Toyota Forklift 7BWS10 7BWS13 Electric Walkie Low-Lift Pallet Truck Service Manual SN 40500 – up – PDF DOWNLOAD

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Toyota Forklift 7BWS10 7BWS13 Electric Walkie Low-Lift Pallet Truck Service Manual SN 40500 – up – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift 7BWS10 7BWS13 Electric Walkie Low-Lift Pallet Truck Service Manual SN 40500 – up – PDF DOWNLOAD

Language : English
Pages : 312
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift 7BWS10 7BWS13 Electric Walkie Low-Lift Pallet Truck Service Manual SN 40500 – up – PDF DOWNLOAD

General Product Information:
1. Truck Presentation:

• The 7BWS10/13 are battery powered adjustable baseleg stacker trucks. These trucks are intended solely to be operated indoors carrying pallets or similar load carriers. The trucks are equipped with a tiller arm with all the controls for operating within easy access. The trucks lifting capacities can be found on the truck’s data plate.
• The 7BWS10/13 trucks are equipped with a 24 volt electrical system. Speed is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving.
• The forks are raised by means of a hydraulic unit. The control of the lift/lower is activated by rotating the control on the tiller arm handle head.

1.1. Truck Side Views:

The terms right-hand and left-hand used indicate the right and left side of the truck as viewed from the operator’s line of sight for proper operation of the truck. Use this view when ordering parts to assure proper selection of parts.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Toyota Forklift 7BWS10 7BWS13 Electric Walkie Low-Lift Pallet Truck Service Manual SN 40500 – up – PDF DOWNLOAD

