PDF Master Service Manual Toyota 7BWS10 7BWS13 Industrial Equipment - 3 MB
This is the master service manual for Toyota 7BWS10 and 7BWS13 walkie stackers.
As the most complete guide available, it covers everything from basic adjustments to major system overhauls.
Technicians will find the detailed troubleshooting charts, wiring diagrams, and step-by-step procedures to be an invaluable asset.
Service your material handling equipment to the highest factory standards using this essential resource.
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--- Page 1 ---
Front Cover
Master Service Manual
7BWS10/13
Electric Walkie Low-Lift Pallet Truck
Effective Serial Number 40500 - UP
Warning Read and observe all warnings on this unit
before operating it.
Warning DO NOT operate this equipment unless all
factory installed guards and covers are
properly secured in place.
Part no: 00700-CL3WS-06 Date: June 12, 2006
--- Page 3 ---
Table of Contents
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
Master Service Manual 2006-06-12 9
--- Page 4 ---
F-code Section C-code
Safety
Version no T-code
001
Do NOT add to or modify truck without written approval from
Toyota
Master Service Manual 2006-06-12 19
--- Page 5 ---
F-code Section C-code
M
Introduction, Service Manual
Version no T-code
000 7BWS10/13
Introduction, Service Manual
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
www.toyotaforklift.com
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.
SECTION SUBJECT
M MACHINE INFORMATION
P PLANNED MAINTENANCE
S SERVICE INSTRUCTIONS
O OPTIONS
Master Service Manual 2006-06-12 29
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F-code Section C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no T-code
000 7BWS10/13
Inch (SAE) and Metric Fasteners
5 9 10
5 9 10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe mechanical
strength and hardness of fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. Many fasteners are similar but cannot be
used as direct replacements.
Service technicians must use replacement fasteners that
have the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called “grade” for SAE
standards and “property” for metric standards. This section
describes identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.
Master Service Manual 2006-06-12 39
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F-code Section C-code
M1.1
Inch (SAE) and Metric Fasteners
Version no T-code
000 7BWS10/13
TEMPERATURE
Multiply By To Get Multiply By To Get
(Fahrenheit
0.56 Celsius (C) (Celsius x 1.8) +32 Fahrenheit (F)
-32)
TORQUE
Multiply By To Get Multiply By To Get
inch pounds
inch pound 0.113 Newton meter (N•m) Newton meter 8.851
in-lbs
foot pounds
feet pound 1.356 Newton meter (N•m) Newton meter 0.738
ft-lbs
VELOCITY
Multiply By To Get Multiply By To Get
kilometer/hour miles/hour
miles/hour 1.609 kilometer/hour 0.621
(km/h) (mph)
VOLUME
Multiply By To Get Multiply By To Get
inches³ 16.387 centimeters³ (cm³) centimeters³ 0.061 inches³ (in³)
inches³ 0.016 liters liters 61.024 inches³ (in³)
quarts, U.S. 0.946 liters liters 1.057 quarts, U.S. (qt)
quarts, U.S. 0.83 quarts, Imp. (qt) quarts, Imp. 1.205 quarts, U.S. (qt)
gallons, U.S.
gallons, U.S. 3.785 liters liters 0.264
(gal)
gallons, U.S.
gallons, U.S. 0.83 gallons, Imp. (gal) gallons, Imp. 1.205
(gal)
ounces 29.57 milliliters (ml) milliliters 0.034 ounces (oz)
Master Service Manual 2006-06-12 49
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F-code Section C-code
P1.0
Introduction, Maintenance
Version no T-code
000 7BWS10/13
Jack only in these areas
Jack under frame
only. “DO NOT Jack
directly on mast.
Figure 0-1: Jacking Truck Off the Floor
1.2. Elevate Either Side of Truck
1. Place jack in the designated jacking position.
2. Jack the side of the truck so that the load wheel is
off the floor no more than 0.50 inch (12.7 mm).
3. Block the truck in place.
2. Lubricants
2.1. Standard
The standard conditioning truck is designed for operation in
temperatures down to 32 degrees F (0 degrees C).
Master Service Manual 2006-06-12 59
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F-code Section C-code
P2.0
Service Schedule
Version no T-code
000 7BWS10/13
2. Before replacing the brake disc see page 115.
2.3.5. Electrical Control System
Check tiller arm angle switches for adjustment (see
page 223).
Check for electrical shorts to chassis (see page 160.)
2.3.6. Battery
Check battery mounting bolt. Check freeplay in battery
mounting area.
2.3.7. Electrical Panel
Clean and check electrical panel mounting to chassis. Check
for connections in harness connectors. Check contactors for
welded conditions. Check contactor tips for free movement.
Clean operation of contactors for proper operation (see
page 237.)
2.3.8. Hydraulic System
Check the fluid level in the hydraulic reservoir (see
page 258). Check hoses and connections on the hydraulic
system for leaks. Repair or replace hoses if worn or
damaged. Check oil reservoir for cracks, leaks and mounting.
