This manual covers service procedures for Toyota forklifts. It provides instructions on maintenance, repairs, and inspections for various components of the vehicles. The manual explains how to use it, defining terms, abbreviations, and safety tips. It also includes sections on frame numbers, lubrication charts, and periodic maintenance schedules. Standard bolt tightening torques and other reference values are provided.

1. This manual covers the service procedures of the TOYOTA FORKLIFT
7FGU/7FDU15-32seriesand 7FGCU20-32series.Pleaseusethismanual
for providing quick, correct servicingof the correspondingforklift mode;&.
Thismanualdeals withthe above modelsas of October 1999.Pleaseunder-
standthat disagreementcantakeplacebetweenthedescriptionsinthemanual
and actual vehicles due to change in designand specifications. Any change
or modifications thereafter will be informed by Toyota Industrial Equipment
Parts & Service News.
For the service proceduresof the mounted engine, read the repair manuals
listedbelow as referencetogether with this manual.
(Reference)
Repair manuals relatedto this manual are as follows:
TOYOTAINDUSTRIAL EQUlPMENT4YENGINE
REPAIRMANUAL (NO. CE602-1)
TOYOTAINDUSTRIALEQUIPMENT1DZ-I1ENGINE
REPAIRMANUAL (NO. CE618-1)
TOYOTA Material Handling Company
A Division of TOYOTA INWSRIESCORPORATION

2. SECTIONINDEX
I W E 1 SECTION
I
GENERAL
ENGINE
TORQUE CONVERTER&
TRANSMISSION
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
y
I
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
$
3

3. GENERAL
Page
EXTERIOR VIEWS ........................................................ 0-2
VEHICLEMODEL .........................................................0-3
FRAMENUMBER ...........................................................0-4
HOW TO USE THIS MANUAL ....................................0-5
EXPLANATIONMETHOD ................................................0-5
TERMINOLOGY..............................................................0-6
ABBREVIATIONS ............................................................0-6
OPERATIONAL TIPS ....................................................0-7
HOISTING THE VEHICLE...........................................0-8
ATTENTIVE POINTS ON SAS .................................... 0-8
CIRCUIT TESTER ............................................ 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE ............................................................ 0-11
BOLTSTRENGTHTYPEIDENTIFICATIONMETHOD ......0-11
TIGHTENINGTORQUETABLE ........................................0-12
PRECOAT BOLTS ........................................................0-13
HIGHPRESSURE HOSE FITTING
TIGHTENING TORQUE ............................................0-13
WIRE ROPE SUSPENSION ANGLE LIST ...............0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSIONANGLE............................................... 0-14
COMPONENTS WEIGHT.............................................0-15
RECOMMENDEDLUBRICANT
QUANTITY & TYPES ................................................. 0-16
LUBRICATIONCHART .................................................0-18
..........................................
PERIODIC MAINTENANCE 0-19
PERIODIC REPLACEMENT OF PARTS AND
LUBRICANTS...............................................................0-25

4. EXTERIOR VIEWS
Pneumatic tire model
Cushion tire model

5. 0-3
VEHICLEMODEL
Pneumatic Tire Models (Pn)
Cushion Tire Models (Cu)
Classificatron
*: USA and CANADA Only
Load Capaclty
3000 Ibs
3500 Ibs
4000 Ibs
5000 Ibs
6000 Ibs
6500 Ibs
Series
Pnl ton series
Pn2ton series
Pn3 ton series
Model
Pn15
Pn18
Pn20
-
Pn25
Pn30
Pn32
Classification
VehicleModel
7FGU15
7FDU15
7FGU18
7FDU18
7FGU20
7FDU20
7FGU25
7FDU25
7FGU30
7FDU30
*7FGU32
*7FDU32
Load Capacity
4000 Ibs
5000 Ibs
6000 Ibs
Series
Cu2ton series
Cu3ton series
Model
Cu20
Cu25
Cu30
TransmissionType
TC
TIC
T/C
TIC
TIC
TK;
TK;
TK;
TIC
T/C
T/C
T/C
Cu32 1 6500 lbs / *7FGCU32 TIC
VehicleModel
7FGCU20
7FGCU25
7FGCU30
I
4Y
Engine
TransmissionType
TIC
TIC
TIC
Gasoline
Engine
4Y
1DZ-ll
4Y
1DZ-ll
4Y
1DZ-ll
4Y
1D
Z
-
1
1
4Y
1DZ-ll
4Y
1DZ-ll
4Y
4Y
4Y
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Gasoline
Gasoline