Front Cover....................................................................................................................................................  1
Ordering Spare Parts...........................................................................................................................................  3
Table Of Contents..............................................................................................................................................  5
Standard Codes................................................................................................................................................. 13
Warning Symbols................................................................................................................................................ 15
	1. Warning Levels.......................................................................................................................................... 15
Prohibitory Symbols............................................................................................................................................ 16
	1. Ordinance Symbols....................................................................................................................................... 16
Safety......................................................................................................................................................... 17
	1. General Safety.......................................................................................................................................... 17
Battery Safety................................................................................................................................................. 22
Static Discharge Precautions................................................................................................................................... 27
Welding Safety................................................................................................................................................. 29
Introduction, Service Manual................................................................................................................................... 31
Contents, Section M............................................................................................................................................ 33
	1. Machine Information..................................................................................................................................... 33
General Product Information.................................................................................................................................... 35
	1. Truck Presentation...................................................................................................................................... 35
		1.1. Truck Side Views.................................................................................................................................. 35
		1.2. Intended Truck Application........................................................................................................................ 35
		1.3. Prohibited Truck Application...................................................................................................................... 36
		1.4. Truck Data........................................................................................................................................ 36
		1.5. Dimensions........................................................................................................................................ 37
		1.6. Data Plate........................................................................................................................................ 38
	2. Main Components......................................................................................................................................... 39
Inch (SAE) and Metric Fasteners................................................................................................................................ 41
	1. Introduction............................................................................................................................................ 41
	2. Nomenclature, Threads................................................................................................................................... 42
	3. Strength Identification................................................................................................................................. 43
	4. Truck Torque Specifications............................................................................................................................. 49
	5. Conversion of Metric and English Units.................................................................................................................. 50
Technical Service Data......................................................................................................................................... 53
Contents, Section P............................................................................................................................................ 57
	1. Planned Maintenance..................................................................................................................................... 57
Introduction, Maintenance...................................................................................................................................... 59
	1. Jacking Truck Off The Floor............................................................................................................................. 60
		1.1. Elevate Rear of Truck............................................................................................................................. 60
		1.2. Elevate Either Side of Truck...................................................................................................................... 61
	2. Lubricants.............................................................................................................................................. 61
		2.1. Standard.......................................................................................................................................... 61
Service Schedule............................................................................................................................................... 63
	1. Planned Maintenance Schedule............................................................................................................................ 63
	2. Planned Maintenance Procedures.......................................................................................................................... 67
		2.1. General........................................................................................................................................... 67
			2.1.1. Hardware.................................................................................................................................... 67
			2.1.2. Noise....................................................................................................................................... 67
			2.1.3. Leaks....................................................................................................................................... 67
			2.1.4. Cables and Connections...................................................................................................................... 68
			2.1.5. Grease Location Points...................................................................................................................... 68
		2.2. Services Performed Daily or Every 8 Operating Hours............................................................................................... 68
			2.2.1. Chassis..................................................................................................................................... 68
			2.2.2. Brakes...................................................................................................................................... 68
			2.2.3. Wheels/Tires................................................................................................................................ 68
			2.2.4. Tiller Arm.................................................................................................................................. 68
			2.2.5. Functions/Operations........................................................................................................................ 69
			2.2.6. Battery..................................................................................................................................... 69
			2.2.7. Battery Connector........................................................................................................................... 69
		2.3. Services Performed Every Six Months or 500 Operating Hours Under Moderate Usage or Three Months or 250 Hours Under Severe Usage................... 70
			2.3.1. Chassis..................................................................................................................................... 70
			2.3.2. Motors...................................................................................................................................... 70
			2.3.3. Drive Unit.................................................................................................................................. 70
			2.3.4. Brake....................................................................................................................................... 70
			2.3.5. Electrical Control System................................................................................................................... 71
			2.3.6. Battery..................................................................................................................................... 71
			2.3.7. Electrical Panel............................................................................................................................ 71
			2.3.8. Hydraulic System............................................................................................................................ 71
			2.3.9. Mast........................................................................................................................................ 71
			2.3.10. Lifting Devices............................................................................................................................ 71
		2.4. Services Performed 12 Months or Every 1000 Operating Hours Under Moderate Usage and Six Months or Every 500 Operating Hours Under Severe Usage.... 72
			2.4.1. Drive Unit.................................................................................................................................. 72
			2.4.2. Hydraulic System............................................................................................................................ 72
Lubrication Chart.............................................................................................................................................. 73
Oil and Grease Specifications.................................................................................................................................. 74
	1. Lubricants.............................................................................................................................................. 74
	2. Grease Location Points.................................................................................................................................. 74
Contents, Section S............................................................................................................................................ 75
	1. Service Instructions.................................................................................................................................... 75
Stabilizer Support Arms........................................................................................................................................ 77
	1. Theory of Operation..................................................................................................................................... 78
	2. Maintenance............................................................................................................................................. 78
		2.1. Support Arm Width Adjustment...................................................................................................................... 78
Inspection, Covers............................................................................................................................................. 83
	1. Theory of Operation..................................................................................................................................... 84
	2. Maintenance............................................................................................................................................. 84
	3. Troubleshooting......................................................................................................................................... 84
	4. Repair and Rebuild...................................................................................................................................... 84
Decals......................................................................................................................................................... 85
	1. Decal with Protective Sheet............................................................................................................................. 85
	2. Decal without Protective Sheet.......................................................................................................................... 85
Electric Motors................................................................................................................................................ 87
	1. Theory of Operation..................................................................................................................................... 87
	2. Maintenance............................................................................................................................................. 87
	3. Troubleshooting......................................................................................................................................... 88
	4. Repair and Rebuild...................................................................................................................................... 89
		4.1. Pump Motor........................................................................................................................................ 89
			4.1.1. Removal..................................................................................................................................... 90
			4.1.2. Installation................................................................................................................................ 91
		4.2. Drive Motor....................................................................................................................................... 92
			4.2.1. Brush Inspection and Replacement............................................................................................................ 92
			4.2.2. Brush Inspection............................................................................................................................ 92
			4.2.3. Brush Replacement........................................................................................................................... 94
