Toyota (BT) Electric Forklift Truck 7FBEST10, 7FBEST12, 7FBEST15 Workshop Service Manual

INDEX - 7FBEST 10-15 NAME SECTION GENERAL 0 BATTERY 1 CONTROLLER 2 MULTI-DISPLAY FUNCTIONS 3 TROUBLESHOOTING 4 MOTOR 5 REAR AXLE 6 STEERING 7 BRAKE 8 BODY & FRAME 9 MATERIAL HANDLING SYSTEM 10 MAST 11 CYLINDER 12 OIL PUMP 13 OIL CONTROL VALVE 14 SAS FUNCTIONS 15 APPENDIX 16 <Tillbaka till Index

0-1 GENERAL VEHICLE EXTERIOR VIEW ....................................................................................0-3 VEHICLE MODELS .................................................................................................0-4 FRAME NUMBER ...................................................................................................0-4 HOW TO USE THIS MANUAL ................................................................................0-5 EXPLANATION METHOD .......................................................................................0-5 DISASSEMBLY · INSPECTION · REASSEMBLY .................................................. 0-5 TERMINOLOGY ......................................................................................................0-6 ABBREVIATIONS ...................................................................................................0-6 SI UNITS ..................................................................................................................0-7 OPERATING TIPS ...................................................................................................0-8 GENERAL INSTRUCTIONS ................................................................................... 0-8 JACK-UP POINT .....................................................................................................0-9 LIFTING THE VEHICLE ..........................................................................................0-10 MEMBER WEIGHTS ...............................................................................................0-11 TOWING THE VEHICLE ......................................................................................... 0-11 ELECTRICAL PARTS INSPECTION ...................................................................... 0-12 NOTES ON SAS ......................................................................................................0-13 TIGHTENING TORQUE TABLE ..............................................................................0-14 RECOMMENDED LUBRICANT QUANTITY AND TYPES ..................................... 0-15 PERIODIC MAINTENANCE TABLE ....................................................................... 0-17 LUBRIFICATION CHART .......................................................................................0-22 Totaldokument Service .........................................................................................0-23

0-3 VEHICLE EXTERIOR VIEW

0-4 VEHICLE MODELS FRAME NUMBER Vehicle model code Load Capacity Vehicle Model Control method Voltage (V) 10 1.0 ton 7FBEST 10 AC microcomputer controller 24 13 1.25 ton 7FBEST 13 ↑ ↑ 15 1.5 ton 7FBEST 15 ↑ ↑ Vehicle model code SN FORMAT Serial number position 10 7FBEST10 10001 13 7FBEST13 10001 15 7FBEST15 10001

0-5 HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operating procedure (1) Operating procedures are described using either pattern A or pattern B. Pattern A: Each step of the operation is explained with its own illustration. Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations. Example of pattern B DISASSEMBLY · INSPECTION · REASSEMBLY Tightening torque unit T=Nm Disassembly Procedure 1 Remove the cover. [Point 1] 2 Remove the bushing. [Point 2] 3 Remove the gear. Point Operations [POINT 1] Disassembly: Make match marks before removing the pump cover [POINT 2] Inspection: Measure the bushing inside diameter. Limit 19.12 mm • Some step numbers may be omitted in some 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 to 48.1 (470 to 490) [34.0 to 35.5] 1 2 3 4 7 6 5 8 5 9 1 Operation to be explained Explanation of operation point with illustration

0-6 1. Matters omitted from this manual (1) This manual omits descriptions of the following jobs, but perform them in actual operation: (a) Cleaning and washing of removed parts as required (b) Visual inspection (partially described) TERMINOLOGY Caution: Important matters, negligence of which may cause accidents. Be sure to observe them. Note: Important items, negligence of which may cause accidents, or matters in operating procedure which require special attention. Standard: Value showing the allowable range in inspection or adjustment Limit: The maximum or minimum value allowed in inspection or adjustment. ABBREVIATIONS Abbreviation Meaning Abbreviation Meaning -- -- RH Right hand ATT Attachment SAE Society of Automotive Engineers (USA) EHPS Electronically controlled fully hydraulic power steering SAS System of active stability FHPS Fully hydraulic power steering SST Special service tool LH Left hand STD Standard L/ Less T= Tightening torque OPT Option { { T Number of teeth ({ { T) O/S Oversize U/S Undersize PS Power steering W/ With

0-7 SI UNITS Meaning of SI This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for smoother international technical communication. New Units Adopted in SI <Reference> * 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the rate for conversion between conventional and SI units. * 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which should be used as the unit of force. Conversion between Conventional and SI Units Equation for conversion When converting, change the unit of the value in conventional or SI units to the one in the conversion rate column in the table above before calculation. For example, when converting 100 W to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499. Item New unit Conventional unit Conversion rate* 1 (1 [conventional unit] = X [SI unit]) Force* 2 N (newton) kgf 1 kgf = 9.80665 N Torque *2 (Moment) N·m kgf·cm 1 kgf·cm = 9.80665 N·m Pressure* 2 Bar kgf/cm 2 1 Bar = 1 kgf / cm 2 Pressure* 2 Pa (pascal) kgf/cm 2 1 kgf/cm 2 = 98.0665 kPa = 0.0980665 MPa ↑ ↑ mmHg 1 mmHg = 0.133322 kPa Revolving speed rpm rpm 1 rpm = 1 r/min Spring con- N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm Volume l cc 1 cc = 1 ml Power W PS system 1 PS = 0.735499 kW Heat quantity W·h cal 1 kcal = 1.16279 W·h Specific fuel g/W·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding to X in the conversion rate column in the table above Value in conventional unit = Value in SI unit ÷ Conversion rate

0-8 OPERATING TIPS GENERAL INSTRUCTIONS 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 plug before the inspection or servicing of electrical parts. 2. Skillful operation (1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation. (2) Check the cable color and wiring state before disconnecting any wiring. (3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting a precision part such as the control valve, use clean tools and operate in a clean location. (5) Follow the specified procedures for disassembly, inspection and reassembly. (6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the “standard tightening torque table”. 3. Protection of functional parts (battery operated vehicles) (1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection. Failure or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers. 4. Defect status check Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect. 5. Waste fluid disposal Always use a proper container when draining waste fluid from the vehicle. Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposal.

0-9 JACK-UP POINT Always observe the following instructions when jacking up the vehicle: • When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface. • Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous. • Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the vehicle with the jack only is very dangerous. • Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle.

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Toyota (BT) Electric Forklift Truck 7FBEST10, 7FBEST12, 7FBEST15 Workshop Service Manual

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