Toyota Forklift 7BRU18 7BRU23 7BDRU15 7BSU20 & 7BSU25 Reach Lift Truck Service Manual – PDF DOWNLOAD

Description

Toyota Forklift 7BRU18 7BRU23 7BDRU15 7BSU20 & 7BSU25 Reach Lift Truck Service Manual – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift 7BRU18 7BRU23 7BDRU15 7BSU20 & 7BSU25 Reach Lift Truck Service Manual – PDF DOWNLOAD

Language : English
Pages : 557
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift 7BRU18 7BRU23 7BDRU15 7BSU20 & 7BSU25 Reach Lift Truck Service Manual – PDF DOWNLOAD

24 Volt Models – Serial No. 21,000 and Up
36 Volt Models – Serial No. 32,000 and Up

Manual Design:
This manual is designed with the following objectives in mind:
• Provide technical coverage for expected levels of user expertise.
• Anticipate your needs and reduce your decisions regarding maintenance.
• Reduce page flipping through a “one-stop shopping” approach.
The two-line running page header at the top of each page tells you:
• the name of the manual (Toyota Reach Service Manual)
• the current Chapter Title
(e.g., this page How to Use This Manual)
• the current topic
(e.g., this page Manual Design)

We suggest you get in the habit of turning to the START page first when you use this manual.
The START page asks a few simple questions to guide you to the proper chapter.
• How to Use This Manual explains the manual format and design and contains the Table of Contents
and START page.
• Safety explains warning and caution notes, general safety rules and safety rules for batteries,
static, jacking, and welding.
• Systems Overview includes truck specifications and functional overview of the major systems.
• Scheduled Maintenance outlines the recommended schedule of preventive services to keep your
truck working most efficiently.
• Troubleshooting is a set of “decision-tree” charts designed to take you from a symptom to a
specific sequence of tests in order to isolate a failing component.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Toyota Forklift 7BRU18 7BRU23 7BDRU15 7BSU20 & 7BSU25 Reach Lift Truck Service Manual – PDF DOWNLOAD

R/M 7BRU18-23, 7BDRU15 & 7BSU25 SN: 21,000 & UP - 24 VOLT MODELS & SN: 32,000 & UP - 36 VOLT....  1
Table of Contents...............................................................................  4
How to Use This Manual..........................................................................  8
	Map of the Manual...........................................................................  9
	Manual Design............................................................................... 10
	START Page.................................................................................. 12
Safety.......................................................................................... 14
	Definitions................................................................................. 15
	General Safety.............................................................................. 16
	Battery Safety.............................................................................. 20
	Static Safety............................................................................... 24
		Figure 2-1: Ground Jack................................................................. 24
		Figure 2-2: Anti-Static Kit with Wrist Strap and Mat.................................... 25
	Jacking Safety.............................................................................. 26
		Figure 2-3: Correct Jacking Locations................................................... 26
	Tie-down for Transport...................................................................... 27
	Welding Safety.............................................................................. 28
Systems Overview................................................................................ 30
	Vehicle Specifications...................................................................... 31
	General System Data......................................................................... 32
		Brake................................................................................... 33
		Steering................................................................................ 33
		Lift/Lower System....................................................................... 33
		Auxiliary System........................................................................ 33
		Traction System......................................................................... 34
	Modes of Operation.......................................................................... 35
		Self-diagnosis Mode..................................................................... 35
		Analyzer (AnL) Mode..................................................................... 35
		Tuning (Tuning) Mode.................................................................... 35
		Calibrate (Calibrte) Mode............................................................... 35
		Configure (Configur) Mode............................................................... 35
Scheduled Maintenance........................................................................... 36
	Maintenance Guidelines...................................................................... 37
	Daily or Every 8 Operating Hours............................................................ 38
	Monthly or Every 200 Operating Hours........................................................ 39
	Semi-annually or Every 1000 Operating Hours................................................. 40
	Annually or Every 2000 Operating Hours...................................................... 41
	Lubricants.................................................................................. 42
		Cold Storage Conditioning............................................................... 42
		Classes Of Cold Storage................................................................. 42
			Figure 4-1: Recommended Oils by Temperature......................................... 42
	Lubrication and Inspection Points........................................................... 44
		Figure 4-2: Lubrication and Inspection Points........................................... 44
Troubleshooting................................................................................. 46
	How to Use This Chapter..................................................................... 47
	Electrical Troubleshooting Guidelines....................................................... 48
	Shorts to Frame Test........................................................................ 49
		To test for shorts to frame:............................................................ 49
			Figure 5-1: Shorts to Frame Test.................................................... 51
	Hydraulic Troubleshooting Guidelines........................................................ 53
	Definitions................................................................................. 54