			4.2.4. Motor Disassembly........................................................................................................................... 95
			4.2.5. Motor Assembly.............................................................................................................................. 96
Transmission...................................................................................................................................................101
	1. Theory of Operation.....................................................................................................................................103
	2. Maintenance.............................................................................................................................................103
		2.1. Fluid Changing....................................................................................................................................103
	3. Troubleshooting.........................................................................................................................................104
	4. Repair and Rebuild......................................................................................................................................106
Parking Brake System...........................................................................................................................................113
	1. Theory of Operation.....................................................................................................................................114
	2. Maintenance.............................................................................................................................................116
		2.1. Mechanical Brake Release..........................................................................................................................116
		2.2. Brake Adjustment..................................................................................................................................116
	3. Troubleshooting.........................................................................................................................................117
	4. Repair and Rebuild......................................................................................................................................118
Drive Wheel....................................................................................................................................................119
	1. Theory of Operation.....................................................................................................................................119
	2. Maintenance.............................................................................................................................................120
		2.1. Drive Wheel Nut Inspection........................................................................................................................120
	3. Troubleshooting.........................................................................................................................................122
	4. Repair and Rebuild......................................................................................................................................123
Load Wheels....................................................................................................................................................127
	1. Theory of Operation.....................................................................................................................................128
	2. Maintenance.............................................................................................................................................128
	3. Troubleshooting.........................................................................................................................................128
	4. Repair and Rebuild......................................................................................................................................128
Tiller Arm Handle..............................................................................................................................................131
	1. Theory of Operation.....................................................................................................................................133
	2. Maintenance.............................................................................................................................................133
		2.1. Inspection........................................................................................................................................133
	3. Troubleshooting.........................................................................................................................................133
	4. Repair and Rebuild......................................................................................................................................134
Tiller Arm Head................................................................................................................................................137
	1. Theory of Operation.....................................................................................................................................139
	2. Maintenance.............................................................................................................................................139
	3. Troubleshooting.........................................................................................................................................139
	4. Repair and Rebuild......................................................................................................................................139
Steering Bearing...............................................................................................................................................141
	1. Theory of Operation.....................................................................................................................................142
	2. Maintenance.............................................................................................................................................142
	3. Troubleshooting.........................................................................................................................................142
	4. Repair and Rebuild......................................................................................................................................142
Electrical Functions...........................................................................................................................................143
	1.2. Battery Plugged In With Key Switch....................................................................................................................146
	1.3. Main ON/OFF Switch/Keypad ON..........................................................................................................................148
	1.4. Travel, Low Speed.....................................................................................................................................150
	1.5. Travel, High Speed....................................................................................................................................152
	1.6. Reverser..............................................................................................................................................154
	1.7. Lift..................................................................................................................................................156
	1.8. Lower.................................................................................................................................................158
	2. Maintenance.............................................................................................................................................161
		2.1. Wiring............................................................................................................................................161
			2.1.1. Definitions.................................................................................................................................161
			2.1.2. Shorts to Frame Test........................................................................................................................162
	3. Troubleshooting.........................................................................................................................................165
		3.1. Troubleshooting Flowchart.........................................................................................................................165
		3.2. Main Harness Replacement..........................................................................................................................168
		3.3. Operator Display and Programming..................................................................................................................172
			3.3.1. Special Modes...............................................................................................................................172
			3.3.2. Service Display.............................................................................................................................173
			3.3.3. Digital Inputs/Outputs from Transistor Controller...........................................................................................174
			3.3.4. Transistor Controller System Mode...........................................................................................................175
		3.4. Changing Driver Accessible Parameters (P).........................................................................................................176
		3.5. Changing Service Parameters.......................................................................................................................178
			3.5.1. Parameter Description.......................................................................................................................181
			3.5.2. Operating Parameter Programming.............................................................................................................185
			3.5.3. Display Part Numbers (Pn)...................................................................................................................185
		3.6. Error Codes (E)...................................................................................................................................185
			3.6.1. Error Code History..........................................................................................................................185
			3.6.2. Truck Fault Codes...........................................................................................................................186
		3.7. Troubleshooting Chart Index.......................................................................................................................196
			3.7.1. Travel (Tractor-first / Forks-first) System.................................................................................................196
			3.7.2. Wiring System...............................................................................................................................196
			3.7.3. Other Possible Troubleshooting Issues.......................................................................................................196
		3.8. Troubleshooting Charts............................................................................................................................197
Battery........................................................................................................................................................201
	1. Theory of Operation.....................................................................................................................................201
	2. Maintenance.............................................................................................................................................201
		2.1. Inspection and Care...............................................................................................................................201
		2.2. Exterior Cleaning.................................................................................................................................202
		2.3. Charging..........................................................................................................................................202
		2.4. Storage...........................................................................................................................................203
		2.5. History Record....................................................................................................................................204
	3. Troubleshooting.........................................................................................................................................204
	4. Repair and Rebuild......................................................................................................................................205
Swing Out Battery Pack.........................................................................................................................................207
	1. Theory of Operation.....................................................................................................................................212
	2. Maintenance.............................................................................................................................................212
		2.1. Electrical Testing................................................................................................................................212
			2.1.1. Required Equipment..........................................................................................................................212
			2.1.2. Instructions................................................................................................................................212
	3. Troubleshooting.........................................................................................................................................217
	4. Repair and Rebuild......................................................................................................................................217
Battery Connector..............................................................................................................................................219
	1. Theory of Operation.....................................................................................................................................219
	2. Maintenance.............................................................................................................................................219
		2.1. Inspection........................................................................................................................................219
	3. Troubleshooting.........................................................................................................................................220
	4. Repair and Rebuild......................................................................................................................................222
Switches.......................................................................................................................................................223
	1. Theory of Operation.....................................................................................................................................224
	2. Maintenance.............................................................................................................................................225
