Toyota 7FBEST 10 User 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

0-2

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 indicatedin 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
591
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.

0-10
LIFTING 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.

0-11
MEMBER WEIGHTS Unit: kg
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 Code Weight
BATTERY 10 min. 381 - max. 420
13 min. 524 - max. 590
15 min. 600 - max. 690
Drive motor All Models Approx.34
Pump motor (Hydraulic pump + electric motor) All Models Approx.40
Rear axle L/Drive motor and wheel All Models Approx.53
Counterweight All models 900
Mast W/ lift bracket (W/ lift cylinder, L/ fork,
Lifting height 4000 mm, V mast All Models Approx 450
Vehicle weight (w/battery) 10 Approx.2550
13 Approx.2820
15 Approx.2930

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
NOTES ON SAS
1. 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.
2. always be sure to operate the vehicle carefully. Be aware of the difference in control features between
with and without SAS.
3. 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.
4. 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.).

0-14
TIGHTENING TORQUE TABLE
The tables here below are valid for screws and bolts without superficial covering, preventively lubricated
with oil.
SCREWS WITH “ISO” METRIC COARSE THREAD
SCREWS WITH “ISO” FINE THREAD
* = screw class
Nominal
diameter
mm
PRELOADING V (N) TORQUE Max (Nm)
6 D 8 G 10 K 12 K 6 D 8 G 10 K 12 K
6,6 8,8 10,9 12,9 6,6 8,8 10,9 12,9
M 4 x 0,7
M 5 x 0,8
M 6 x 1
M 7 x 1
M 8 x 1,25
M 9 x 1,25
M 10 x 1,5
M 12 x1,75
M 14 x 2
M 16 x 2
M 18 x 2,5
M 20 x 2,5
M 22 x 2,5
M 24 x 3
M 27 x 3
M 30 x 3
21781
3502
4974
7142
9025
11870
14519
20797
28351
38750
47480
60430
74850
87309
112815
138321
3865
6229
8849
12753
16088
21190
25506
37082
50620
68866
84366
107910
133416
155979
202086
247212
5435
8780
12459
17854
22661
29921
35905
52189
71123
97119
118701
151565
187371
218763
283509
347274
6524
10497
14911
21386
27174
35610
42968
62588
85347
116739
142245
181485
224649
261927
340407
415944
1,7
3,2
5,7
9,2
13,6
20,1
27,8
46,5
74
113
157
218
294
383
549
755
3
5,8
10
16,6
24,3
36
49
83
132
200
279
388
520
687
991
1354
4,2
8,2
14,3
23
34
50,8
69
117
186
283
392
545
731
961
1393
1893
5,1
9,9
17,1
27,8
41,1
60,5
82
140
223
339
471
653
883
1148
1668
2276
Nominal
diameter
mm
PRELOADING V (N) TORQUE Max (Nm)
6 D* 8 G* 10 K* 12 K* 6 D* 8 G* 10 K* 12 K*
6,6* 8,8* 10,9* 12,9* 6,6* 8,8* 10,9* 12,9*
M 8 x 1
M 10 x1,25
M 12 x1,25
M 12 x1,5
M 14 x 1.5
M 16 x 1,5
M 18 x 1,5
M 20 x 1,5
M 22 x 1,5
M 24 x 2
M 27 x 2
M 30 x 2
9761
15107
23740
21778
30902
41202
53268
67689
82404
94667
122625
154017
17168
26879
40613
38848
54936
73575
95157
118701
147150
168732
218763
272718
24231
37867
56898
54642
77303
103005
133416
168242
206010
237402
307053
384552
29038
45420
68474
65531
92705
123606
159903
202086
247212
284490
367875
461070
14,5
28,4
52
49
78
118
171
239
314
402
589
814
25,5
51
89
87
140
211
304
422
564
721
1050
1442
36,2
72
126
123
196
294
422
598
790
1010
1472
2040
43
85
151
147
235
353
510
716
952
1216
1766
2453