7bws10-13 repair manual cl3ws-06.pdf

Master Service Manual
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and covers are
properly secured in place.
Warning
Warning
Part no: 00700-CL3WS-06 Date: June 12, 2006
7BWS10/13
Electric Walkie Low-Lift Pallet Truck
Effective Serial Number 40500 - UP
Front Cover

© Copyright 2006 by Toyota Industrial Equipment
All rights reserved. No portion of this manual may be reproduced mechanically, electronically
or by any other means, including photocopying, electronic retrieval or transfer, or recording
without the written permission of the publisher.
Toyota Industrial Equipment believes the information in this manual is accurate and current as of
the publication date; such information is subject to change without notice. Toyota Industrial
Equipment is not responsible for any errors that may appear in the manual.

Ordering Spare Parts
F-code Section C-code
Version no T-code
000 7BWS10/13
1
2006-06-12
Supply the following information will assure prompt, efficient
handling of the order:
1. Identify truck model and serial number.
2. Refer to Parts Book and locate page with the
exploded diagram.
3. Find item number for the part required. Select the
column for the actual truck model and serial
number.
4. The following is an explanation of a serial number:
5. Note part number.
6. Call your local Toyota Dealer and state part
number.
7. If the truck model, serial number, or article number
cannot be found on the truck, call your local
Toyota Dealer for assistance.
Although some trucks appear to be similar,
component parts may not be
interchangeable. If an incorrect part is
used, the truck may malfunction.
7BWS10 40500
Truck number
Capacity 10-2000 lbs
Model (7BWS)
13-2500 lbs
CAUTION

000 7BWS10/13
Version no T-code
2 2006-06-12
This page is intentionally left blank.

Table of Contents
3
Master Service Manual 2006-06-12
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

Table of Contents
5
Support Arm Width Adjustment .................................................................................... 76
Inspection, Covers ....................................................................................... 81
Maintenance ......................................................................................................... 82
Troubleshooting .................................................................................................... 82
Repair and Rebuild ............................................................................................... 82
Decals ............................................................................................................ 83
Decal with Protective Sheet ................................................................................. 83
Decal without Protective Sheet ............................................................................ 83
Electric Motors .............................................................................................. 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
Maintenance ........................................................................................................ 114
Mechanical Brake Release .......................................................................................... 114
Brake Adjustment ........................................................................................................ 114
Drive Wheel .................................................................................................. 117
Maintenance ........................................................................................................ 118
Drive Wheel Nut Inspection ......................................................................................... 118
Load Wheels ................................................................................................ 125

Table of Contents
Maintenance ....................................................................................................... 126
Troubleshooting .................................................................................................. 126
Repair and Rebuild ............................................................................................. 126
Tiller Arm Handle ........................................................................................ 129
Maintenance ....................................................................................................... 131
Inspection .................................................................................................................... 131
Tiller Arm Head ............................................................................................ 135
Maintenance ....................................................................................................... 137
Steering Bearing ......................................................................................... 139
Maintenance ....................................................................................................... 140
Electrical Functions .................................................................................... 141
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 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

Table of Contents
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
Maintenance ........................................................................................................ 199
Inspection and Care .................................................................................................... 199
Exterior Cleaning ......................................................................................................... 200
Charging ...................................................................................................................... 200
Storage ........................................................................................................................ 201
History Record ............................................................................................................. 202
Swing Out Battery Pack .............................................................................. 205
Maintenance ........................................................................................................ 210
Electrical Testing ......................................................................................................... 210
Required Equipment .............................................................................................. 210
Instructions ............................................................................................................. 210
Battery Connector ....................................................................................... 217
Maintenance ........................................................................................................ 217
Inspection .................................................................................................................... 217
Switches ....................................................................................................... 221
Maintenance ........................................................................................................ 223
Main ON/OFF Switch ................................................................................................... 225
Arm Angle Switches .................................................................................................... 225
Key Switch (Optional) .................................................................................................. 227
Horn Switch ................................................................................................................. 227
Converting Keypad to Key Switch ............................................................................... 227
Fuses ............................................................................................................ 229
Maintenance ........................................................................................................ 229

Table of Contents
Wiring Harness ............................................................................................................ 230
Power Cables .............................................................................................................. 231
Master Control Relay ................................................................................................... 232
Contactor Panel ........................................................................................... 235
Maintenance ....................................................................................................... 237
Resistance Testing ...................................................................................................... 237
Transistor Controller .................................................................................. 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
Diagnostics and Troubleshooting ................................................................................ 245
Fault Codes ................................................................................................................. 245
Electronic Tiller Arm Card (ETAC) ............................................................. 249
Lift Cutout. ................................................................................................................... 251
Maintenance ....................................................................................................... 251
Hydraulic System ........................................................................................ 253
Lift ................................................................................................................................ 254
Lower ........................................................................................................................... 255
Relief Pressure ............................................................................................................ 256
Maintenance ....................................................................................................... 257
Changing Hydraulic System Fluid ............................................................................... 257
Hydraulic Pump Pressure Relief Valve ....................................................................... 259
Troubleshooting Chart Index ....................................................................................... 260
Troubleshooting Charts ............................................................................................... 260
Hydraulic Unit .............................................................................................................. 265
Reservoir ..................................................................................................................... 266

Table of Contents
9
Filter Screen and Inlet Tube ........................................................................................ 267
Lift Pump ..................................................................................................................... 268
Lift Cylinder .................................................................................................. 269
Maintenance ........................................................................................................ 270
Inspection .................................................................................................................... 270
Mast .............................................................................................................. 275
Maintenance ........................................................................................................ 275
Visual Inspection ......................................................................................................... 275
Lift Chain Inspection .................................................................................................... 275
Lift Chain Lubrication ................................................................................................... 280
Lift Chain Adjustment .................................................................................................. 281
Mast Guides/Dampers Adjustment .............................................................................. 281
Forks ............................................................................................................. 297
Maintenance ........................................................................................................ 298
Inspection .................................................................................................................... 298
Appendix ...................................................................................................... 301

Table of Contents

Standard Codes
Version no T-code
000 7BWS10/13
11
2006-06-12
Standard Codes
B-Code = Business area
F-Code = Product family
T-Code = Product type
C-Code = Component function
Worksheet standard
W-Code = Working code
R-Code = Reason code
SO-Code = Assortment
F-Code List
T-Code List
No. Model
7BWS10/13
C-Code List
No Function Group C-Code
0 Chassis / Frame 0000
1 Motors 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Mast / Cylinders 7000
8 Peripheral / Installation Equipment 8000
9 Optionals / Attachments 9000
10 Tools 10000

000 7BWS10/13
Version no T-code
Standard Codes
12 2006-06-12

Warning Symbols
Version no T-code
001
13
Warning Symbols
Always follow the warnings given in this Service Manual
and on the truck to avoid accidents from occurring.
1. Warning Levels
Warning levels
Warning text is given in four levels and provide information on
the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of a accident or breakdown if the
instructions are not followed.

