Toyota 7FBE10 User manual

FOREWORD
This manual covers the service procedures of the TOYOTA ELECTRIC
POWERED FORKLIFT 7FBE10 to 20 series.
Please use these manuals for providing quick, correct servicing of the corre-
sponding forklift models.
This manual deals with the above models as of February 2003. Please under-
stand that disagreement can take place between the descriptions in the man-
ual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.

SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CHARGER (OPT) 2
CONTROLLER 3
MULTI-DISPLAY FUNCTIONS 4
TROUBLESHOOTING 5
MOTOR 6
DRIVE UNIT & FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY & FRAME 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
SAS FUNCTIONS (OPT) 17
APPENDIX 18

0-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GENERAL
Page Page
VEHICLE EXTERIOR VIEW........... 0-2
VEHICLE MODELS.......................... 0-3
FRAME NUMBER............................. 0-3
HOW TO USE THIS MANUAL ...... 0-4
EXPLANATION METHOD ................. 0-4
TERMINOLOGY................................. 0-5
ABBREVIATIONS .............................. 0-5
SI UNITS ............................................ 0-6
OPERATING TIPS ............................ 0-7
GENERAL INSTRUCTIONS .............. 0-7
JACK-UP POINT ............................... 0-8
HOISTING THE VEHICLE ................. 0-9
WIRE ROPE SUSPENSION ANGLE
LIST .............................................. 0-10
SAFE LOAD FOR EACH WIRE ROPE
SUSPENSION ANGLE ................. 0-10
MEMBER WEIGHTS........................ 0-11
TOWING THE VEHICLE .................. 0-11
ELECTRICAL PARTS
INSPECTION ................................ 0-12
NOTES ON SAS .............................. 0-14
STANDARD BOLT & NUT
TIGHTENING TORQUE ............. 0-15
BOLT STRENGTH CLASS
IDENTIFICATION METHOD ......... 0-15
TIGHTENING TORQUE TABLE ...... 0-16
PRECOATED BOLTS ...................... 0-17
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE............. 0-17
RECOMMENDED LUBRICANT
QUANTITY AND TYPES ........... 0-18
LUBRICATION CHART................. 0-19
PERIODIC MAINTENANCE......... 0-20
PERIODIC REPLACEMENT OF
PARTS AND LUBRICANTS ..... 0-25

0-2
VEHICLE EXTERIOR VIEW

0-3
VEHICLE MODELS
FRAME NUMBER
Vehicle model code Payload (ton) Vehicle Model Control method Voltage (V)
10 1.0 7FBE10 AC microcomputer controller 48
13 1.25 7FBE13 ↑↑
15 1.5 7FBE15 ↑↑
18 1.75 7FBE18 ↑↑
20 2.0 7FBE20 ↑↑
Vehicle model Drive motor model Punching format Punching position
7FBE10
AR09
7FBE13-50011
7FBE13
7FBE15
7FBE18-50011
7FBE18
7FBE20 7FBE20-50011
Punching position
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

0-4
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=N·m(kg·m)[ft·lbf]
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.
T = 46.1 to 48.1
(470 to 490)
[34.0 to 35.5]
1
2
3
4
7
6
5
8
5
91
Operation to be explained
Explanation of operation point with illustration

0-5
1. How to read component figures
(1) The component figures use the illustration in the parts
catalog for the vehicle model. Please refer to the catalog
to check the part name.
2. 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
ASSY Assembly SAE Society of Automotive Engineers
(USA)
ATT Attachment SAS System of active stability
LH Left Hand SST Special Service Tool
L/ Less STD Standard
OPT Option T= Tightening Torque
O/S Oversize {{T Number of teeth ({{T)
PS system Power Steering U/S Undersize
RH Right Hand W/ With
(Example)
3201
Parts catalog
FIG number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

0-6
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*2N (newton) kgf 1 kgf = 9.80665 N
Torque*2
(Moment) N·m kgf·cm 1 kgf·cm = 9.80665 N·m
Pressure*2Pa (pascal) kgf/cm21 kgf/cm2= 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

0-7
OPERATING TIPS
GENERAL INSTRUCTIONS
1. 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”.
2. 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.
3. Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or
replacement is necessary for the defect.
4. 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.

0-8
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.
Jack-up point
Wooden block or stand
setting points

0-9
HOISTING THE VEHICLE
When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist
by any other attachment section as it is very dangerous.