6. FRAMENUMBER
Frame No. Punching Position
Pneumatictire
Cushiontire
Series
1 ton series
Engine
2 ton series
3 ton series
4Y
1DZ-ll
4Y
Vehiclemodel
7FGU15
4Y
*: EEC spec.
Punchingformat
.
7FGU18
7FDU20
7FDU25
7FGU30
2 ton series
3 ton series
7FGU18-60011
7FGU25
7FDU25-60011
7FGU32-60011
7FGU25-60011
1DZ-ll
4Y
4Y
7FDU30
7FDU32
7FGCU20
7FGCU25
7FGCU30
I
7FDU32-60011
7FGCU25-60011
I 7FGCU25@60011
7FGCU32-60011

7. HOW TO USE THIS MANUAL
EXPLANATIONMETHOD
1. Operationprocedure
(1) The operationprocedure is describedin either patternA or patternB below.
PatternA: Explanationof eachoperation stepwithillustration.
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 descriptionin pattern B
Step Nos. are partially sometimes
omitted in illustrations.
When a part requiring tightening
torque instructionis not indicatedin
the illustration,the part name is de-
scribed in the illustrationframe.
T= 46.1 -48.1
(470 -490)
r34.0-35.5)
8
DISASSEMBLY-INSPECTION-REASSEMBLY Tghteningtorqueunit T= N.m(kgf-cm)[ft-lbfl
DisassemblyProcedure
1 Remove the cover. [Point 11
2 Remove the bushing[Point 21 C Operation explained later
3 Remove the gear.
Point Operations Explanationof key point for operationwith an illustration
[Point 11
LL
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measurethe bush inside diameter.
Limit: 19.12 mm(0.7528 in)

8. 2. How to read components figures (Example)
(1) Thecomponentsfigureusestheillustration
in the parts catalog for the vehicle model.
Please refer to the catalog for checkingthe
part name.
The number at the right shoulder of each
components figure indicates the Fig. num-
ber in the parts catalog.
FIGnumber inpartscatalog
I
3. Matters omitted inthis manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removedparts as required
@ Visualinspection(partially described)
TERMINOLOGY
Caution:
lmportantmattersnegligenceof whichmaycausephysicaldamage. Be sure to observethem.
Note:
lmportant items negligence of which may cause breakage or breakdown. And operation pro-
cedure requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
Abbreviation(code)
ASSY
Meaning Abbreviation(code) Meaning
Assembly
Cu Cushiontiremodels
-
-
L
H Lefthand
SAE
SAS
SST
5
-
m
T =
TK;
O O T
U/S
W/
U
U C
M/T
Societyof Automotive
Engineers (USA)
System of active stability
Specialservicetool
Standard
Tighteningtorque
Torqueconverter &
transmission
Number of teeth (00)
Undersize
With
Less
Longlifecoolant
-
-
Manualtransmission
-
-
No-loadmaximum
speed
OPT
01s
Pn
PS
QFV
Option
Oversize
Pneumatic tiremodels
Power steering
4-stagemast
(Quadruple)

9. OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, alwayssupport with wooden blocks or rigid stands.
(2) Whenhoistingthe vehicle or its heavy component, use wire rope(s) with a sufficientreserveinload
capacity.
(3) Always disconnect the battery terminal before the inspectionor servicing of electrical parts.
2. Tactful operation
(1) Preparethe mechanic tools, necessary measuringinstruments (circuit tester, megger, oil pressure
gauge, etc.) and SSTsbefore starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhaulingfunctionalparts, complicatedportions or relatedmechanisms,arrangethe parts
neatlyto prevent confusion.
(4) When disassembling and inspecting such a precisionpart as the control valve, use cleantools and
operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packing's and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyotaparts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
Tightento the center of the specifiedtighteningtorque range.
If no tighteningtorqueis specified,tightenthe bolt or nut accordingto the standardtighteningtorque
table.
3. Graspingthe troublestate
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 substanceis directly dischargedor 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
Front side:
Jack up at the bottom surface of the frame.
Rear side:
Jack up at the under the counteweight or the bottom
surface of the frame.

