Toyota Industrial Equipment 7BWS10-13 Master Service Manual – PDF DOWNLOAD
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Toyota Industrial Equipment 7BWS10-13 Master Service Manual – PDF DOWNLOAD
Size : 16.0 MB
Format : PDF
Language : English
Number of Pages: 312 Pages
DESCRIPTION:
Toyota Industrial Equipment 7BWS10-13 Master Service Manual – PDF DOWNLOAD
INTRODUCTION:
- The information in this service manual covers model 7BWS10/13. Federal and State laws require that operators be completely trained in the safe operation of lift trucks in accordance with OHSA regulation 1910.178.
- An operator’s manual is sent with every Toyota truck when it is manufactured. If the operator’s manual is missing from the truck, a new manual may be obtained by contacting: Toyota Industrial Equipment The information contained in this service manual is intended as a guide to help trained, qualified, and authorized technicians safely service the truck.
- The service manual is divided into four separate sections which cover needed information for servicing the truck types. The main subject for each of these sections is described below.
TABLE OF CONTENTS:
Toyota Industrial Equipment 7BWS10-13 Master Service Manual – PDF DOWNLOAD
Ordering Spare Parts 1
Standard Codes 11
Warning Symbols 13
Warning Levels 13
Prohibitory Symbols 14
Ordinance Symbols 14
Safety 15
General Safety 15
Battery Safety 20
Static Discharge Precautions 25
Welding Safety 27
Introduction, Service Manual 29
Contents, Section M 31
Machine Information 31
General Product Information 33
Truck Presentation 33
Truck Side Views 33
Intended Truck Application 33
Prohibited Truck Application 34
Truck Data 34
Dimensions 35
Data Plate 36
Main Components 37
Inch (SAE) and Metric Fasteners 39
Introduction 39
Nomenclature, Threads 40
Strength Identification 41
Truck Torque Specifications 47
Conversion of Metric and English Units 48
Technical Service Data 51
Contents, Section P 55
Planned Maintenance 55
Introduction, Maintenance 57
Jacking Truck Off The Floor 58
Table Of Contents
Table of Contents
4 Master Service Manual 2006-06-12
Elevate Rear of Truck 58
Elevate Either Side of Truck 59
Lubricants 59
Standard 59
Service Schedule 61
Planned Maintenance Schedule 61
Planned Maintenance Procedures 65
General 65
Hardware 65
Noise 65
Leaks 65
Cables and Connections 66
Grease Location Points 66
Services Performed Daily or Every 8 Operating Hours 66
Chassis 66
Brakes 66
Wheels/Tires 66
Tiller Arm 66
Functions/Operations 67
Battery 67
Battery Connector 67
Services Performed Every Six Months or 500 Operating Hours Under Moderate
Usage or Three Months or 250 Hours Under Severe Usage 68
Chassis 68
Motors 68
Drive Unit 68
Brake 68
Electrical Control System 69
Battery 69
Electrical Panel 69
Hydraulic System 69
Mast 69
Lifting Devices 69
Services Performed 12 Months or Every 1000 Operating Hours Under
Moderate Usage and Six Months or Every 500 Operating Hours Under Severe Usage 70
Drive Unit 70
Hydraulic System 70
Lubrication Chart 71
Oil and Grease Specifications 72
Lubricants 72
Grease Location Points 72
Contents, Section S 73
Service Instructions 73
Stabilizer Support Arms 75
Theory of Operation 76
Maintenance 76
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Master Service Manual 2006-06-12 5
Support Arm Width Adjustment 76
Inspection, Covers 81
Theory of Operation 82
Maintenance 82
Troubleshooting 82
Repair and Rebuild 82
Decals 83
Decal with Protective Sheet 83
Decal without Protective Sheet 83
Electric Motors 85
Theory of Operation 85
Maintenance 85
Troubleshooting 86
Repair and Rebuild 87
Pump Motor 87
Removal 88
Installation 89
Drive Motor 90
Brush Inspection and Replacement 90
Brush Inspection 90
Brush Replacement 92
Motor Disassembly 93
Motor Assembly 94
Transmission 99
Theory of Operation 101
Maintenance 101
Fluid Changing 101
Troubleshooting 102
Repair and Rebuild 104
Parking Brake System 111
Theory of Operation 112
Maintenance 114
Mechanical Brake Release 114
Brake Adjustment 114
Troubleshooting 115
Repair and Rebuild 116
Drive Wheel 117
Theory of Operation 117
Maintenance 118