001
Version no T-code
Prohibitory Symbols
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
OPEN FLAMES PROHIBITED
If open flames are used in situations where open flames are
prohibited, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.

Safety
Version no T-code
001
15
Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operator’s Manual.
Know the truck controls and what they do.
Do NOT operate truck if it needs repair or if it is in any way
unsafe.

001
Version no T-code
Safety
Operate truck only from the position of the operator.
Before working on this truck always press the red OFF (O)
key on the keypad and disconnect truck battery connector
(unless this manual states otherwise).
Do NOT wear watches, rings, or jewelry when working on this
truck.

Safety
Version no T-code
001
17
Follow the scheduled lubrication, maintenance, and
inspection steps.
Follow exactly the safety and repair instructions in this
manual. Do NOT take “shortcuts”.
Do NOT Use an open flame near the truck.
Do NOT use gasoline or other flammable liquids for cleaning
parts.

001
Version no T-code
Safety
Clean up any hydraulic fluid, oil, or grease that has leaked or
spilled on the floor.
Always operate and park truck indoors.
Do not park truck in a cold storage area overnight.
Do NOT wash truck with a hose.

Safety
Version no T-code
001
19
Do NOT add to or modify truck without written approval from
Toyota

001
Version no T-code
Battery Safety
Battery Safety
Read, understand and follow procedures, recommendations
and specifications available by the battery and battery
charger supplier.
As a battery is being charged, an explosive
gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
WARNING
WARNING

Battery Safety
Version no T-code
001
21
Wear personal protective equipment to protect eyes, face,
and skin when checking, handling, or filling batteries. This
equipment includes goggles or face shield, rubber gloves
(with or without arm shields) and a rubber apron.
Make sure a shower and eyewash station are nearby in case
there is an accident.
A battery gives off explosive gases. Never smoke, use an
open flame, or use anything that gives off sparks near a
battery.

001
Version no T-code
Battery Safety
Keep the charger area well-ventilated to avoid hydrogen gas
concentration.
Press the red OFF (O) key on the keypad before
disconnecting the battery from the truck at the battery
connector. Do NOT break live circuits at the battery terminals.
A spark often occurs at the point where a live circuit is
broken.
Do NOT lay tools or metal objects on top of battery. A short
circuit or explosion could result.
Keep batteries clean. Corrosion causes shorts and possibly
sparks to the frame.

Battery Safety
Version no T-code
001
23
Keep plugs, terminals, cables, and receptacles in good
condition to avoid shorts and sparks.
Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.
Do NOT allow cleaning solution, dirt, or any foreign matter to
enter the cell.
Filler
Plugs
Cable
Filler Plug Vent Hole

001
Version no T-code
Battery Safety
Make sure to install the correct size and weight battery. A
smaller or lighter weight battery could seriously affect truck
stability. See the truck specification (data) plate for more
information.
Never plug a battery charger into the truck battery connector.
Plug battery charger ONLY into battery connector from
battery.
Follow the charging procedures available by the supplier on
the “Battery” and “Battery Charger”.

Static Discharge Precautions
Version no T-code
001
25
Electronic circuit board and devices used on the truck can be
damaged by the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal operation of the
truck as well as movement or contact between non-
conductive materials such as plastic bags, synthetic clothing,
synthetic soles on shoes, styrofoam coffee cups, etc.
Accumulated static can be discharged through human skin to
a circuit board or component by touching the parts. Static
discharge is also possible through the air when a charged
object is placed close to another surface at a different
electrical potential. Static discharge can occur without
seeing or feeling it.
Whenever working on or near static-sensitive electronics,
always use static discharge precautions.
1. Static-sensitive items are to remain in their
protective containers except when actually in use
at the static-free station.
2. Before removing the item(s) from their protective
container, the operator should place the container
on the conductive grounded bench top. Make sure
the wrist strap fits snugly around the wrist and is
properly plugged in/attached to ground receptacle
or the truck. The operator should then touch hands
to the conductive bench top, workstation, or truck.
3. All operations should be performed with the items
in contact with the truck or grounded bench top.
4. Do not allow conductive magazine (static-sensitive
items) to touch hard-grounded test gear or bench
top.
5. Ordinary plastic solder-suckers and other plastic
assembly aids should not be used.
6. In cases where it is impossible or impractical to
ground the operator with a wrist strap, a conductive
shoe strap can be used along with conductive tile/
mats.

001
Version no T-code
7. When the operator moves from any other place to
the static-free station, the start-up procedure
should be the same as the preparation for working
at a static-free workstation.
8. “Plastic snow” polystyrene foam, peanuts, or other
high-dielectric materials should never come in
contact with or be used around electrostatic
sensitive items, unless they have been treated with
an antistatic compound. Such treatment is often
indicated by a pink color on the foam material.
9. Static-sensitive items should not be transported or
stored in trays, tote boxes, vials, or similar
containers made of untreated plastic material
unless items are protectively packaged in
conductive material.

Welding Safety
Version no T-code
001
27
Welding Safety
Before working on the truck, make sure of the following:
• Fire protection equipment is nearby.
• Know where the nearest eyewash station is located.
Flame cutting or welding on painted
surfaces may produce potentially harmful
fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where the
operation(s) will be performed.
Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting and/
or welding operations should be carried out
in well ventilated areas using local exhaust
if necessary.
WARNING
WARNING

001
Version no T-code
Welding Safety
• Check for shorts to frame. If any shorts are detected,
remove before proceeding with the welding operation.
• Clean the area to be welded.
• Protect all truck components from heat, weld spatter and
debris.
• Attach the ground cable as close to the weld area as
possible.
• Disconnect all electrical cards before any type of electric
resistance welding is done.
• Only trained, qualified, and authorized personnel should
weld on the truck.
• Do not perform any welding operations near the electrical
components.
• If welding must be done, disconnect and remove the
battery from the truck.
• When welding is completed, perform all ground tests and
electrical inspections before the truck is operated.
Disconnect battery before attempting to
inspect, service or repair truck. Discharge
residual charge in the transistor controller
by connecting a load across the transistor
controllers B+ and B- terminals (such as a
contactor coil or by pressing the horn
button).
CAUTION