2.3.9. Mast
Check mast (see page 275) for damage and cracks. Check
clearance of rollers. Check lateral play of inner section.
Check for wear and adjustment of lift chains. Check chain
anchors and sheaves.
2.3.10. Lifting Devices
Inspect the fork carriage and forks for damage and cracks.
Master Service Manual 2006-06-12 69
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F-code Section C-code
S0.1 0300
Stabilizer Support Arms
Version no T-code
000 7BWS10/13
(Desired I.D.) Divided by (2) minus 12 = Distance
between Surface “A” and Surface “B”. (See
Figure 0-6.)
B A
Distance to Adjust
Figure 0-6: Support Arm Adjustment
8. Move one support arm outward until the width
calculated in step 7 is reached. Repeat this step for
the other support arm. Tighten bolts to 40 ft-lbs
(54.2 N•m) in a cross pattern for both arms.
9. Measure the distance between points “C” and “D”
as shown in Figure 0-7. If the measurement is less
than desired ID, adjust each support arm equally
until the desired ID is reached. Make sure
adjustments made to each arm are in equal
amount and are torqued to 40 ft-lbs (54.2 N•m)
before remeasuring. Make sure the distance
between points “A” and “B” on both support arms
are equal once desired ID is achieved.
10. Snug the adjustment bolts in a cross pattern in 40
ft-lbs (54.2 N•m) increments and continue in a
cross pattern until all bolts reach 180-200 ft-lbs
(244-271 N•m) It is very important that a cross
pattern is maintained in 40 ft-lbs (54.2 N•m)
increments and each bolt is torqued between 180-
200 ft-lbs (244-271 N•m) when finished.
11. Using a toe jack remove the blocks that were
installed under the frame one side at a time
returning the unit to the ground.
12. Using a carpenters level, check the mast again
ensuring it is plumb and level. See Figure 0-4.
Master Service Manual 2006-06-12 79
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F-code Section C-code
S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
4.1.2. Installation
WARNING When using compressed air, wear effective
chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
1. Thoroughly clean all parts with non-corrosive
cleaning fluid and air dry all parts.
2. Install pump/motor assembly in truck and secure
with bolts to truck frame. (For torque values see
page 47.)
3. Properly connect electrical power cables and coil
wiring, noting their positions recorded earlier. For
torque values see page 47.
4. Uncap and connect hydraulic hose to hydraulic
pump assembly.
5. Fill hydraulic reservoir with new clean oil (see
“Lubricants” on page 72).
6. Install battery and secure with mounting bolt, if
applicable (see page 203.)
7. Install truck cover(s) [see page 81].
8. Reconnect battery connector to the truck.
9. Remove wheel blocks.
10. Turn the main ON/OFF switch to the ON position.
Enter key code and press the press green ON
button (I) on the keypad.
11. Check the reservoir fluid level. Operate the truck’s
hydraulic system and check operation of system as
a whole. Inspect for leaks.
Master Service Manual 2006-06-12 89
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F-code Section C-code
S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
Transmission
Transmission
TransmissionMounting
Mounting
3 5
2 4 7
1 6 9
23
8
10
11
22 12
13
25 14
10 11
24
15
16
17
18
20 21
19
Master Service Manual 2006-06-12 99
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F-code Section C-code
S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
17. Install truck covers (4, 8) as shown on page 81.
18. Reconnect battery connector to the truck.
19. Turn the main ON/OFF switch to the ON position.
Enter key code and press the press green ON
button (I) on the keypad.
Master Service Manual 2006-06-12 109
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F-code Section C-code
S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
Figure 3-4: Support Arm Toe Jack Positioning
7. Visually inspect lug nuts for signs of being loose.
Inspect studs to see if one or more studs protrude
through the lug nut farther than the others. If either
condition exists, proceed as follows.
8. Loosen lug nuts to finger tight. If one or more studs
turn while loosening the lug nuts, proceed as
follows.
9. If any of the studs appear damaged, replace studs.
NOTE! The installation procedure of the studs,
wheel and lug nuts must be completed in
less than 0.50 hour to ensure the thread
locking compound does not start to set up
before the installation is complete.
10. Remove and clean studs.
11. Install two lug nuts, jammed together, to the end of
the stud. This will allow the tightening of the studs
using a torque wrench.
12. Apply Loctite 290® thread-locking compound to
studs.
Service Manual 2006-06-12 119
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F-code Section C-code
S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13
Tiller Arm Handle
3 5
2 4 7
1 6 9
23
8
10
11
22 12
13
25 14
10 11
24
15
16
17
18
20 21
19
Master Service Manual 2006-06-12 129
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F-code Section C-code
S4.2 4180
Steering Bearing
Version no T-code
000 7BWS10/13
Steering Bearing
1
2
3
4
5
Item No. Description
1 Screw
2 Lockwasher
3 Bearing
4 Stop, steering
5 Transmission assembly
Master Service Manual 2006-06-12 139
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F-code Section C-code
S5.0 5000
Electrical Functions
Travel, Low Speed Version no T-code
000 7BWS10/13
B+ Circuit B- Circuit Signal Pre-Charge Voltage
NOTE: Electrical schematics are found in Appendix A starting on page 302.