10. HOISTING THE VEHICLE
When hoisting the vehicle, use the mast hook on the front of
the vehicle and a wire net on the rear wheel.
Caution:
Use wire ropes having sufficient strength.
Never hoist the forklift by the weight hook holes
or head guard.
ATTENTIVE POINTS ON SAS
1. Referenceshouldbemadeto seperatemanual"NewModelFeature 7FGUnFDUl5-32 Pub. No.PU015"
for the explanations of SAS functions and operations.
2. Read Section 15 SAS "Precautionsfor Repairn
on Page 15-7 in this repair manual in advance.
3. Whenever the repair or replacement is performed to the place where relative to SAS function, re-
setting procedureby which the SAS regain proper function must be performed. (See Page 15-19)
4. The warning on the SAS caution labelmust be confirmedwhen the modification c, changeis such as
to change the originalspecification.
If improper, change the label.(SeePage 15-10)
5. Care should always be exercisedfor safety operationwhenever you operate the truck.
Make distinctionbetweenthe SAS featuredtrucks andthose of none, because the controlfeaturesare
different.
6. The SAS oil control valves comprise many precision valves. Since dirty or contaminatedhydraulic oil
will adversely affect the functions of these valves, alwayswash the parts clean at the time of installa-
tion after disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replace-
ment of the hydraulic oil is very important.
7. Since this vehicle uses high-precision electronicdevices, modification of electricalparts may cause
faults. Always use genuine Toyota parts when replacing or installingelectricalparts (auxiliary equip-
ment, optionalparts, etc.).

11. CIRCUITTESTER
Circuit testers are availablein boththe analoganddigitaltypes. They shouldbe usedselectively according
to the purpose of measurement.
Analogtype: This type is convenient for observing movement during operation, but the measuredvalue
shouldonly be usedfor referenceor roughjudgement.
Digitaltype: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.
1. Differencein measurementresults with the digitaltype and analog type
* The result may be differentbetween measurements with the analogtype and digitaltype.
Always use a circuit tester accordingto its operation manual.
Cautions when the polarities are different betweenthe analog type and digital type are described
below.
(1) Analog circuit tester
-
Forward direction Reverse direction
(2) Digital circuit tester
i
Forward direction Reverse direction
Measurementresult example
Testerrange: kC?range
Measurementresult example
Testerrange: M
S
2range
-
Forward
Reverse
Analog type
Continuity exists
I1 kc2
No continuity
00
-
Fo~mrd
Reverse
i
Digitaltype
No continuity
1
Continuity exists
2 MR

12. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
Theresistanceof asemiconductorsuchas a diode varieswiththe circuit testerpower supply voltage.
The diode characteristics are shown in the figurebelow.
4
(mA) 6
- 5
c
4
3
0
g 3
2
9 2
1
O
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (v)
The resistance values of the same semiconductor mea-
suredwithtwotypes of circuittestershavingdifferentpower
supply voltagesare different.
This manual describes the results of measurement with a
circuit tester whose power supply voltage is 3.0 V.
3. Differencein measurement result by measurementrange (analog type)
In the analog type circuit tester, changingthe measurementrange switches over the internalcircuit to
vary the circuit resistance. Even when the same diodeis measured, the measurement result varies
with the measurement range.
Always use the range described in the repair manual for
measurement.
z
=
-
c
I
f
TEer
source: 1.5 v
@
O
Red 6,"
Black
Variable resistor
,
- ,,,
Resistor
Range: x 10 (sw1)
Resistor
h 1
Range: x 1 (sw2)
I