Introduction, Service Manual
M
Version no T-code
000 7BWS10/13
29
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

M
000 7BWS10/13
Version no T-code
30 2006-06-12

Contents, Section M
M
Version no T-code
000
31
Contents, Section M
1. Machine Information
M1.0 GENERAL PRODUCT INFORMATION
M2.0 TECHNICAL SERVICE DATA

M
000
Version no T-code
Contents, Section M
32 2006-06-12

General Product Information
M1.0
Version no T-code
000 7BWS10/13
33
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.
1.2. Intended Truck Application
The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.
Right Side
Left Side
Tractor-first Forks-first

M1.0
000 7BWS10/13
Version no T-code
34 2006-06-12
1.3. Prohibited Truck Application
The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
• As a towing tractor for trailers.
• To tow other trucks.
• To transport/lift passengers.
• To drive on gravel or grass.
1.4. Truck Data
The following table provides information regarding technical
data which is of value with daily use of the trucks. Lifting
capacity and weight can be found on the truck’s data plate
(see page 36).
Metric dimensions and capacities are shown in parenthesis
and have been rounded for convenience.
Truck Data 7BWS10/13
Traveling speed mph (kph)
Without Load
0 - 3.6 mph
(0 - 5.7)
Loaded
0 - 3.4 mph
(0 - 5.4)
Service weight, lb (kg)
Without battery
1610 - 1875
(730 - 850)
With battery
1910 - 2425
(866 - 1100)

M1.0
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000 7BWS10/13
35
1.5. Dimensions
The following diagram shows external dimensions for the
7BWS10/13 truck in its standard design.
R
E
H
P
D B
C
A
S
V
U
J
L
M
N
Q
W
F
T
X
G
K
T
A = 58.9 inch (1496 mm) J = 48.6 inch (1234 mm) S = 3.9 inch (99 mm)
B = 47.0 inch (1194 mm) K = 24.2 inch (615 mm) T = 10/31.5 inch (254/800 mm)
C = 21.0 inch (553 mm) L = 10.0 inch (254 mm) U = 6 inch (152 mm) [Fork Free Lift Height]
D = 7.2 inch (183 mm) M = 27.3 X 7.8 inch (693 X 198 mm) U = 128 inch (3251 mm) [Max Fork Height]
E = 33.2 inch (843 mm) N = 1.6 inch (41 mm) V = 2.0 inch (51 mm)
F = 54.2 inch (1377 mm) P = 4 inch (100 mm) W = 84 inch (2134 mm)
G = 28.0 inch (711 mm) Q = 32 to 51 inch (813 to 1295 mm) X = 168 inch (4267 mm)
H = 32.8 inch (833 mm) R = 40 to 59 inch (1016 to 1499 mm)
G
P
Q
W
R
J
X
H
U
L
B
V
S
C
A
D
N
K
8°
38°
87°
35°
6°
E
M
F
41°

M1.0
000 7BWS10/13
Version no T-code
36 2006-06-12
Battery packs available from the factory.
1.6. Data Plate
The illustration shows the data plate used on this truck.
Battery Pack Dimension Specifications
24 Volt Battery Pack Amp Hour Length Width Height Weight
Swing-out Upper Trays
with 15 amp charger
152
26.5 inch
(675 mm)
7.5 inch
(192 mm)
26.45 inch
(672 mm)
330 lbs (150 kg)
GNB PalletPro™
with 25 amp charger
195
26.5 inch
(675 mm)
7.5 inch
(192 mm)
26.25 inch
(665 mm)
375 lbs (171 kg)
Legend
1 Truck model number 7 Minimum battery weight
2 Truck serial number 8 Maximum battery weight
3 Truck type 9 Battery maximum AMP hours
4 Truck weight (less battery) 10 Hour Rate
5 Attachment 11 Truck voltage DC
6 Truck lifting capacity 12 Battery type UL class
1 2
3 4 5
6
7 8
9 10 11 12
C
A
B

M1.0
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2. Main Components
1. Tiller Arm:
The truck is to be controlled by the operator with 180 degree
steering angle. The brake is applied in the upper and lower
position of the tiller arm head.
2. Hydraulic unit:
Pump motor, pump, electric valve and oil tank reservoir
integrated in a compact unit.
3. Hydraulic lowering valve:
For controlling lifting and lowering functions with hydraulic
lowering valve.
4. Battery:
24 volt with different capacities and weights.
5. Drive unit with brake:
Drive unit with a spring-loaded electromagnetic brake, drive
motor, drive wheel, and transmission assembly. The steering
bearing is located at the top of the drive unit.
6. Steering pivot point.
7. Data plate:
See data plate on page 36.
8. Operator Display:
Display includes hourmeter, error codes, parameters, hardware
and software part numbers.
9. Electrical panel:
24 volt electrical system. Truck speed is regulated by means of
a transistor controller.
10.Fuse:
10A, Fuse Keypad and ETAC (supplied with main harness)
10A, Fuse Main ON/OFF (supplied with main harness)
130A, Fuse (one for drive motor and one for pump motor)
11.Load wheel:
The load wheels have seals on the outside of the bearings to
protect them in wet environments.
12.Keypad:
Enter PIN-key code in the keypad and press green ON (I) key
on the keypad starts truck. Press red OFF (O) on the keypad to
shut off electrical power to the control system. Up to 10 drivers
can be assigned their own individual PIN-key code for access
to the truck.
13.Main ON/OFF Switch:
The main ON/OFF switch will cut off all electrical power to the
control functions on the truck when pressed.

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14.Travel speed / direction selection:
To select direction, rotate thumb controls in the direction of
travel. The further you rotate in that direction the faster the
travel.
15.Fork lower switch:
Forks will lower when switch is pressed or until mast reaches
the top. Then, if dead headed, the relief valve relieves the
pressure.
16.Fork raise switch:
Forks raise when switch is pressed or until mast reaches the
top. Then, if dead headed, the relief valve relieves the
pressure.
17.Horn switch:
Activates horn to warn others of your position. Horn button is
also used to cycle through special truck mode displays (see
page 170).
18.Battery Connector:
Disconnects off all electrical power to the truck.
19.Mast Guard.
20.Baselegs:
Adjustable in width from 32 to 51 inch (813 to 1300 mm).
2, 3
5
8
9, 10
7
12
11
4
6
13
1
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
O
0
I

Inch (SAE) and Metric Fasteners
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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.
5 9 10
5 9 10