	3. Troubleshooting.........................................................................................................................................226
	4. Repair and Rebuild......................................................................................................................................227
		4.1. Main ON/OFF Switch................................................................................................................................227
		4.2. Arm Angle Switches................................................................................................................................227
		4.3. Key Switch (Optional).............................................................................................................................229
		4.4. Horn Switch.......................................................................................................................................229
		4.5. Converting Keypad to Key Switch...................................................................................................................229
Fuses..........................................................................................................................................................231
	1. Theory of Operation.....................................................................................................................................231
	2. Maintenance.............................................................................................................................................231
		2.1. Wiring Harness....................................................................................................................................232
		2.2. Power Cables......................................................................................................................................233
		2.3. Master Control Relay..............................................................................................................................234
	3. Troubleshooting.........................................................................................................................................235
	4. Repair and Rebuild......................................................................................................................................235
Contactor Panel................................................................................................................................................237
	1. Theory of Operation.....................................................................................................................................239
	2. Maintenance.............................................................................................................................................239
	3. Troubleshooting.........................................................................................................................................239
		3.1. Resistance Testing................................................................................................................................239
	4. Repair and Rebuild......................................................................................................................................240
Transistor Controller..........................................................................................................................................241
	1. Theory of Operation.....................................................................................................................................241
		1.1. Basics Of Circuit Operation.......................................................................................................................241
		1.2. Interface.........................................................................................................................................242
		1.3. Control Features..................................................................................................................................243
		1.4. Motor Circuit.....................................................................................................................................243
		1.5. Control Circuit...................................................................................................................................244
		1.6. Definitions.......................................................................................................................................245
	2. Maintenance.............................................................................................................................................246
		2.1. Safety............................................................................................................................................246
		2.2. Cleaning..........................................................................................................................................246
	3. Troubleshooting.........................................................................................................................................247
		3.1. Diagnostics and Troubleshooting...................................................................................................................247
		3.2. Fault Codes.......................................................................................................................................247
	4. Repair and Rebuild......................................................................................................................................249
Electronic Tiller Arm Card (ETAC)..............................................................................................................................251
	1. Theory of Operation.....................................................................................................................................252
		1.1. Lift Cutout.......................................................................................................................................253
	2. Maintenance.............................................................................................................................................253
	3. Troubleshooting.........................................................................................................................................253
	4. Repair and Rebuild......................................................................................................................................253
Hydraulic System...............................................................................................................................................255
	1. Theory of Operation.....................................................................................................................................255
		1.1. Lift..............................................................................................................................................256
		1.2. Lower.............................................................................................................................................257
		1.3. Relief Pressure...................................................................................................................................258
	2. Maintenance.............................................................................................................................................259
		2.1. Changing Hydraulic System Fluid...................................................................................................................259
		2.2. Hydraulic Pump Pressure Relief Valve..............................................................................................................261
	3. Troubleshooting.........................................................................................................................................261
		3.1. Troubleshooting Chart Index.......................................................................................................................262
		3.2. Troubleshooting Charts............................................................................................................................262
	4. Repair and Rebuild......................................................................................................................................265
		4.1. Hydraulic Unit....................................................................................................................................267
		4.2. Reservoir.........................................................................................................................................268
		4.3. Filter Screen and Inlet Tube......................................................................................................................269
		4.4. Lift Pump.........................................................................................................................................270
Lift Cylinder..................................................................................................................................................271
	1. Theory of Operation.....................................................................................................................................272
	2. Maintenance.............................................................................................................................................272
		2.1. Inspection........................................................................................................................................272
	3. Troubleshooting.........................................................................................................................................272
	4. Repair and Rebuild......................................................................................................................................273
Mast...........................................................................................................................................................277
	1. Theory of Operation.....................................................................................................................................277
	2. Maintenance.............................................................................................................................................277
		2.1. Visual Inspection.................................................................................................................................277
		2.2. Lift Chain Inspection.............................................................................................................................277
		2.3. Lift Chain Lubrication............................................................................................................................282
		2.4. Lift Chain Adjustment.............................................................................................................................283
		2.5. Mast Guides/Dampers Adjustment....................................................................................................................283
	3. Troubleshooting.........................................................................................................................................284
	4. Repair and Rebuild......................................................................................................................................285
Forks..........................................................................................................................................................299
	1. Theory of Operation.....................................................................................................................................300
	2. Maintenance.............................................................................................................................................300
		2.1. Inspection........................................................................................................................................300
	3. Troubleshooting.........................................................................................................................................300
	4. Repair and Rebuild......................................................................................................................................301
Appendix.......................................................................................................................................................303
Index..........................................................................................................................................................309
	A..........................................................................................................................................................309
	B..........................................................................................................................................................309
	C..........................................................................................................................................................309
	D..........................................................................................................................................................309
	E..........................................................................................................................................................309
	F..........................................................................................................................................................309
	G..........................................................................................................................................................309
	H..........................................................................................................................................................309
	I..........................................................................................................................................................309
	J..........................................................................................................................................................310
	L..........................................................................................................................................................310
	M..........................................................................................................................................................310
	O..........................................................................................................................................................310
	P..........................................................................................................................................................310
	S..........................................................................................................................................................310
	T..........................................................................................................................................................310
	W..........................................................................................................................................................310
Back Cover.....................................................................................................................................................312

Questions? Email us: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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