13. 0-11
STANDARD BOLT & NUT TIGHTENING TORQUE
Standardbolt andtighteningtorquesarenot indicated.
Judge the standard tighteningtorque as shown below.
1. Findout the type of the bolt from the list below and thenfind the bolt tighteningtorquefromthe table.
2. Thenuttighteningtorque canbe judgedfromthe mating bolttype.
BOLTSTRENGTHTYPEIDENTIFICATIONMETHOD
IDENTIFICATION BY BOLT SHAPE IDENTIFICATION BY PART NO.
Hexagonheadbolt
Parts No.
9161 1-40625
Length (mm)
Diameter (mm)
Es
iameter
Stud bolt
Part No.
9 2 1 3 2 - 4 0 6 1 4
Length (mm)
Diameter (mm)
Class
4=4T
5=5T
6 =6T
7=7T
8=8T
4T
4T
Shape and class
Hexagon Two protruding
head bolt lines
5T
Hexagon
head bolt
Hexagon
flangebolt
@Bolt head No.
0 No mark
No mark

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15. 0-12
TIGHTENINGTORQUETABLE
A
Pitch
mm
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.
O
1.25
1.25
1.25
1.5
1.5
1.
O
1.25
1.25
1.25
1.5
1.5
Class
a
5T
6T
7-r
ST
Specified
Hexagon
headbolt
N-m ! kgfcm ! ft-lbf
5.4 I 55 48in-lbf
13
I
I 9
130
25 1 260 1 19
47 1 480 1 35
75 1 760 1 55
113 1 1150 1 83
6.4 1 65 1 56in-lbf
16 I 160 I 12
I
32 1 I 24
330 1
59 1 600 1 43
91 1 930 1 67
137 1 1400 I101
7.8 1 80 1 69 in-lbf
19 195 I 14
38 I 400
I
I 29
I
72 I 730 1 53
I10 1 1100 1 80
170 1 1750 1127
11 1 110 1 8
25 1 260 1 19
52 I 530 I 38
' 970 I 70
95 I
147 1 1500 1 108
226 1 2300 ( 166
12 1 125 1 9
29 1 300 1 22
61 1 620 1 45
108 I 1100
I
I 80
I
172 1 1750 1 127
265 1 2700 1 195
Diameter
mm
6
8
10
12
14
16
6
8
10
12
14
16
6
8
10
12
14
16
6
8
10
12
14
16
6
8
10
12
14
16
toque
Hexagon
flangebolt
N-m ! k- ! ft-lbf
5.9 I 60 52 in4bf
I
l4 I
I 10
28 1
145
1
290
1 21
53 1 540 1 39
83 1 850 ( 61
- I - I -
7.5 1 75 1 65in-lbf
18 ' 175
I
I 13
36 1
26
65 1 670 1 4 8
100 1 1050 1 7 6
157 1 1600 1 116
8.8 1 90 1 78 in-lbf
21 215 16
43 440
I
32
79 1
I
810 1 59
123 1 1250 1 9 0
191 1 1950 1141
12 1 120 1 9
28 1 290 I 2 1
58 I 590 43
103 1050 76
167 1 1700 1123
- I - -
14 1 145 1 9
32 1 330 1 24
68 1 690 1 5 0
123 I 1250 90
I
I 2000 1 145
299 1 3050 1 221
1

16. PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do notuse the precoatbolt as it is ineither of the follow-
ing cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allow-
able tightening torque range. If the bolt moves, re-
tighten it according to the steps below.
2. Method for reuse of precoatbolts
(1) Wash the bolt andthreadedhole. (The threadedhole
must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specifiedseallock agentto thethreadedpor-
tion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connectinga high pressurehose, wipe the hose fittingand mating nipple contact surfaces with
clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact
surfaces before installation.
2. When connecting ahighpressure hose,holdthe hoseto alignthe fitting withthe nippleandtightenthe
fitting.
3. The maximum tightening torque must not exceedtwice the standardtighteningtorque.
Nominal diameter
of screw
7116-20UNF
9116-18UNF
314-16UNF
718-14UNF
1-1116-12UNF
1-5116- 12UNF
PF114
PF318
PF112
PF314
PFI
Hoseinside
diametermm (in)
6 (0.24)
9 (0.35)
12(0.47)
12 (0.47),15 (0.59)
19(0.75)
25(0.98)
6 (0.24)
9 (0.35)
12(0.47)
19(0.75)
25 (0.98)
Standardtighteningtorque N-m(kgf-cm) [ft-lbfl
Standard
25( 250) [ 18.11
49 ( 500)[ 36.21
59 ( 600) [ 43.41
59 ( 600) [ 43.41
118 (1200)[ 86.81
137(1400)[101.3]
25 ( 250)[ 18.I ]
49 ( 500) [ 36.21
59 ( 600) [ 43.41
118 (1200)[ 86.81
137(1400)[101.3]
Tighteningrange
24 - 26 ( 240 - 270) I17.4- 19.51
47 - 52 ( 480 - 530) [34.7- 38.31
56 - 62 ( 570 - 630) [41.2 - 45.61
56 - 62 ( 570 - 630) [41.2 - 45.61
112-123(1140-1250)[82.5- 90.41
130 -144 (1330 -1470) [96.2 -106.41
24 - 26 ( 240 - 270) [17.4- 19.51
47 - 52 ( 480 - 530) [34.7 - 38.31
56 - 62 ( 570 - 630) [41.2- 45.61
112-123(1140-1250)[82.5- 90.41
130 -144 (1330 -1470) [96.2 -106.41

17. WlRE ROPE SUSPENSIONANGLE LIST
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit:N (tf)[~bfl
Suspension
method
6
,d A
Tension
1.41 time
2.00 time
Wng angle
x0
120"
Comipres-
sion
1.OO time
1.73 time
Lifting angle
o0
30"
60"
Single-rope
suspension
o0
3040
(0.31)
(683.61
4410
(0.45)
[992.3]
6960
(0.71)
[1565.6]
10980
(1.12)
12469.51
13730
(1.4)
(30871
Rope
diameter
6mm
(0.24 in)
8 rnrn
(O." in)
10 mm
(0'4 in)
12.5 mm
(0.5 in)
14 rnrn
(0.56 in)
Compes-
sion
Otime
0.27 time
0.58 time
Tension
1
.OO time
1.04 time
1.16 time
Cutting
load
21380
(2.18)
[4807
31480
(3.21)
170781
49230
(5.02)
[11.69]
76880
(7.84)
[I7387
96400
(9.83)
(216751
Two-rope suspension
Suspension
method
6
b
h'
o0
6080
(0.62)
[I367
8830
(0.9)
[I9851
14020
(1.43)
131531
21570
(2.2)
[4851]
27460
(2.8)
[6174]
Four-rope suspension
30"
5880
(0.6)
[I3231
8530
(0.87)
[ I9181
13440
(1.37)
[3021]
21280
(2.1)
[4631]
26480
(2.7)
(59541
o0
12160
(1.24)
I27341
17650
(1.8)
I39691
27460
(2.8)
[6174]
43150
(4.4)
197021
54920
(5.6)
1123481
60"
10400
(1.06)
12337
15300
(1.561
[ N O ]
23540
(2.4)
[5292]
37270
(3.8)
[8379]
47070
(4.8)
[I05841
30°
11770
(1.2)
[2646]
17060
(1.74)
[3937]
26480
(2.7)
[5954]
41190
(4.2)
192611
52960
(5.4)
(119071
90°
8630
(0.88)
(19401
12550
(1.28)
[2322]
19610
(2.0)
[4410]
29420
(3.0)
[6615]
37270.
(3.8)
[8379]
60°
5200
(0.53)
(11691
7650
(0.78)
[1720]
11770
(1.2)
[2646]
18630
(1.9)
[4190]
23540
(2.4)
[5292]
90"
4310
(0.44)
[970]
6280
(0.64)
[I4111
9810
(1.0)
[2205]
14710
(1.5)
[3308]
18630
(1.9)
(41901