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2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below). The
diameter of shank of fastener is shown first in the series, e.g.
M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4 inch).
The number of threads per inch is normally not shown for inch
nomenclature and only UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
Inch Metric
1/2 x 13 UNC x 1-1/2
A B C D
M12 x 1.75 x 50
A B C
A =Shank diameter
B =Number of threads per unit of length
C =Type of thread
D =Shank length
A =Thread size
B =Pitch
C =Length

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3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
then 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show marks that identify grades and property
classes for different fasteners.
When fasteners must be replaced new
fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE! Identification marks are according to bolt
strength. The higher the number, or
increase in number of marks, indicates
increased bolt strength.
WARNING

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Table 1. Bolt and Screw Designations
Types of
Fasteners
Inch Fasteners
Strength Levels: SAE Grades
Metric Fasteners
Strength Levels: Property Classes
* Markings Not Required
Markings
Hex Head Bolts
& Cap Screws
Hex Head
Flange Screws
Same As Above
12 Point
Flange Screws
Markings Not Required
Hex Socket Head
Cap Screws
Sems
for size
M5 and
Larger
2 5 7 8
5 8
5 8
5.1
4.8* 9.8
8.8 12.9
4.6* 4.8* 5.8* 8.8
9.8 10.9 12.9
4.6 4.8 5.8 8.8
9.8 10.9 12.9
8.8 12.9
4.8 9.8
5.2

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Table 2. Stud and Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
5*
Studs
5.2*
8* 8.1
Hex Nuts
Hex Slotted Nuts
Hex Flange Nuts
2 5 8
or or
5 8 9
10 12
5 8 9 10 12
5 8 9 10 12
5 8 9 10 12
5 8 9 10 12
5
5
8
8
9
9
12
12
10
10
or
4.6* 4.8* 5.8* 8.8
9.8 10.9 12.9
Optional Geometric Symbols for
Size M5 through M11.
Markings
for size
M5 and
Larger
4.6 4.8 5.8 8.8
9.8 12.9
10.9

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Table 3. Torque Nut Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
All Metal Prevailing
Torque Nuts
or
or
or
All Metal Prevailing
Torque Flange Nuts
B
A C
B C
5 9 10
9 10
F G
5 9 10
9 10

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Table 4. Torque Nut with Nylon Insert Designations
Types of
Fasteners
Inch Fasteners
Metric Fasteners
Nylon Insert Pre-
vailing Torque
Nuts
Nylon Insert Pre-
vailing Torque
Flange Nuts
or
9 10
9 10
5 9 10
5 9 10
or
or
or

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Table 5. Fastener Torque Values
* Property class 8.8, Protective Treatment CMHC
Specification “H” (zinc phosphate), applies also to
internally threaded fasteners made of property
class 8 material.
** Property class 10.9, Protective Treatment CMHC
internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC
internally threaded fasteners of property class 12
material.
Size and
Pitch
Property, Class
8.8*
Property, Class
10.9**
Property, Class
12.9***
N•m in-lbs N•m in-lbs N•m in-lbs
M5 x 0.8
M6 x 1
M8 x 1.25
5-6
8-10
20-25
44-53
71-88
177-221
7-8
12-14
30-35
62-71
106-124
265-309
8-10
14-16
------------
71-88
124-142
------------
Size and
Pitch
N•m ft-lbs N•m ft-lbs N•m ft-lbs
M8 x 1.25
M10 x 1.5
------------
40-45
------------
30-33
29-35
60-65
22-26
44-48
34-40
70-75
26-30
52-55
M12 x 1.75
M14 x 2
70-80
110-125
30-33
52-59
100-110
155-180
74-81
114-133
115-130
180-210
85-96
133-155
M16 x 2
M20 x 2.5
170-190
340-380
125-140
251-280
240-270
450-500
177-199
332-369
280-320
550-600
207-236
406-443
M24 x 3 580-650 428-479 800-900 590-664 900-1050 664-774
M30 x 3.5 1150-1300 848-959 1600-1800 1180-1328 1850-2100 1364-1549
M36 x 4 2000-2250 1479-1660 2800-3150 2065-2323 3250-3700 2397-2729

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4. Truck Torque Specifications
Description Torque Specification
Drive motor end cover bolts 50 in-lbs (5.6 N•m)
Gear case cover mounting bolts 200 in-lbs (22.6 N•m) (sealant, see page 107)
Drive wheel lug nuts 55 ft-lbs (74.6 N•m)
Drive wheel studs 23 - 28 ft-lbs (32-38 N•m) Loctite 290®
Drive unit assembly 30 - 33 ft-lbs (40-45 N•m)
Steering bearing 336 - 384 in-lbs (38.0-43.4 N•m)
Stem mount nut 79 in-lbs (8.9 N•m)
Friction disc mounting bolts 50 in-lbs (5.6 N•m)
Electrical panel screws 48 - 60 in-lbs (5-7 N•m)
Hydraulic motor contactor coil nut 30 - 40 in-lbs (3.4-4.5 N•m)
Hydraulic reservoir clamp 48 - 60 in-lbs (5.5-7 N•m)
Hydraulic unit mounting bolts 20.5 - 24 ft-lbs (28-33 N•m) Loctite 243®
Hydraulic motor to adapter body 96 - 120 in-lbs (10.8-13.6 N•m)
Pump to adapter body nut 100 - 134 in-lbs (11.3-15.0 N•m)
Baseleg bolts 180 - 200 ft-lbs (244-271 N•m)
Support arm bolts 40 ft-lbs (54.2 N•m)
Truck bumper bolts 246 - 283 in-lbs (27.8-32.0 N•m)
Mast mounting bolts 140 - 150 ft-lbs (190-203 N•m)

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5. Conversion of Metric and English
Units
AREA
Multiply By To Get Multiply By To Get
inches² 6.451 centimeters² (cm²) centimeters² 0.155 inches² (in²)
feet² 0.093 meters² (m²) meters² 10.764 feet² (ft²)
LINEAR
inches 25.4 millimeters(mm) millimeter 0.03937 inches (in)
feet 0.305 meters (m) meter 3.280 feet (ft)
yards 0.914 meters (m) meter 1.094 yards (yd)
miles 1.609 kilometers (km) kilometer 0.621 miles (mi)
MASS
ounces (oz) 28.49 grams (g) grams 0.035 ounces (oz)
pounds (lb) 0.454 kilograms (kg) kilograms 2.205 pounds (lb)
tons (2000 lb) 907.18 kilograms (kg) kilograms 0.001 tons (2000 lb)
tons (2000 lb) 0.907 metric ton (t) metric ton 1.102 tons (2000 lb)
POWER
horsepower 0.746 kilowatts (kW) kilowatts 1.34 horsepower (hp)
PRESSURE
pounds/in² 6.895 kilopascal (kPa) kilopascals 0.145 pounds/in² (psi)
pounds/in² 0.007 megapascal (MPa) megapascals 145.04 pounds/in² (psi)