0-10
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
Unit: N (tf) [lbf]
Suspension
Angle Tension Compression Suspension method
Suspension
Angle Tension Compression Suspension method
0°1.00
time 0 time 90°1.41 time 1.00 time
30°1.04
time 0.27 time 120°2.00 time 1.73 time
60°1.16
time 0.58 time
Rope
diameter
Cutting
load
Single-
rope Two-rope suspension four-rope suspension
0°0°30°60°90°0°30°60°90°
6 mm
(0.24 in)
21380
(2.18)
[4807]
3040
(0.31)
[683.6]
6080
(0.62)
[1367]
5880
(0.6)
[1323]
5200
(0.53)
[1169]
4310
(0.44)
[970]
12160
(1.24)
[2734]
11770
(1.2)
[2646]
10400
(1.06)
2337
8630
(0.88)
[1940]
8 mm
(0.32 in)
31480
(3.21)
[7078]
4410
(0.45)
[992.3]
8830
(0.9)
[1985]
8530
(0.87)
[1918]
7650
(0.78)
[1720]
6280
(0.64)
[1411]
17650
(1.8)
[3969]
17060
(1.74)
[3937]
15300
(1.56)
[3440]
12550
(1.28)
[2322]
10 mm
(0.4 in)
49230
(5.02)
[11690]
6960
(0.71)
[1565.6]
14020
(1.43)
[3153]
13440
(1.37)
[3021]
11770
(1.2)
[2646]
9810
(1.0)
[2205]
27460
(2.8)
[6174]
26480
(2.7)
[5954]
23540
(2.4)
[5292]
19610
(2.0)
[4410]
12.5 mm
(0.5 in)
76880
(7.84)
[17387]
10980
(1.12)
[2469.5]
21570
(2.2)
[4851]
21280
(2.1)
[4631]
18630
(1.9)
[4190]
14710
(1.5)
[3308]
43150
(4.4)
[9702]
41190
(4.2)
[9261]
37270
(3.8)
[8379]
29420
(3.0)
[6615]
14 mm
(0.56 in)
96400
(9.83)
[21675]
13730
(1.4)
[3087]
27460
(2.8)
[6174]
26480
(2.7)
[5954]
23540
(2.4)
[5292]
18630
(1.9)
[4190]
54920
(5.6)
[12348]
52960
(5.4)
[11907]
47070
(4.8)
[10584]
37270
(3.8)
[8379]
1tf
2t 2t
1.41tf
90°
2t
1.04tf
30°
2t
2tf
120°
2t
1.16tf
60°

0-11
MEMBER WEIGHTS
Unit: kg (lbs)
TOWING THE VEHICLE
Note the cautions below when towing the vehicle.
1. Lift the rear wheels for towing
2. The traveling speed when towing must not exceed the
maximum traveling speed of the forklift.
3. Before starting towing, always set the key switch to OFF
and the direction switch to the neutral position.
4. Before towing, either remove the fork or take action to
prevent the fork from coming into contact with the
ground due to bouncing.
Member Vehicle model Weight
BATTERY ASSY See P1-2
Drive motor ASSY All Models Approx. 37 (82)
Pump motor ASSY All Models Approx. 31 (68)
Front axle ASSY W/ drive motor ASSY All Models Approx. 122 (269)
Rear axle ASSY W/ rear axle cylinder ASSY All Models Approx. 45 (99)
Counterweight
7FBE10 Approx. 405 (893)
7FBE13 Approx. 598 (1319)
7FBE15 Approx. 697 (1537)
7FBE18 Approx. 853 (1881)
7FBE20 Approx. 1040 (2293)
Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork,
Lifting height 3000mm, V mast)
7FBE10 to 7FBE18 330 (730)
7FBE20 400 (880)
Vehicle weight
7FBE10 2225 (4906)
7FBE13 2425 (5347)
7FBE15 2685 (5920)
7FBE18 2840 (6262)
7FBE20 3155 (6957)

0-12
ELECTRICAL PARTS INSPECTION
1. Always disconnect the battery plug before inspecting or servicing electrical parts.
2. Pay sufficient attention when handling electronic parts.
(1) Never subject electronic parts, such as computers
and relays, to impact.
(2) Never expose electronic parts to high temperature or
moisture.
(3) Do not touch connector terminals, as they may be
deformed or damaged due to static electricity.
3. Use a circuit tester that matches the object and purpose of measurement.
Analog type: This type is convenient for observing movement during operation and the operating
condition. Measured value is only a reference
Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or
movement.
(1) Difference between results of measurement with analog and digital types
∗The results of measurements using the analog type and the digital type may be different.
Differences between the polarities of the analog type and the digital type are described below.
1) Analog circuit tester
Example of measurement result
Tester range: kΩrange
2) Digital circuit tester
Example of measurement result
Tester range: 2 MΩrange
Forward Reverse
Analog type
Forward Continuity
11 kΩ
Reverse No continuity
∞
Forward Reverse
Digital type
Forward No continuity
1
Reverse Continuity
2 MΩ