		Auxiliary Function...................................................................... 54
		Continuity.............................................................................. 54
		Deadman Switch.......................................................................... 54
		High Speed Travel Limit................................................................. 54
		Mast Assembly........................................................................... 54
		Mast Switch............................................................................. 54
		Open Circuit............................................................................ 54
		Overtemperature (Power Amplifiers)...................................................... 54
		Pulse Width Modulation.................................................................. 54
		Short Circuit or “Short”................................................................ 54
		Tractor................................................................................. 54
		Undertemperature........................................................................ 54
	Electrical Connector Locator Chart.......................................................... 55
	Electrical Connector Locator Photos......................................................... 57
		Figure 5-2: Electrical Connectors, Electrical Compartment (Operator Right Side)......... 57
		Figure 5-3: Power Amplifier Connections................................................. 58
		Figure 5-4: Electrical Connectors, Motor Compartment.................................... 59
		Figure 5-5: Electrical Connectors, Operator Display/Display Card........................ 60
	List of Troubleshooting Flowcharts.......................................................... 62
		Hydraulic Charts........................................................................ 62
		Travel Charts........................................................................... 62
		Wiring Charts........................................................................... 62
			TS1: START TROUBLESHOOTING.......................................................... 64
			GEN1: General Troubleshooting....................................................... 65
			MISC: Miscellaneous Problems........................................................ 66
			END1: End of Troubleshooting Procedure.............................................. 67
			H-1: Hydraulic Problem with One Function............................................ 68
			H-2: Lift/Lower Problem............................................................. 69
			H-3: Reach Problem.................................................................. 70
			H-4: Retract Problem................................................................ 71
			H-5: Tilt Problem................................................................... 72
			H-6: Sideshift Problem.............................................................. 73
			H-7: Hydraulic Problem.............................................................. 74
			H-10: Lift Does Not Respond for Lift or Aux. Function............................... 75
			H-11: No Lift, Lift Motor Operates.................................................. 78
			H-12: Lift Functions But Works Slow, Lift Motor Runs................................ 83
			H-13: Reach Does Not Work........................................................... 87
			H-14: Reach Works Slow.............................................................. 91
			H-15: Reach and Lift Pump Do Not Work............................................... 94
			H-16: Retract Does Not Work......................................................... 95
			H-17: Retract Works Slow............................................................ 99
			H-18: Retract and Lift Pump Do Not Work.............................................102
			H-19: Tilt Does Not Work (Up or Down)...............................................103
			H-20: Tilt Works Slow...............................................................106
			H-21: Tilt and Lift Pump Do Not Work................................................108
			H-22: Sideshift Does Not Work (Either Direction)....................................109
			H-23: Sideshift Works Slow..........................................................112
			H-24: Sideshift and Lift Pump Do Not Work...........................................114
			H-25: Load Drifts Down While Forks Are Elevated.....................................115
			H-26: Cannot Pick Up A Load.........................................................117
			H-27: Aux Functions Work Only One Side/Direction....................................119
			H-28: No Lower......................................................................121
			T-1: Travel Problem.................................................................125
			T-2: No Travel In Either Direction..................................................126
			T-3: Travel In One Direction Only...................................................128
			T-4: Problem With Slow Travel.......................................................129
			T-5: Truck Does Not Accelerate Properly.............................................130
			T-6: Plugging Does Not Operate Properly.............................................132
			T-18: No Slow Travel Above Mast Switch1.............................................133
			T-19: Slow Travel Speed At All Times................................................134
			W-1: Truck Functions Partially......................................................137
Electrical Codes and Tests......................................................................138
	Modes of Operation..........................................................................139
		Figure 6-1: Menu Structure for Modes of Operation.......................................139
		Passwords...............................................................................140
		Disable the Brush Wear Warning..........................................................140
		Start the Hour Meter....................................................................140
	Self-diagnosis Mode.........................................................................141
		Maneuvering within Self-diagnosis Mode..................................................141
		Adjusting the Date......................................................................141
		Adjusting the Time......................................................................141
	Analyzer (AnL) Mode.........................................................................142
		Entering the Secondary Password.........................................................142
		Entering Analyzer Mode..................................................................142
		Maneuvering within Analyzer Mode........................................................142
	Calibrate (Calibrte) Mode...................................................................143