Drive Wheel Nut Inspection 118
Troubleshooting 120
Repair and Rebuild 121
Load Wheels 125
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6 Master Service Manual 2006-06-12
Theory of Operation 126
Maintenance 126
Troubleshooting 126
Repair and Rebuild 126
Tiller Arm Handle 129
Theory of Operation 131
Maintenance 131
Inspection 131
Troubleshooting 131
Repair and Rebuild 132
Tiller Arm Head 135
Theory of Operation 137
Maintenance 137
Troubleshooting 137
Repair and Rebuild 137
Steering Bearing 139
Theory of Operation 140
Maintenance 140
Troubleshooting 140
Repair and Rebuild 140
Electrical Functions 141
Theory of Operation 142
Battery Plugged In With Keypad 142
Battery Plugged In With Key Switch 144
Main ON/OFF Switch/Keypad ON 146
Travel, Low Speed 148
Travel, High Speed 150
Reverser 152
Lift 154
Lower 156
Maintenance 159
Wiring 159
Definitions 159
Shorts to Frame Test 160
Troubleshooting 163
Troubleshooting Flowchart 163
Main Harness Replacement 166
Operator Display and Programming 170
Special Modes 170
Service Display 171
Digital Inputs/Outputs from Transistor Controller 172
Transistor Controller System Mode 173
Changing Driver Accessible Parameters (P) 174
Changing Service Parameters 176
Parameter Description 179
Operating Parameter Programming 183
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Master Service Manual 2006-06-12 7
Display Part Numbers (Pn) 183
Error Codes (E) 183
Error Code History 183
Truck Fault Codes 184
Troubleshooting Chart Index 194
Travel (Tractor-first / Forks-first) System 194
Wiring System 194
Other Possible Troubleshooting Issues 194
Troubleshooting Charts 195
Battery 199
Theory of Operation 199
Maintenance 199
Inspection and Care 199
Exterior Cleaning 200
Charging 200
Storage 201
History Record 202
Troubleshooting 202
Repair and Rebuild 203
Swing Out Battery Pack 205
Theory of Operation 210
Maintenance 210
Electrical Testing 210
Required Equipment 210
Instructions 210
Troubleshooting 215
Repair and Rebuild 215
Battery Connector 217
Theory of Operation 217
Maintenance 217
Inspection 217
Troubleshooting 218
Repair and Rebuild 220
Switches 221
Theory of Operation 222
Maintenance 223
Troubleshooting 224
Repair and Rebuild 225
Main ON/OFF Switch 225
Arm Angle Switches 225
Key Switch (Optional) 227
Horn Switch 227
Converting Keypad to Key Switch 227
Fuses 229
Theory of Operation 229
Maintenance 229
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8 Master Service Manual 2006-06-12
Wiring Harness 230
Power Cables 231
Master Control Relay 232
Troubleshooting 233
Repair and Rebuild 233
Contactor Panel 235
Theory of Operation 237
Maintenance 237
Troubleshooting 237
Resistance Testing 237
Repair and Rebuild 238
Transistor Controller 239
Theory of Operation 239
Basics Of Circuit Operation 239
Interface 240
Control Features 241
Motor Circuit 241
Control Circuit 242
Definitions 243
Maintenance 244
Safety 244
Cleaning 244
Troubleshooting 245
Diagnostics and Troubleshooting 245
Fault Codes 245
Repair and Rebuild 247
Electronic Tiller Arm Card (ETAC) 249
Theory of Operation 250
Lift Cutout 251
Maintenance 251
Troubleshooting 251
Repair and Rebuild 251
Hydraulic System 253
Theory of Operation 253
Lift 254
Lower 255
Relief Pressure 256
Maintenance 257
Changing Hydraulic System Fluid 257
Hydraulic Pump Pressure Relief Valve 259
Troubleshooting 259
Troubleshooting Chart Index 260
Troubleshooting Charts 260
Repair and Rebuild 263
Hydraulic Unit 265
Reservoir 266
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Master Service Manual 2006-06-12 9
Filter Screen and Inlet Tube 267
Lift Pump 268
Lift Cylinder 269
Theory of Operation 270
Maintenance 270
Inspection 270
Troubleshooting 270
Repair and Rebuild 271
Mast 275
Theory of Operation 275
Maintenance 275
Visual Inspection 275
Lift Chain Inspection 275
Lift Chain Lubrication 280
Lift Chain Adjustment 281
Mast Guides/Dampers Adjustment 281
Troubleshooting 282
Repair and Rebuild 283
Forks 297
Theory of Operation 298
Maintenance 298
Inspection 298
Troubleshooting 298
Repair and Rebuild 299
Appendix 301
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