0-13
(2) Difference in result of measurement with a 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.
The resistance of a semiconductor, such as a diode, varies with the circuit tester power supply
voltage.
The diode characteristics are shown in the figure below.
The resistance values of the same semiconductor measured
with two types of circuit testers having different power supply
voltages are different.
This manual describes the results of measurement with a
circuit tester whose power supply voltage is 3.0 V.
(3) Difference in measurement result by measurement range (analog type)
In the analog type circuit tester, changing the measurement range switches over the internal circuit
to vary the circuit resistance. Even when the same diode is measured, the measurement result
varies with the measurement range.
Always use the range described in the repair manual for
measurement.
0
1
2
3
4
5
6
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
(V)Forward voltage
Germanium
diode
(mA)
Forward current
Silicon
diode
Resistor Meter
0 Ω
Variable resistor
Resistor
Resistor
Range:×10
Range:×1
Power source: 1.5V
Red Black
(SW1)
Current flow

0-14
NOTES ON SAS
1. For the explanations of SAS functions and operation, also see “New Model Feature 7FBE10 to 20 Pub.
No.PE314”.
2. See page 17-6 FOR REPAIR WORK of this repair manual before servicing.
3. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform
necessary matching to ensure proper SAS function (see page 4-47).
4. always be sure to operate the vehicle carefully. Be aware of the difference in control features between
with and without SAS.
5. Many precision valves are used in the SAS oil control valves. When disassembling or replacing
hydraulic parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of
the hydraulic oil is also very important.
6. As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may
cause vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the
electrical parts (auxiliary equipment, optional parts, etc.).

0-15
STANDARD BOLT & NUT TIGHTENING TORQUE
Tightening torque of standard bolts and nuts are not indicated throughout the manual.
Use the charts and table below to judge the standard tightening torque.
1. Find the class of the bolt strength on the table below and then find the bolt tightening torque on the
tightening torque table.
2. The nut tightening torque can be judged from its corresponding bolt type.
BOLT STRENGTH CLASS IDENTIFICATION METHOD
Identification by bolt shape Identification by part No.
Shape and class Class
Hexagon
head bolt
Hexagon
bolt
(standard)
Bolt with raised
or etched
numeral on head
4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon
flange bolt No mark 4T
Hexagon
head bolt
(standard)
Bolt with two
raised lines on
head
5T
Hexagon
flange bolt
Bolt with two
raised lines on
head
6T
Hexagon
head bolt
(standard)
Bolt with three
raised lines on
head
7T
Hexagon
head bolt
(standard)
Bolt with four
raised lines on
head
8T
Welded bolt 4T
Stud bolt
No mark 4T
2 mm groove(s)
on one/both
edge(s)
6T
Hexagon head bolt
Part No.
91611-40625
Length (mm)
Nominal diameter (mm)
Class
Stud bolt
Part No.
92132-40614
Length (mm)
Nominal diameter (mm)
Class
Nominal diameter
Length
Nominal diameter
Length

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0-16
TIGHTENING TORQUE TABLE
Class
Nominal
diameter
mm
Pitch
mm
Standard tightening torque
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
4T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
5.4
13
25
47
75
113
55
130
260
480
760
1150
48in·lbf
9
19
35
55
83
5.9
14
28
53
83

60
145
290
540
850

52in·lbf
10
21
39
61

5T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
6.4
16
32
59
91
137
65
160
330
600
930
1400
56in·lbf
12
24
43
67
101
7.5
18
36
65
100
157
75
175
360
670
1050
1600
65in·lbf
13
26
48
76
116
6T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
7.8
19
38
72
110
170
80
195
400
730
1100
1750
69in·lbf
14
29
53
80
127
8.8
21
43
79
123
191
90
215
440
810
1250
1950
78in·lbf
16
32
59
90
141
7T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
11
25
52
95
147
226
110
260
530
970
1500
2300
8
19
38
70
108
166
12
28
58
103
167

120
290
590
1050
1700

9
21
43
76
123

8T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
12
29
61
108
172
265
125
300
620
1100
1750
2700
9
22
45
80
127
195
14
32
68
123
196
299
145
330
690
1250
2000
3050
9
24
50
90
145
221
Hexagon
head bolt
Hexagon
flange bolt

0-17
PRECOATED BOLTS
1. Do not replace or restore a precoated bolt as it is in the
following cases:
(1) After it has been removed.
(2) When it has been moved by tightness check, etc.
(loosened or tightened)
NOTE:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves,
retighten it according to the steps below.
2. How to reuse precoated bolts
(1) Wash the bolt and threaded hole.
(The threaded hole must be washed even when
replacing the bolt with a new one)
(2) Completely dry the washed parts by blowing with air.
(3) Apply a specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact
surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or
other damage on the contact surfaces before installation.
2. When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Seal lock agent
Nominal diameter
of screw
Tightening torque standard N·m (kgf·cm) [ft·lbf] Inside diameter
of hose
mm (in)
Standard Tightening range
7/16-20UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16-18UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
3/4-16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8-14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15 (0.59)
1•1/16-12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
1•5/16-12UNF 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
PF3/8 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35)
PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98)