TOYOTA Forklift 7FBE10-20 Series Repair Manual CE327 & CE328 PDF

Description

TOYOTA Forklift 7FBE10-20 Series Repair Manual CE327 &CE328 – PDF DOWNLOAD

FILE DETAILS:

TOYOTA Forklift 7FBE10-20 Series Repair Manual CE327 &CE328 – PDF DOWNLOAD

Language : English
Pages : 513
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

TOYOTA Forklift 7FBE10-20 Series Repair Manual CE327 &CE328 – PDF DOWNLOAD

FOREWORD 1
SECTION INDEX 2
GENERAL 3
VEHICLE EXTERIOR VIEW 4
VEHICLE MODELS 5
FRAME NUMBER 5
HOW TO USE THIS MANUAL 6
EXPLANATION METHOD 6
TERMINOLOGY 7
ABBREVIATIONS 7
SI UNITS 8
OPERATING TIPS 9
GENERAL INSTRUCTIONS 9
JACK-UP POINT 10
HOISTING THE VEHICLE 11
WIRE ROPE SUSPENSION ANGLE LIST 12
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE 12
MEMBER WEIGHTS 13
TOWING THE VEHICLE 13
ELECTRICAL PARTS INSPECTION 14
NOTES ON SAS 16
STANDARD BOLT & NUT TIGHTENING TORQUE 17
BOLT STRENGTH CLASS IDENTIFICATION METHOD 17
TIGHTENING TORQUE TABLE 18
PRECOATED BOLTS 19
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 19
RECOMMENDED LUBRICANT QUANTITY AND TYPES 20
LUBRICATION CHART 21
PERIODIC MAINTENANCE 22
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS 27
BATTERY 29
BATTERY COMPARTMENT AND REQUIRED WEIGHT 30
SERVICE STANDARDS 31
DISPLAY 31
TROUBLESHOOTING 32
BATTERY ASSY 33
REMOVAL · INSTALLATION 33
INSPECTION 34
REPLACING BATTERY PLUG TERMINAL 37
CHARGER (OPT) 39
GENERAL 40
ON-VEHICLE CHARGER 40
APPLICABLE CHARGER LIST 40
SPECIFICATIONS 41
COMPONENTS 42
WIRING DIAGRAM 43
TAP LAYOUT 43
BEFORE CHARGING 44
SWITCH BOX 45
MAGNETIC SWITCH ASSY 47
TRANSFORMER ASSY 49
TIMER TEST 53
TROUBLESHOOTING 54
OFF-VEHICLE CHARGER 64
APPLICABLE CHARGER LIST 64
GS 65
YUASA 81
CONTROLLER 93
GENERAL 94
SPECIFICATIONS 95
COMPONENTS 96
BEFORE REPAIR 98
CONNECTOR INSPECTION 99
CONTROLLER111
MAIN CONTROLLER ASSY111
TRAVELING AC DRIVER112
MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL ASSY113
CHECK MOTOR INPUT VOLTAGE115
REASSEMBLY117
DISPLAY118
DIRECTION SWITCH119
REMOVAL · INSTALLATION119
DISASSEMBLY · INSPECTION · REASSEMBLY121
ACCELERATOR POTENTIOMETER ADJUSTMENT122
BRAKE SWITCH ADJUSTMENT123
FOOT BRAKE123
PARKING BRAKE123
MATERIAL HANDLING LEVER SWITCH ADJUSTMENT124
MULTI-DISPLAY FUNCTIONS125
MULTI-SCREEN DISPLAY126
GENERAL126
SPECIFICATIONS130
GENERAL FUNCTIONS131
DISPLAY INDICATION LIST132
ABBREVIATIONS DISPLAYED ON THE SCREEN133
GENERAL FUNCTIONS134
OPERATING PROCEDURE OF FUNCTION SETTING135
DIAGNOSIS139
DIAGNOSIS CODE LIST139
MASK FUNCTIONS144
GENERAL144
PASSWORD146
OPERATION ON MASK MENU SCREEN147