		Entering the Secondary Password.........................................................143
		Entering Calibrate Mode.................................................................143
		Maneuvering within Calibrate Mode.......................................................143
	Configure (Configur) Mode...................................................................145
		Entering the Secondary Password.........................................................145
		Entering Configure Mode.................................................................145
		Maneuvering within Configure Mode.......................................................145
		Exiting Configure Mode..................................................................145
	Tuning (Tuning) Mode........................................................................146
		Entering the Secondary Password.........................................................146
		Maneuvering within Tuning Mode..........................................................146
		Exiting Tuning Mode.....................................................................148
	Code Summary Table..........................................................................149
		Table 6-1: Steer Controller Codes......................................................219
		Table 6-2: Steering Counterclockwise...................................................230
		Table 6-3: Steering Clockwise..........................................................230
	Tests.......................................................................................259
		Test 11 - Simple Test...................................................................260
		Test 12 - Analog Inputs.................................................................261
		Test 13 - Traction Speed Sensor.........................................................264
		Test 14 - Throttle/Lift Command Test....................................................265
		Test 21 - Error Code Display............................................................266
		Test 33 - Switch Input Test.............................................................267
		Test 34 - Short Circuit Test............................................................268
		Test 41 - Drive Unit Proximity Sensor Test (180 Steering)..............................269
		Test 41 - Drive Unit Proximity Sensor Test (360 Steering)..............................270
		Test 51 - Output Test...................................................................271
		Test 61 - Software Versions.............................................................272
	Analog Tests (Category 1, Class 2)..........................................................273
		Test 12-00 - Drive Motor Armature Current...............................................273
		Test 12-01 - Drive Motor Field Current..................................................273
		Test 12-02 - Traction Pot. Voltage......................................................274
		Test 12-03 - Traction Motor Temperature Sensor..........................................274
		Test 12-04 - Traction Motor Power Amplifier Temperature Sensor..........................275
		Test 12-05 - Lift Motor Armature Current................................................275
		Test 12-06 - Lift Pot Voltage...........................................................275
		Test 12-07 - Lift Motor Temperature Sensor..............................................276
		Test 12-08 - Lift Motor Power Amplifier Temperature Sensor..............................276
		Test 12-10 - Pressure Transducer........................................................277
		Test 12-11 - Battery Voltage............................................................277
		Test 12-12 - Stored Battery Voltage.....................................................277
		Test 12-13 - 12V Supply on the Display Card.............................................278
		Test 12-14 - MM Contactor Sense.........................................................278
		Test 12-15 - EPO Sense..................................................................278
		Test 12-16 - Left Pedal Pot.............................................................279
Component Procedures............................................................................280
	List of Component Procedures................................................................281
	Component Locator Photos....................................................................284
	Frame and Accessories.......................................................................292
	Panels and Covers...........................................................................293
		General.................................................................................293
			Figure 7-1: Tractor Panels and Covers...............................................293
		Console Cover...........................................................................293
		Electrical Compartment Access Panel.....................................................294
		Motor Compartment Door..................................................................294
		Left Operator Compartment Panel.........................................................295
		Left Side Panel.........................................................................295
		Floor Board.............................................................................297
			Figure 7-2: Floor Board Removal.....................................................297
	Decals......................................................................................299
		Decal with Protective Sheet.............................................................299
		Decal without Protective Sheet..........................................................299
	Steering and Controls.......................................................................300
	Steering Wheel..............................................................................301
		Figure 7-3: Steering Wheel Mounting and Components......................................301
		Removal.................................................................................301
		Installation............................................................................301
	Steer Tachometer............................................................................302
		Figure 7-4: Steer Tach Mounting.........................................................302
	Steer Motor.................................................................................303
		Figure 7-5: Steer Motor.................................................................303
		Figure 7-6: Spacer and O-Rings..........................................................303
		Figure 7-7: Mounting Bolts and Grommets.................................................304
		Steer Motor Gear Replacement............................................................304
