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

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

VEHICLE EXTERIOR VIEW

 0-3

VEHICLE MODELS
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 ↑ ↑
0
20 2.0 7FBE20 ↑ ↑
1
FRAME NUMBER 2
Vehicle model Drive motor model Punching format Punching position
3
7FBE10
4
7FBE13-50011

7FBE13
5
6
7FBE15 AR09
7
7FBE18-50011
8
7FBE18
9
7FBE20 7FBE20-50011
Punching position
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]

• Some step numbers may be 4

1
omitted in some illustrations. 2
3

5 6

T = 46.1 to 48.1
(470 to 490)
[34.0 to 35.5]

5
9 1

Disassembly Procedure
1 Remove the cover. [Point 1] Operation to be explained
2 Remove the bushing. [Point 2]
3 Remove the gear.
Point Operations
Explanation of operation point with illustration
[POINT 1]
Disassembly:
Make match marks before removing the pump cover

[POINT 2]
Inspection:
Measure the bushing inside diameter.
Limit 19.12 mm
 0-5

1. How to read component figures (Example)

(1) The component figures use the illustration in the parts
catalog for the vehicle model. Please refer to the catalog 3201
to check the part name. Parts catalog
FIG number
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)
0
TERMINOLOGY 1
CAUTION:
Important matters, negligence of which may cause accidents. Be sure to observe them. 2
NOTE:
Important items, negligence of which may cause accidents, or matters in operating procedure 3
which require special attention.
Standard: Value showing the allowable range in inspection or adjustment 4
Limit: The maximum or minimum value allowed in inspection or adjustment. 5
ABBREVIATIONS 6
Abbreviation Meaning Abbreviation Meaning 7
Society of Automotive Engineers
ASSY Assembly SAE
(USA) 8
ATT Attachment SAS System of active stability 9
LH Left Hand SST Special Service Tool
L/ Less STD Standard
10
OPT Option T= Tightening Torque 11
O/S Oversize {{T Number of teeth ({{T)
12
PS system Power Steering U/S Undersize
RH Right Hand W/ With 13
14
15
16
17
18
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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

Item New unit Conventional Conversion rate*1 (1 [conventional unit] = X [SI

unit unit])
Force*2 N (newton) kgf 1 kgf = 9.80665 N
Torque*2 N·m kgf·cm 1 kgf·cm = 9.80665 N·m
(Moment)
Pressure*2 Pa (pascal) kgf/cm2 1 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
<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
Value in SI unit = Conversion rate × Value in conventional unit Conversion rate: Figure corresponding
to X in the conversion rate column in
Value in conventional unit = Value in SI unit ÷ Conversion rate the table above
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.
 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.