ANALYZER148
TUNING165
OPTION SET168
MATCHING172
TIRE CONSTANT SET175
TROUBLESHOOTING177
BEFORE TROUBLESHOOTING178
TROUBLESHOOTING METHOD180
SST SETTING METHOD181
DIAGNOSIS CODE LIST187
WHEN AN ERROR CODE IS DISPLAYED190
CPU BOARD190
TRAVELING/MATERIAL HANDLING AC DRIVER223
SAS SYSTEM255
MULTI-DISPLAY268
WHEN NO ERROR CODE IS DISPLAYED269
MOTOR279
DRIVE MOTOR280
GENERAL280
SPECIFICATIONS280
COMPONENTS281
REMOVAL · INSTALLATION282
DISASSEMBLY · INSPECTION · REASSEMBLY284
PUMP MOTOR287
GENERAL287
SPECIFICATIONS287
COMPONENTS288
REMOVAL · INSTALLATION289
DISASSEMBLY · INSPECTION · REASSEMBLY291
DRIVE UNIT & FRONT AXLE295
GENERAL296
SPECIFICATIONS297
COMPONENTS297
TIRES · WHEELS299
FRONT AXLE HUB & DRIVE UNIT300
REMOVAL · INSTALLATION300
DISASSEMBLY · INSPECTION · REASSEMBLY302
REAR AXLE305
REAR AXLE ASSY306
GENERAL306
SPECIFICATIONS307
COMPONENTS307
TIRES · WHEELS309
REMOVAL · INSTALLATION310
DISASSEMBLY · INSPECTION · REASSEMBLY312
REAR AXLE HUB317
REMOVAL · INSTALLATION317
REAR AXLE CYLINDER ASSY320
REMOVAL · INSTALLATION320
DISASSEMBLY · INSPECTION · REASSEMBLY322
STEERING325
GENERAL326
SPECIFICATIONS327
COMPONENTS327
STEERING WHEEL · MAST JACKET332
REMOVAL · INSTALLATION332
DISASSEMBLY · REASSEMBLY334
HYDROSTATIC STEERING VALVE ASSY335
TROUBLESHOOTING335
REMOVAL · INSTALLATION337
DISASSEMBLY · INSPECTION · REASSEMBLY338
INSPECT AND ADJUST THE RELIEF PRESSURE341
PRIORITY VALVE342
COMPONENTS342
REMOVAL · INSTALLATION344
DISASSEMBLY · INSPECTION · REASSEMBLY345
BRAKE347
GENERAL348
SPECIFICATIONS349
COMPONENTS349
PARKING BRAKE349
BRAKE PEDAL350
DISC BRAKE351
DISC BRAKE354
REMOVAL · INSTALLATION354
DISASSEMBLY · INSPECTION · REASSEMBLY356
DISK BRAKE ADJUSTMENT357
BRAKE DISC WHEEL358
REMOVAL · INSTALLATION358
BRAKE PEDAL360
REMOVAL · INSTALLATION360
BRAKE PEDAL ADJUSTMENT361
PARKING BRAKE362
REMOVAL · INSTALLATION362
PARKING BRAKE ADJUSTMENT363
BODY & FRAME365
COMPONENTS366
BATTERY HOOD ASSY369
REMOVAL • INSTALLATION369
COUNTERWEIGHT370
REMOVAL • INSTALLATION370
OPERATOR’S SEAT371
REMOVAL • INSTALLATION371
FUSES372
FUSE INSTALLATION LOCATIONS372
NAMES (APPLICABLE FUNCTIONS) AND CAPACITIES372
MATERIAL HANDLING SYSTEM373
HYDRAULIC CIRCUIT374
COMPONENTS375
RETURN FILTER380
REMOVAL · INSTALLATION380
NATURAL DROP TEST381
NATURAL FORWARD TILT TEST381
OIL LEAK TEST382
LIFT CYLINDER382
TILT CYLINDER382
MAST383
V MAST ASSY384
COMPONENTS384
REMOVAL • INSTALLATION386
REMOVAL • INSTALLATION (W/LIFT BRACKET)388
MAST ASSY DISASSEMBLY • INSPECTION • REASSEMBLY390
LIFT BRACKET DISASSEMBLY • INSPECTION • REASSEMBLY392