			Figure 7-8: Steer Motor Gear........................................................304
	Steer Controller............................................................................305
		Figure 7-9: Steer Controller............................................................305
		Exterior Cleaning.......................................................................305
		Removal.................................................................................305
		Installation............................................................................306
			Figure 7-10: Steer Controller Mounting..............................................306
		Adjustments.............................................................................306
	Control Handle..............................................................................308
		Figure 7-11: Control Handle.............................................................308
		Figure 7-12: Control Handle Mounting Screw..............................................308
		Figure 7-13: JP10 Connection at Tractor Interface Card..................................308
	Traction and Braking........................................................................310
	Deadman Pedal...............................................................................311
		Figure 7-14: Deadman Pedal Component Identification.....................................311
		Pedal Bearing Replacement...............................................................313
	Caster Assembly with Brake..................................................................314
		Figure 7-15: Caster Assembly with Brake Component Identification........................314
		Caster Brake Adjustment.................................................................315
			Figure 7-16: Upper Adjustment Location..............................................316
			Figure 7-17: Lower Adjustment Location..............................................317
	Caster Assembly w/o Brake...................................................................320
		Figure 7-18: Caster Assembly without Brake Component Identification.....................320
		Caster Pivot............................................................................321
		Thrust Bearing..........................................................................323
			Figure 7-19: Jacking Location.......................................................323
		Caster Springs..........................................................................324
			Figure 7-20: Caster Adjustment Springs..............................................324
		Caster Axle.............................................................................326
		Caster Stops............................................................................327
	Electromagnetic Brake.......................................................................330
		Figure 7-21: Brake Components...........................................................330
		Coil Check On Brake.....................................................................332
	Electromagnetic Brake, Armature and Magnetic Coil...........................................333
		Removal.................................................................................333
		Installation............................................................................333
	Brake Friction Plate........................................................................334
		Inspection..............................................................................334
			Figure 7-22: Friction Plate.........................................................334
		Replacement.............................................................................334
	Drive Wheel.................................................................................335
		Figure 7-23: Drive Wheel Components.....................................................335
		Removal.................................................................................335
			Figure 7-24: Jacking Tractor End....................................................335
			Figure 7-25: Drive Wheel and Tire...................................................336
		Installation............................................................................336
			Figure 7-26: Drive Tire Installation................................................337
		Drive Tire Pressing Procedure...........................................................337
	Drive Unit..................................................................................339
		Figure 7-27: Drive Unit Drain Plug......................................................339
		Fluid Changing Procedure................................................................339
		Removal.................................................................................339
			Figure 7-28: Drive Tire Cradle for Drive Unit.......................................340
		Installation............................................................................340
	Tooth Pattern of Drive Unit.................................................................341
		Figure 7-29: Drive Unit Gear Tooth Pattern..............................................341
	Drive Housing Steering Bearing..............................................................342
		Figure 7-30: Steering Bearing Location..................................................342
		Removal.................................................................................342
		Installation............................................................................343
	Axle Seal Replacement.......................................................................344
		Figure 7-31: Lower End of Drive Unit....................................................344
		Procedure...............................................................................344
			Figure 7-32: Ring Gear Before Being Pressed Toward Flange...........................344
			Figure 7-33: Ring Gear After Being Pressed Toward Flange............................344
			Figure 7-34: Removing Bearing Spacer Using Bearing Puller...........................345
			Figure 7-35: Removing External Snap Ring............................................345
			Figure 7-36: Removing Output Shaft..................................................345
			Figure 7-37: Removal/Installation of Shaft Seal.....................................346
			Figure 7-38: Installing Ring Gear...................................................346
	Electrical..................................................................................348
	Battery.....................................................................................349
		Figure 7-39: Battery Connector..........................................................349
		Removal.................................................................................349
		Installation............................................................................349