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TEMPERATURE
(Fahrenheit
-32)
0.56 Celsius (C) (Celsius x 1.8) +32 Fahrenheit (F)
TORQUE
inch pound 0.113 Newton meter (N•m) Newton meter 8.851
inch pounds
in-lbs
feet pound 1.356 Newton meter (N•m) Newton meter 0.738
foot pounds
ft-lbs
VELOCITY
miles/hour 1.609
kilometer/hour
(km/h)
kilometer/hour 0.621
miles/hour
(mph)
VOLUME
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. 3.785 liters liters 0.264
gallons, U.S.
(gal)
gallons, U.S. 0.83 gallons, Imp. (gal) gallons, Imp. 1.205
gallons, U.S.
(gal)
ounces 29.57 milliliters (ml) milliliters 0.034 ounces (oz)

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Technical Service Data
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NOTE! When the battery is fully charged,
performance may vary due to motor and
system efficiency tolerance. Technical
service data represents nominal values
obtained under typical operating conditions.
Specifications are subject to change
without notice.
DRIVE UNIT
Type Shunt wound
Power - horsepower [hp] (kilowatts [kW]) 1.2 (0.90)
Duty factor 1 hour
Min carbon brush length - inch (mm) 0.59 (15)
Min commutator diameter - inch (mm) 1.85 (47)
Min brush - ounce-force (N•) 44.8 (12.4)
Gear ratio 22:1
Oil volume, oz (liter) 13.5 (0.4)
Standard operation (see page 59)
temperature down to 32° F (0° C)
Mobil-1 Synthetic Gear Lube 75W-90
or Texaco Synstar GL 75W-90
WHEELS
Drive wheel - inch (mm) 10.0 x 5.0 (255 x 125)
Drive wheel % load distribution without load
(7.8” battery compartment 128” LFL Mast
(7.8” battery compartment 128” FFL Mast
7BWS13
62%
64.3%
64.4%
Drive wheel % load distribution with maximum load
7BWS13
29%
30.2%
27.6%
Torque drive lug nut, ft-lbs (N•m) 55 (74.6)
Load wheel - inch (mm) 4.0 x 3.0 (101 x 76)

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LOAD WHEELS
Percent load distribution without load
7BWS13 (EACH WHEEL)
19%
17.8%
17.8%
LOAD WHEELS
Percent load distribution with maximum load
7BWS13 (EACH WHEEL)
35.5%
34.9%
36.2%
HYDRAULIC UNIT
Power - horsepower [hp] (kilowatts [kW]) 4 (3)
Duty factor 20% on 5 min. cycles
Minimum brush length - inch (mm) 0.59 (15)
Minimum commutator diameter - inch (mm) 1.89 (48)
Minimum brush spring tension - ounce-force (N•) 36 (10)
Relief pressure - psi (bar) 3100 (213)
Pump flow 2.0 cc
Tank volume - gallons (liters) 1.3 (5)
Standard operation (see page 59)
temperature down to 32° F (0° C)
Union 76 TH
FUSES
Keypad and ETAC Fuse 10 Amp
Control Circuit Fuse 10 Amp
Drive Motor Fuse 130 Amp
Pump Motor Fuse 130 Amp
BATTERIES
Compartment Dimension L x W - inch (mm)
27.3 x 6.8 (693 x 172) Optional
27.3 x 7.8 (693 x 198) Standard
27.3 x 9.0 (693 x 228) Optional
Capacity (recommended Max. Amp-hrs.) 255

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Weight (Minimum) - lbs (kg) 330 (150)
Weight (Maximum) - lbs (kg) 375 (171)
Lead length - inch (mm) 18 (457)
Lead position B
DRIVING SPEEDS (FORKS DIRECTION)
Without load - mph (kph) 3.6 (5.7)
With rated load - mph (kph) 3.4 (5.4)
LIFTING/LOWERING TIME (128 inch LFL [3251 mm] mast)
Lift without load (fpm) 41
Lift with rated load (fpm) 22
Lower without rated load (fpm) 44
Lower with rated load (fpm) 48
AVERAGE CURRENT READINGS
Driving without load (with truck on level floor) 17 Amps
Driving with rated load (with truck on level floor) 30 Amps
Lifting without load 61 Amps
Lifting with rated load 130 Amps

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Contents, Section P
P
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55
Contents, Section P
1. Planned Maintenance
P1.0 INTRODUCTION, MAINTENANCE
P2.0 SERVICE SCHEDULE
P3.0 LUBRICATION CHART
P4.0 OIL AND GREASE SPECIFICATIONS

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Introduction, Maintenance
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The schedule of maintenance and lubrication given in this
section of the service manual cover up to one year’s
operation of the truck. These schedules are based on hourly
usage and can be adapted to suit most schedules. The
following hourly usage figures have been used when
calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The “Planned Maintenance Schedule” on page 61 is
based on the single shift schedule. The schedules are
intended only as a guide, not as a rigid structure. Owners of
the trucks may wish to adapt to local requirements; but it is
emphasized that the schedules represent minimum
manufacturer requirements, and all items should be included
in a service program to ensure minimum downtime and a high
status of the equipment.
• Use spare parts approved by Toyota.
• Always clean the equipment and carry out a full
check after service.

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1. Jacking Truck Off The Floor
To perform maintenance that requires the truck to be lifted
from the floor, observe the proper precautions as follows:
1. Lower the forks completely. Remove any load.
2. Press the red OFF (O) key on the keypad.
Disconnect battery connector from the truck.
3. If possible, stabilize the top of the mast with an
overhead chain hoist.
4. Position the jack under the designated jacking
points.
1.1. Elevate Rear of Truck
1. Place jack in the designated jacking position.
2. Jack the truck so that the drive tire is off the floor
no more than 3.0 inch (76 mm).
3. Block the truck in place.
Use extreme care whenever the truck is
jacked up for any reason. Never block the
truck between the mast column and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath the truck while jacking. After the
truck is jacked, position solid blocks
beneath it to support it. DO NOT rely on the
jack alone to support the truck.
WARNING

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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).
Figure 0-1: Jacking Truck Off the Floor
Jack only in these areas
Jack under frame
only. “DO NOT Jack
directly on mast.

