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Driven by the increasing needs in the process industry for designing fault-tolerant control systems based on process data and maintaining its performance during online operation, data-driven realization and design of feed-forward fault-tolerant control systems with embedded residual generation are studied. To this end, a parameterized and data-driven realization form of stable image representation in a feedback control loop is derived first. On this basis, a feed-forward controller design scheme is proposed for fault-tolerant purpose. It is followed by a recursive approach for online tuning the feed-forward controller in case of malfunctions, which is triggered by a fault detection scheme based on the so-called stable kernel representation. The effectiveness of the proposed fault-tolerant method is demonstrated by a case study on the laboratory three-tank system.