🏷️ Basic Information Identification Make: Toyota (BT) Product Type: Forklift Truck Model Series: 7FDF / 7FDJ Covered Models: 7FDF15, 7FDF18, 7FDF20, 7FDF25, 7FDF30, 7FDJ35 Generation Series Generation: 7F Series 👋 Introduction Market Position Market Segment: Industrial Forklift Trucks Brand Reputation: Toyota's reputation for reliability and durability in material handling equipment Competitive Analysis Competitors: Other major forklift manufacturers such as Hyster, Yale, Komatsu, Caterpillar Key Features Diesel Engine: Focus on diesel engine models for robust operation Comprehensive Coverage: Detailed coverage of all major mechanical, hydraulic, and electrical systems Visual Aids: High-quality images and circuit diagrams 📋 Manual Details Coverage Areas Manual Scope: Workshop Service and Repair Page Count Page Count: 612 Manual Type Manual Type: Factory Workshop Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Propeller Shaft, Differential, Front Axle, Rear Axle Chassis: Steering, Brakes, Tires & Wheels Material Handling: Hydraulics, Mast, Cylinders (Lift & Tilt), Oil Pump, Oil Control Valve, SAS (System of Active Stability) Electrical: Circuit Diagrams, Battery, Wiring, Components (Headlamps, Meters, Switches) Body And Operator Compartment: Covers body components like engine hood, counterweight, headlamps, combination meter, and combination switch replacement and inspection. Differential And Axles: Detailed coverage of differential assembly, front axle components (shaft, hub, bracket, housing), and rear axle assembly, hub, knuckle, and cylinder. Mast Types: Covers V Mast Assy and FV-SV Mast Assy, including their components, disassembly, adjustment, and specific lift cylinder rod shim adjustments. Hydraulic Controls: Oil pump assembly (with specific procedures for different engine types), oil control valve assembly, and control valve lever assembly are comprehensively detailed. Procedures Included Maintenance: Scheduled maintenance, Lubrication schedules, Filter replacement, Fluid checks and changes Repair: Component removal, installation, disassembly, inspection, and reassembly for all major systems Troubleshooting: System-specific troubleshooting guides, diagnosis of common issues, error code interpretation (e.g., DPF system) Hydraulic System Diagnostics: Hydraulic circuit diagrams for Material Handling System and Transmission are included, alongside oil leak tests and natural drop/tilt tests. Hoisting And Lifting: Includes wire rope suspension angle lists and safe load charts for hoisting the vehicle. Tire And Wheel Service: Tire and wheel service is covered under Front Axle and Rear Axle sections. Brake Adjustment Procedures: Specific procedures for brake master cylinder, parking brake, brake pedal, and inching pedal inspection and adjustment. Technical Depth Depth Level: Comprehensive factory-level repair and diagnostic procedures Diagnostic Tools: Guidance on using circuit testers, torque specifications, and specific diagnostic systems (e.g., SAS analyzer) Torque Specifications: Extensive tables for standard bolt & nut tightening torque, bolt strength identification, and high-pressure hose fitting tightening torque. Lubrication Schematics: 'Smörjschema' (Lubrication Schema) and 'Periodiskt Underhåll' (Periodic Maintenance) are provided, indicating detailed lubrication points and schedules. Catalytic Converter Maintenance: Specific maintenance procedures for Catalytic Muffler are included in the Engine section. 📊 Manual Specifications File Format PDF Quality: High quality with printable pages Searchability: Searchable text Navigation: Navigation bookmarks Print Quality Printability: Printable pages Binding Type Binding: Digital (PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Diesel Engine Models Covered: 4Y, 1DZ-II, 2Z (Specific engine variants for different models) Performance Engine Performance Curves: Included in manual for diagnosis and tuning Fuel System Fuel System Procedures: Air bleeding from fuel system (diesel vehicle) Ancillary Systems Cooling System: Radiator components, specifications, coolant capacity, and antifreeze table Intake System: Air cleaner specifications, components, cleaning, and inspection Emission Control Dpf System: DPF-II System (Optional) coverage including components, diagrams, troubleshooting, regeneration, and error code clearing 🔧 Transmission Standard Transmission Type: Automatic (Hydraulic) Features Torque Converter: Torque converter and oil pump removal, installation, disassembly, inspection, and reassembly Control System Control Valve Assembly: Transmission and control valve assembly removal, installation, disassembly, inspection, and reassembly Diagnostics Oil Pressure Measurement: Oil pressure measurement and stall test procedures Variants Speed Transmission: 2-speed transmission specific details 📐 Dimensions Vehicle Model Variations Load Capacities: Models cover capacities from 1500 kg (7FDF15) to 3500 kg (7FDJ35) Weights Component Weights: Recommended lubricant quantity and types; Component weights listed for hoisting calculations 🛡️ Safety Features Active Features Sas System: System of Active Stability (SAS) coverage: controller, sensors (tire angle, tilt angle, speed), swing lock cylinder, steering knob position correcting valve, fork height switch Brake Assist: Inching pedal inspection and adjustment procedures for controlled movement Passive Features Operator Protection: Manual details body components, engine hood, counterweight, headlamps, and combination meter relevant to operator environment and visibility. 💡 Technology Features Driver Assistance Sas System: Advanced System of Active Stability (SAS) provides enhanced stability control, detailed in the manual. Speed Control: Vehicle Speed Control System (Optional) coverage, including diagrams and troubleshooting. Diagnostics Diagnostic Interface: SAS Plug-in Analyzer basic operation, re-setting, and option set customization detailed for advanced diagnostics. Control Systems Dpf System Control: DPF Controller removal, installation, and specific regeneration methods detailed. Operator Interface Control Lever Systems: Morse Controls Elservospakar mentioned in hydraulic schematics, indicating advanced control...