectrum Fuel System Terminology hotline tech tips-2007-05.pdf 216 KB 9/24/2007 32 HTT-6-2007 - New Active Radiator, Troubleshooting Smoke hotline tech tips-2007-06.pdf 162 KB 9/24/2007 33 HTT-7-2007 - New Hydraulic Oil, Troubleshooting Overheating, Spectrum III LP and/or Gasoline hotline tech tips-2007-07.pdf 600 KB 9/24/2007 34 HTT-9-2007 - Spectrum Fuel System Calibration hotline tech tips-2007-09.pdf 502 KB 9/24/2007 35 HTT-10-2007 - LP Lockoff Solenoid Orientation hotline tech tips-2007-10.pdf 303 KB 10/30/2007 36 HTT-11-2007 - Spectrum Calibration changes, Spectrum DTC 1152 hotline tech tips-2007-11.pdf 155 KB 11/19/2007 37 HTT-12-2007 - Spectrum hard start, Engine Block Heaters hotline tech tips-2007-12.pdf 490 KB 12/12/2007 38 HTT-1-2008 - Threshold Voltages hotline tech tips-2008-01.pdf 363 KB 1/28/2008 39 HTT-2-2008 - Proper Wheel Torque hotline tech tips-2008-02.pdf 204 KB 2/28/2008

SECTION INDEX NAME SECTION I GENERAL ENGINE TORQUE CONVERTER & TRANSMISSION PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE SAS APPENDIX

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 ............................................................. A6BR EVl ATIONS 0 - 6 .................................................... OPERATIONAL TIPS 0 - 7 HOISTING THE VEHICLE ........................................ 0 - 7 ATTENTIVE POINTS ON SAS .................................... 0 - 8 .................................................. CIRCUIT TESTER 0 - 9 STANDARD BOLT & NUT TIGHTENING TORQUE ........................................................... 0-11 BOLT STRENGTH TYPE IDENTIFICATIONMETHOD ...... 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 WlRE ROPE ............................................... SUSPENSION ANGLE 0 - 14 ............................................. COMPONENTS WEIGHT 0 - 15 RECOMMENDED LUBRICANT QUANTITY & TYPES ................................................. 0 - 16 ................................................. LUBRICATION CHART 0 - 17 .......................................... PERIODIC MAINTENANCE 0-20 PERIODIC REPLACEMENT OF PARTS AND ............................................................... LUBRICANTS 0-26

EXTERIOR VIEWS Pneumatic tire model Cushion tire model

VEHICLE MODEL Pneumatic Tire Models (Pn) Cushion Tire Models (Cu) Note: The G4 engine is the same as the GM6-262 engine except for the nomenclature. Vehicle Model 7FGU35 7FDU35 7FGKU40 7FDKU40 7FGU45 7FDU45 7FGAU50 7FDAU50 7FGU60 7FDU60 7FGU70 7FDU70 7FGU80 7FDU80 Load Capacity 8000 Ibs 9000 lbs 10000lbs 11000 Ibs 13500 Ibs 15500 Ibs 17500 Ibs Classification Series Pn3.5 ton series Pn4.5 ton series Pn6.0 ton series Model Pn35 Pn40 Pn45 Pn50 Pn60 Pn70 Pn80 Transmission Type TIC TIC TIC TIC TIC TIC TIC TIC TIC TIC TIC TIC TIC TIC Transmission Type TIC TIC TIC TIC TIC Engine Classification G4 (GM6-262) G4 (GM6-262) G4 (GM6-262) G4 (GM6-262) G4 (GM6-262) Engine Load Capacity 8000 Ibs 10000lbs 12000 Ibs 13500 Ibs 15500 Ibs Series Cu3.5 ton series Cu5.5 ton series Gasoline Gasoline Gasoline Gasoline Gasoline G4 (GM6-262) 132 G4 (GM6-262) 1 32 G4 (GM6-262) 132 G4 (GM6-262) 132 G4 (GM6-262) 132 G4 (GM6-262) 132 G4 (GM6-262) 132 Vehicle Model 7FGCU35 7FGCU45 7FGCU55 7FGCU60 7FGCU70 Model Cu35 Cu45 Cu55 Cu60 Cu70 Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel

FRAME NUMBER Frame No. Punching Position Punching position *: EEC spec. Pneumatic tire Cushion tire Series 3.5 ton series 4.5 ton series 6.0 ton series 3.5 ton series 5.5 ton series Engine G4 (GM6-262) 1 32 G4 (GM6-262) 132 G4 (GM6-262) 132 G4 (GM6-262) G4 (GM6-262) Vehicle model 7FGU35 7FGKU40 7FDU35 7FDKU40 7FGU45 7FGAU50 7FDU45 7FDAU50 7FGU60 7FGU70 7FGU80 7FDU60 7FDU70 7FDU80 - 7FGCU35 7FGCU45 7FGCU55 7FGCU60 7FGCU70 Punching format 7FGKU40 - 6001 1 7FDKU40 - 6001 1 7FGAU50 - 6001 1 7FDAU50 - 6001 1 7FGU80 - 6001 1 7FDU80 - 6001 1 7FGCU45 - 6001 1 * 7FGCU45 O 6001 1 7FGCU70 - 6001 1 -

HOW TO USE THIS MANUAL EXPLANATIONMETHOD 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 6: 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] Step Nos. are partially sometimes omitted in illustrations. 1 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 51 8 Disassembly Procedure 1 Remove the cover. [Point 11 2 Remove the bushing [Point 21 C Operation explained later 3 Remove the gear. Point Operations Explanation of key point for operation with an illustration [Point 11 LL Disassembly: Put a match mark when removing the pump cover. [Point 21 Inspection: Measure the bushing inside diameter. Limit: 19.12 mm (0.7528 in)

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. FIG number in parts catalog I 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: lmportant matters of which negligence may cause hazards on human body. Be sure to ob- serve them. Note: lmportant items of which negligence may cause breakage or breakdown, 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 Society of Automotive Engineers (USA) System of active stability Special service tool Standard Tighteningtorque Torque converter & transmission Number of teeth (0 0) Undersize With Less RH Right hand Abbreviation(code) SAE Abbreviation(code) ASSY Cu Meaning Assembly - - Cushion tire models SAS SST STD T= - TIC OOT UIS WI U U-l Left hand LLC M/T Long life coolant - - Manual transmission NMR OPT 01s Pn PS No-load maximum speed Option Oversize Pneumatic tire models Power steering

Toyota Diesel Forklift Truck 7FDAU50, 7FDKU40, 7FDU35, 7FDU45, 7FDU60, 7FDU70, 7FDU80 Workshop Service Manual

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