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Service Schedule
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Service Schedule
1. Planned Maintenance Schedule
ITEM
WORK REQUIRED Time Interval
Moderate Usage
1 Day
8 Hrs.
6 Months
or 500 Hrs.
12 months
or 1000 Hrs.
Check Severe Usage
1 Day
8 Hrs.
3 Months
or 250 Hrs.
6 months
or 500 Hrs.
General
1 Check for loose hardware. Tighten as necessary. X
2 Note any unusual noise during operation. X
3 Check for leaks around drive unit and hydraulic
system.
X
4 Visually inspect all cables for damage. X
5 Check grease location points (See Section P4.0 for
locations and specific Section S.0 for information.)
X
0300 Chassis
0300.1 Check truck data plate and decals for legibility. X
0300.2 Check for crack formation and damage. X
1700 Motors
1700.1 Check connections for proper contact. X
1700.2 Clean motor of dirt and dust. X
1700.3 Check condition of brushes, springs, and holders. X
1700.4 Check brush length. Replace brushes if necessary
(see page 90.)
X
2550 Drive Unit
2550.1 Check oil in drive housing. Check for contamination
in the oil (see page 102.)
X
2550.2 Change transmission oil (see page 101.) X
3300 Brake
3300.1 Check brake operation. X
3300.2 Clean dust and debris. X
3300.3 Check brake disc for wear. X
3500 Wheels
3500.1 Remove all string, wrapping, and debris. X
3500.2 Check all wheels for wear. X
4100 Tiller Arm
4100.1 Check return of tiller arm to upper rest position. X
5000 Electrical Control System
5000.1 Check operation of horn button. X
5000.2 Check speed and thumb controls. X
5000.3 Check tiller arm/angle switches for adjustment. X

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Service Schedule
5000.4 Check steering operation. X
5000.5 Check lift/lower functions. X
5000.6 Check operation of main ON/OFF switch. X
5000.7 Check for electrical shorts in chassis. X
5000.8 Check operation of reverse button. X
5110 Battery
5110.1 Check cleanliness and exterior conditions. X
5110.2 Check the battery charge. X
5110.3 Check the battery weight. X
5110.4 Check all connections; battery, battery and charger
plugs.
X
5110.5 Check battery mounting bolt or freeplay. X
5111 Battery Connector
5111.1 Check battery connector. Make sure all powered
functions shut down when disconnected.
X
5400 Electrical Panel
5400.1 Clean and check mounting to chassis. X
5400.2 Check contactors for welded conditions. X
5400.3 Check contactor tips for free movement. X
6000 Hydraulic System
6000.1 Check hoses for wear and damage. X
6000.2 Check reservoir for cracks, leaks, and mounting. X
6000.3 Check for correct oil level. X
6000.4 Check hydraulic connections and mounting. X
6000.5 Change hydraulic oil. Clean filters. X
7100 Mast
7100.1 Check for damage and cracks. X
7100.2 Check clearance of rollers. Check rollers for unusual
wear patterns.
X
7100.3 Check lateral play of inner section. X
7100.4 Check for wear on lift chains and chain rollers. X
7100.5 Check adjustment of lift chains. X
7100.6 Clean and lube lift chains. X
7100.7 Clean and lube mast columns. X
7100.8 Lube chain sheaves. X
ITEM
Moderate Usage
1 Day
8 Hrs.
6 Months
or 500 Hrs.
12 months
or 1000 Hrs.
Check Severe Usage
1 Day
8 Hrs.
3 Months
or 250 Hrs.
6 months
or 500 Hrs.

Service Schedule
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7400 Lift Device
7400.1 Check clearance of fork carriage/yoke rollers. X
7400.2 Check fork carriage/yoke for damage and crack
formation.
X
7400.3 Check forks for wear and cracks. X
ITEM
Moderate Usage
1 Day
8 Hrs.
6 Months
or 500 Hrs.
12 months
or 1000 Hrs.
Check Severe Usage
1 Day
8 Hrs.
3 Months
or 250 Hrs.
6 months
or 500 Hrs.

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Service Schedule
5110
5400
5110
5000
1700
6000
3500
3300
2550
5700
4100
1700

Service Schedule
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2. Planned Maintenance Procedures
This section describes how to perform the services listed in
the Schedule of Planned Maintenance Operations. As with
the “Schedule”, this section is subdivided into service
intervals.
2.1. General
The following general inspections are to be made by the
operator. The frequency of these inspections are based on
the usage of the truck (see page 61). It is the operator's
responsibility to report any problems with the truck to the
appropriate personnel. The truck should not be operated until
it has been inspected and repaired by a trained, qualified, and
authorized technician. The operator is ultimately responsible
for the safe operation of the truck.
2.1.1. Hardware
Inspect the truck for loose, damaged, or missing parts. All
shields and covers must in place and functional. Inspect truck
for missing data plate or decals and make sure they are
legible. Report any problems to the appropriate personnel.
DO NOT operate the truck until it has been inspected and
repaired by a trained, qualified, and authorized technician.
Check all fasteners and connections, torque as required (see
page 47). Check the drive wheel studs. Ensure that the lug
nuts and studs are tightened to the proper torque
specification (see page 47). Check torque on motor end cap
bolts. Check that support arm adjustment bolts are torqued to
180 - 200 ft-lbs (244 - 271 N•m) [see page 76].
2.1.2. Noise
Check for an abnormal noise coming from the truck.
2.1.3. Leaks
Inspect the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinders. Any sign of oil
on the floor under the truck is an indication that the truck may
be leaking hydraulic oil or transmission fluid. Report any
problems to the proper authorities. DO NOT operate the truck
until it has been inspected and repaired by a trained,
qualified, and authorized technician.

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Version no T-code
Service Schedule
Check for proper fluid level in drive unit. When truck is level,
oil must be up to the bottom of the plug opening. If fluid is low,
check for leaks (see page 101).
2.1.4. Cables and Connections
Tighten connections. Check all cable insulation for damage.
Check that all electrical connections are clean and tight. Plug-
in connectors should be unplugged and plugged back in to
clean terminals.
2.1.5. Grease Location Points
Lubricate load wheel bearings. For location of the grease
points see page 72. Clean and lube lift chains. Clean and
lube mast columns (for proper lube, see page 71.)
2.2. Services Performed Daily or Every 8
Operating Hours
Daily inspection is to be made by the operator prior to each
operating shift. It is the operator's responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
The operator is ultimately responsible for the safe operation
of the truck.
2.2.1. Chassis
Check truck data plate and decals to see that data is legible.
2.2.2. Brakes
Check operation of brakes.
2.2.3. Wheels/Tires
Inspect wheels and tires for wear and damage. Remove any
steel chips and foreign material to prevent damage to the
wheels. Check for gouging and chunking of the surface.
Trash that is wrapped around wheels and axles will cause
premature tire wear and bearing damage. The floors should
be kept clear of trash to prevent damage to the wheels and
tires.
2.2.4. Tiller Arm
Check return of tiller arm to upper rest position.