Master Service Manual 2006-06-12 149
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F-code Section C-code
S5.0 5000
Electrical Functions
Version no T-code
000 7BWS10/13
2. Maintenance
Connections must be kept clean and tight. The electrical
components should be protected from moisture.
2.1. Wiring
Many electrical problems are caused by a bad or dirty battery.
Make sure battery is clean. Check the electrolyte level and
battery level.
CAUTION Unless otherwise directed, disconnect
battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Visually inspect all wiring and electrical components for the
following:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips
• Broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
Use an ohmmeter to check for wiring continuity.
2.1.1. Definitions
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than one megohms.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called “chopping,” controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
Overtemperature. Overtemperature of the transistor
controller is from 185 degrees F (85 degrees C) and above.
At overtemperature, the drive current limit is linearly
decreased from full set current down to zero. Plug current is
Master Service Manual 2006-06-12 159
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F-code Section C-code
S5.0 5000
Electrical Functions
Version no T-code
000 7BWS10/13
Wire 24
Wire 50
Switch S24
Wire 51
Switch S25
Wire 24
Figure 5-6: Stem Mount Switch Wiring
15. Refer to Figure 5-3 on page 166 when installing
ring terminals. Install ring terminal and secure
middle nut and torque to 79 in-lbs (8.9 N•m). Install
ring terminal and secure outer nut, making sure
wire is out of the way, before torquing outer nut to
79 in-lbs (8.9 N•m).
16. Install the up-stop (see Figure 5-4 on page 167)
and truck covers.
17. Reconnect battery connector to the truck.
18. Turn the main ON/OFF switch to the ON position.
Enter the key code and press the green ON button
(I) on the keypad or turn the key switch ON.
19. Check all operating functions on the tiller arm
handle.
Master Service Manual 2006-06-12 169
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F-code Section C-code
S5.0 5000
Electrical Functions
Version no T-code
000 7BWS10/13
Service Parameters
Parameters 1-7 (driver number) are Driver Parameters, 10-40 are Service Parameters
Parameter Name Unit Range Step Default Description
39 Access 1 to 4 1 3 Defines whether truck has key switch or
code keypad and what access level personnel
will have to parameters
1=key switch/operator parameters open
2=key switch and closed
3=keypad and open
4=keypad and closed (when closed,
service key is required to access driver
parameters)
All other Not defined 0 0 0 Not used (always 0)
parameter
numbers not
listed above
3.5.1. Parameter Description
Parameter 1
Maximum speed value sent to transistor controller while in
Slow mode except during turtle torque (gives torque boost if
high load is encountered).
Parameter 2
Reduces speed value sent from the Electronic Tiller Arm
Card (ETAC) to the transistor controller while in Fast mode
(all throttle positions).
Parameter 3
Defines truck’s acceleration characteristic when truck starts
from a stop. A high number gives maximum acceleration, a
lower number gives less aggressive acceleration.
Parameter 4
Defines truck’s automatic plug-braking characteristic when
throttle is reduced (including to neutral). A lower number
gives less aggressive acceleration.
Parameter 5
Time until the truck is switched OFF (energy saving feature)
when truck is idle and the brake is applied. Time is counted
from the latest power output is requested. If truck has the
key switch option, the truck never powers OFF.
Master Service Manual 2006-06-12 179
--- Page 22 ---
F-code Section C-code
S5.0 5000
Electrical Functions
Version no T-code
000 7BWS10/13
Code E104 - Brake Power Error
Reason Transistor controller could not detect presence of brake coil.
Possible Causes 1. Open circuit in brake circuit.
with corrective a. Check brake and wiring.
actions/checks 2. Master control relay missing or stuck open.
3. Main contactor open circuit (especially after it has closed).
4. Communication error due to transistor controller handset.
a. Unplug handset from transistor controller, allow handset to completely boot
before turning truck ON.
5. Bad transistor controller.
a. Check transistor controller for error code.
Code E106 - Digital Output or Field Overcurrent
Reason Transistor controller attempted to deliver more current than allowed to main contactor
coil; traction motor field winding, or digital output.
Possible Causes 1. Short circuit in transistor controller output circuit.
with corrective a. Check main contactor coil, traction motor field winding, digital output and
actions/checks associated wiring.
b. Replace transistor controller.
Code E110 - Braking System Fault
Reason Transistor controller detected problem with braking functions.
Possible Causes 1. Short circuit in brake circuit.
with corrective a. Check brake and wiring.
actions/checks 2. Bad transistor controller.
a. Check transistor controller for error code.
Code E112 - Arm Angle Sequence Fault
Reason Improper sequence of arm angle inputs.
Possible Causes 1. Arm angle input stuck on or off.
with corrective 2. Problem with tiller arm angle input wiring.
actions/checks 3. Problem with tiler arm.