MAST ADJUSTMENT (V MAST)394
MAST ROLLER REMOVAL • INSTALLATION401
CHAIN402
INSPECTION402
REASSEMBLY402
ADJUSTMENT403
FORK403
REMOVAL403
INSTALLATION403
INSPECTION403
SV · FV · FSV MAST ASSY404
COMPONENTS404
MAST ADJUSTMENT (SV • FV • FSV)410
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)416
CYLINDER417
LIFT CYLINDER (V • SV) • REAR LIFT CYLINDER (FV • FSV)418
GENERAL418
SPECIFICATIONS419
COMPONENTS420
REMOVAL • INSTALLATION422
DISASSEMBLY • INSPECTION • REASSEMBLY424
FLOW REGULATOR VALVE (V • SV • FV • FSV)426
REMOVAL · INSTALLATION427
SAFETY DOWN VALVE (V • SV • FV • FSV)428
REMOVAL • INSTALLATION (V)429
REMOVAL • INSTALLATION (SV • FV • FSV)430
FRONT LIFT CYLINDER (FV • FSV)431
GENERAL431
SPECIFICATIONS431
COMPONENTS432
REMOVAL • INSTALLATION432
DISASSEMBLY • INSPECTION • REASSEMBLY433
TILT CYLINDER435
GENERAL435
SPECIFICATIONS435
COMPONENTS436
REMOVAL • INSTALLATION438
DISASSEMBLY • INSPECTION • REASSEMBLY440
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING)442
OIL PUMP443
GENERAL444
COMPONENTS445
REMOVAL • INSTALLATION446
DISASSEMBLY • INSPECTION • REASSEMBLY447
TEST METHOD449
OIL CONTROL VALVE451
GENERAL452
SPECIFICATIONS454
COMPONENTS455
OIL CONTROL VALVE FOR VEHICLE WITH SAS (OPT)457
GENERAL457
SPECIFICATIONS460
COMPONENTS461
OIL CONTROL VALVE ASSY462
REMOVAL • INSTALLATION462
DISASSEMBLY • INSPECTION • REASSEMBLY463
DISASSEMBLY • INSPECTION • REASSEMBLY (VEHICLE WITH SAS)464
RELIEF PRESSURE ADJUSTMENT465
LIFT LOCK UNLOCKING BOLT (OPT)466
CONTROL VALVE LEVER ASSY467
REMOVAL • INSTALLATION467
SAS FUNCTIONS (OPT)469
GENERAL470
COMPONENTS471
FOR REPAIR WORK475
STEERING KNOB SYNCHRONIZER VALVE476
REMOVAL • INSTALLATION476
TIRE ANGLE SENSOR478
REMOVAL • INSTALLATION478
TILT ANGLE SENSOR480
REMOVAL • INSTALLATION480
LOAD SENSOR481
REMOVAL • INSTALLATION481
MAST LIFTING HEIGHT SWITCH483
REMOVAL • INSTALLATION483
MATCHING484
VEHICLE STANDARD STATE485
CAUTIONS ON MODIFYING VEHICLES486
APPENDIX487
SST LIST488
SERVICE STANDARDS492
CPU BOARD CONNECTOR500
CONNECTOR DRAWING501
CONNECTING DIAGRAM511
ELECTRIC WIRING DIAGRAM512
PUBLISHED513

DESCRIPTION:

TOYOTA Forklift 7FBE10-20 Series Repair Manual CE327 &CE328 – PDF DOWNLOAD

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 corresponding forklift models.
• This manual deals with the above models as of February 2003. Please understandthat disagreement can take place between the descriptions in the manual 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.

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.

S.V 25/02/2025