Service Schedule
P2.0
Version no T-code
000 7BWS10/13
67
2.2.5. Functions/Operations
Test truck for the proper operation of all functions including
the speed and thumb controls (arm angle switches), lift and
lower functions, brakes, steering, reverser button, horn button
and the main ON/OFF switch. Devices must be operational.
Report any problems to the proper authorities. DO NOT
operate the truck until it has been inspected and repaired by a
trained, qualified, and authorized technician.
2.2.6. Battery
Contact your battery supplier for specific instructions on
care and maintenance of the battery. Determine if the
battery needs to be washed down. This can only be done by
a trained, qualified, and authorized technician.
An average battery will have a specific gravity of 1.170 at the
80 percent discharged level. However, there are many
different batteries on the market. The battery supplier can
accurately determine the fully charged and 80 percent
charged levels. Contact an authorized battery supplier to
determine the overall condition of the battery.
Check status of the Battery Discharge Indicator (BDI) on the
truck. If the BDI displays a flashing “O”, then lift-cutout is
enabled and travel only is allowed. Drive unit safely to battery
charging location and replace battery or charge existing
battery in unit. The BDI should decrement from “100” (Fully
Charged Battery) to “O” (Completely Discharged Battery)
during truck operation.
2.2.7. Battery Connector
On the battery connector inspect the negative and positive
cables for breaks and wear. Check connectors for damage
and to ensure proper connections of cables.

P2.0
000 7BWS10/13
Version no T-code
Service Schedule
2.3. Services Performed Every Six Months
or 500 Operating Hours Under Moderate
Usage or Three Months or 250 Hours
Under Severe Usage
The following inspections are to be made by the operator.
The frequency of these inspections are based on the usage
of the truck. It is the operator's responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
The operator is ultimately responsible for the safe operation
of the truck.
2.3.1. Chassis
Check chassis for crack formation and damage.
2.3.2. Motors
Check motors for improper connections due to poor
connections. Check tightness on all connections. Blow
carbon, copper, and plastic particle accumulations out from
the drive motor fan and vents using compressed air. Check
for signs of oil on the drive motor air vents. Check for any
damage to the air vents. For minimum brush lengths see
page 51 or page 52.
2.3.3. Drive Unit
Check oil in drive housing. Check for contamination in the oil
(see page 102).
2.3.4. Brake
Clean brake of dust and debris. Check brake disc for wear.
1. Remove brake coil, and inspect brake disc for
wear. If the brake disc is damaged or worn, replace
with a new disc (see page 116).
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).
WARNING

Service Schedule
P2.0
Version no T-code
000 7BWS10/13
69
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.

P2.0
000 7BWS10/13
Version no T-code
Service Schedule
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
2.4.1. Drive Unit
Fluid from the transmission should be drained and new fluid
added (see page 101).
2.4.2. Hydraulic System
The hydraulic system should be drained, flushed, and refilled.
Clean hydraulic filters when hydraulic fluid is changed. The
pressure relief valve setting should be checked.
To drain reservoir, disconnect and remove the hydraulic
pump assembly (see page 257).
Before siphoning oil from reservoir, make
certain siphon is clean.
WARNING

Lubrication Chart
P3.0
Version no T-code
000 7BWS10/13
71
Lubrication Chart
L= Lubrication C = Check O = Oil change
Pos. No Service Point
Interval/Running
Hours
Lubricant
(See “Lubricants”
on page 72)
500 h 1000 h
1 Wheel bearings L A
2 Mast columns L E
3 Lifting chains L D
4 Hydraulic system C O B
5 Transmission C O C
1
5
4
3
2

P4.0
000 7BWS10/13
Version no T-code
Oil and Grease Specifications
72 2006-06-12
Oil and Grease Specifications
1. Lubricants
2. Grease Location Points
Lubricant Specifications
Location
Lubricant
Standard Operation Down
To 32° F (0° C)
Application area
A Grease Mystik JT-6 Bearings and bushings
B Hydraulic oil Union 76 TH Hydraulic system
C Transmission oil
Mobil-1 Synthetic Gear Lube 75W-90
or Texaco Synstar GL 75W-90
Gears
D Lifting chains #10W40 Lifting chains
E Grease Gleitmo 805 or equivalent Mast beams
C
B
A
Optional
E
D

Contents, Section S
S
Version no T-code
000
73
Contents, Section S
1. Service Instructions
NO FUNCTION GROUP C-CODE
0 CHASSIS 0000
1 MOTORS 1000
2 DRIVE GEAR / TRANSMISSION 2000
3 BRAKE / WHEEL SYSTEM 3000
4 STEERING SYSTEM 4000
5 ELECTRICAL / PNEUMATIC SYSTEM 5000
6 HYDRAULIC SYSTEM / CYLINDERS 6000
10 TOOLS 10000

S
000
Version no T-code
Contents, Section S
74 2006-06-12

Stabilizer Support Arms
S0.1 0300
Version no T-code
000 7BWS10/13
75
Plate
Bolt

S0.1 0300
000 7BWS10/13
Version no T-code
1. Theory of Operation
The truck is designed with the stabilizer support arms
(baselegs), with separate mounting points from the mast and
lift cylinder, bolted to the drive unit chassis. The support arms
of the straddle chassis are adjustable in width from 32 to 51
inch (813 to 1300 mm) to suit different pallet sizes. Normally,
the support arms are adjusted to the customers specifications
prior to delivery.
2. Maintenance
The fastening of the support arms (baselegs) need to be
checked at the regular planned maintenance service (see
page 61).
2.1. Support Arm Width Adjustment
1. Make sure truck is unloaded and parked on a level
surface.
2. Lift forks high enough to place a toe jack under the
frame as shown in the Figure 0-2. Shut truck off,
unplug the battery and remove the battery.
Remove both side plates by lifting up and out as
shown in Figure 0-5.
NOTE! Think Safety First!
Figure 0-2: Lift Forks for Toe Jack

S0.1 0300
Version no T-code
000 7BWS10/13
77
3. Jack truck up one side just high enough to raise
load wheels off the floor. No more than 1/4 inch (6
mm) should be allowed between the floor and the
load wheel. Place a wood or metal block under the
frame as shown in Figure 0-3.
4. Slowly lower the jack until the frame rests on the
block.
5. Repeat step 3 for the other side. When blocking
the other side place a carpenter’s level on the side
of the mast and make sure it remains level from
side to side as shown in Figure 0-4.
Figure 0-3: Blocking Truck to Raise Load Wheels
Block

S0.1 0300
000 7BWS10/13
Version no T-code
6. Loosen the four adjustment bolts on each support
arm.
7. To determine the correct amount of adjustment for
the desired I.D., use the following calculation. This
measurement will be a starting point and further
adjustments may be necessary.
Figure 0-4: Blocking Opposite Load Wheel
Figure 0-5: Side Plate Removal

S0.1 0300
Version no T-code
000 7BWS10/13
79
(Desired I.D.) Divided by (2) minus 12 = Distance
between Surface “A” and Surface “B”. (See
Figure 0-6.)
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.
Figure 0-6: Support Arm Adjustment
B A
Distance to Adjust

S0.1 0300
000 7BWS10/13
Version no T-code
13.Install battery. Replace the side panels, plug in the
battery, turn truck on, and check truck for correct
operation.
Figure 0-7: Support Arm Measuring Distances
D
C
Measure between these points

Inspection, Covers
S0.2 0340
Version no T-code
000 7BWS10/13
81
Inspection, Covers
Item No. Description Item No. Description
1 Cover, upper 6 Nut
2 Screw 7 Bumper
3 Cover, lower 8 Plate, left
4 Plate, right 9 Clip
5 Screw
1
2
3
4
5
6 7
8
9
No function on this truck

S0.2 0340
000 7BWS10/13
Version no T-code
Inspection, Covers
The truck covers are easily removed for access to the
components. The windshield is standard on the truck. During
operation of the truck, the covers must be secured to the
truck.
2. Maintenance
See “Planned Maintenance Schedule” on page 61.
3. Troubleshooting
Inspect covers and windshield for damage. Damaged covers
and windshield should be replaced.
4. Repair and Rebuild
When the covers and windshield become damaged and do
not fit properly, replace with new as necessary.
Windshield

Decals
S0.3 0851
Version no T-code
000 7BWS10/13
83
Decals
Remove and replace any decals that are damaged or
missing. Remove a damaged decal by using a sharp edge to
peel the decal from the surface. Use caution not to scratch or
damage the paint on the truck when removing the decal. New
warning decals are free from Toyota. Refer to truck parts book
for location and quantities of the decal.
Using a cleaning solution, thoroughly clean the surface of the
truck before applying a new decal. Allow the surface to dry
completely, be sure that there is no residue. Before applying
decal, touch up the paint in area of the decal, as required.
1. Decal with Protective Sheet
To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Rub over the protective over-sheet with a firm, straight,
plastic edge to remove air bubbles and any wrinkles. Peel off
the over-sheet.
2. Decal without Protective Sheet
To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Smooth the decal into place using clean fingers. Be
sure all the edges are secured to the surface.

S0.3 0851
000 7BWS10/13
Version no T-code
Decals
84 2006-06-12

Electric Motors
S1.0 1700
Version no T-code
000 7BWS10/13
85
Electric Motors
Electric motors provide power to the transmission and
hydraulic systems. Motor speed and direction are controlled
by the transistor controller or contactor with inputs from the
operator controls.
The lift pump motor assembly consists of the pump motor,
pump assembly and lift valve assembly. The pump motor and
pump are an integrated unit. The drive unit assembly consists
of the electromagnetic brake assembly, drive motor,
transmission assembly, and drive wheel. The drive motor is
integral part of the drive unit. The steering bearing is mounted
on top of the drive unit assembly.
2. Maintenance
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operation, is
related to time spent making inspections and correcting minor
problems as they occur.
Inspect the motor more frequently when working in an
abnormally severe environment or if in a rigorous duty cycle.
Set up and maintain a strict inspection schedule to obtain the
maximum efficiency from the electrical equipment.
Operating environments of truck motors varies widely.
The following recommendations should be applied as actual
conditions dictate:
Normal Service: Basically an eight hour shift of indoor
material handling.
Severe Service: Extended operating hours, or constant
usage.
Extreme Service: Chemical processing
Processing plants (poultry, meat)

S1.0 1700
000 7BWS10/13
Version no T-code
Electric Motors
86 2006-06-12
Each partial inspection of the motor must include:
1. Inspect the brushes for wear and for correct
contact with the commutator. Record the level of
wear on the brushes. This history will indicate
whether a brush must be changed or if it can wait
until the next inspection. For acceptable brush
length see page 51 or page 52.
2. Check the brush spring tension. For acceptable
brush spring tension see page 51 or page 52.
3. Clean the brushes and holders. Wipe the
commutator with a dry, lint-free cloth. Do not use
lubricants of any kind on or around the
commutator.
4. Check the brush holders for solid connection to the
mounting support. Tighten the mounting screws as
necessary.
5. Check the cap screws holding the brush cross
connectors to the brush holder body.
6. Make sure the motor terminals are secured tightly
to the motor frame. Do not strip the threads or
crush the insulating parts.
7. Check all the cap screws around the frame for
tightness.
8. Keep the outside frame of the motor clean and free
from dirt. Maintain a free air passage around the
motor to permit heat radiation.
3. Troubleshooting
See “Planned Maintenance Schedule” on page 61.
NOTE! Overloading a unit is ultimately reflected in
the motor and brush wear. Therefore, take
this into account when considering brush
replacement.

Electric Motors
S1.0 1700
Version no T-code
000 7BWS10/13
87
4. Repair and Rebuild
4.1. Pump Motor
Pump Motor Mounting
To Mast
Pump / Motor Assembly
Item
No.
Description
1 Pump Motor Assembly
2 Kit, brush and spring
3 Cover, “EE”
1
2
3

S1.0 1700
000 7BWS10/13
Version no T-code
Electric Motors
88 2006-06-12
4.1.1. Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on tiller arm until lift cylinders
are completely collapsed.
3. Press red OFF button (O) on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect battery connector from the truck.
Remove battery from the truck (see page 203).
5. Remove truck cover(s) [see page 81].
6. Remove hydraulic line from hydraulic pump
assembly and cap end to prevent contaminants
from entering the hydraulic system.
7. Disconnect hydraulic motor power cables and mark
their positions. Disconnect coil wiring, noting their
positions.
8. Remove bolts securing hydraulic pump and motor
assembly to frame. Remove pump/motor assembly
from truck.
9. Repair pump/motor as necessary.

7bws10-13 repair manual cl3ws-06.pdf

7bws10-13 repair manual cl3ws-06.pdf

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