			Figure 7-40: Battery Gate...........................................................350
		Battery Gates...........................................................................350
			Figure 7-41: Battery Rollers........................................................350
		Battery Rollers.........................................................................350
		Battery Maintenance.....................................................................351
		Battery Inspection and Care.............................................................351
		Battery Exterior Cleaning...............................................................351
		Charging................................................................................352
		Storage.................................................................................352
		Battery History Record..................................................................353
	Power Cables................................................................................354
	Wiring Harness..............................................................................355
		Terminology.............................................................................355
	Contactors, General.........................................................................359
		Testing Resistance......................................................................359
		Contactor Tip Inspection................................................................359
		Contactor Removal.......................................................................359
		Contactor Installation..................................................................360
	Switches (General)..........................................................................361
		Test/Inspection.........................................................................361
	Key Switch (S1).............................................................................362
		Inspection..............................................................................362
			Figure 7-42: Key Switch.............................................................362
		Removal.................................................................................362
		Installation............................................................................362
	EPO Switch (S2).............................................................................363
		Figure 7-43: EPO Switch.................................................................363
		Inspection..............................................................................363
		Removal.................................................................................363
		Installation............................................................................363
	Lift Inhibit Switch (S4)....................................................................365
		Removal.................................................................................365
		Installation............................................................................365
	Mast Switch 1 (S6) (High Speed Travel Limit)................................................366
		Adjustment..............................................................................366
		Removal.................................................................................366
		Installation............................................................................367
	Deadman (Left Foot) Switch (S3).............................................................368
		Removal.................................................................................368
		Installation............................................................................368
		Adjustment..............................................................................368
	Platform (Right Foot) Switch (S7)...........................................................370
		Figure 7-44: Platform Switch Location...................................................370
		Removal.................................................................................370
		Installation............................................................................370
			Figure 7-45: Platform Switch Installation...........................................370
	Staging Switch (S8).........................................................................371
		Adjustment..............................................................................371
		Removal.................................................................................371
		Installation............................................................................372
	180 Sensor.................................................................................373
		Figure 7-46: 180 Sensor Location.......................................................373
		Adjustment..............................................................................373
		Removal.................................................................................374
		Installation............................................................................374
	Drive Wheel Position Proximity Sensors (360 Steering)......................................375
		Figure 7-47: Drive Wheel Position Proximity Sensor Location.............................375
		Adjustment..............................................................................375
		Removal.................................................................................376
		Installation............................................................................376
	Steer Stop Proximity Sensors (180 Steering)................................................377
		Adjustment..............................................................................377
	Drive Motor Speed/Direction Sensors.........................................................379
		Figure 7-48: Drive Motor Speed/Direction Sensors........................................379
		Removal.................................................................................379
		Installation............................................................................379
			Figure 7-49: Drive Speed/Directional Sensor Components..............................379
	Horn........................................................................................380
		Removal.................................................................................380
		Installation............................................................................380
	Motors, General.............................................................................381
		Maintenance Schedule....................................................................381
		Maintenance Inspection Chart............................................................382
		Motor Cleaning..........................................................................382
		Motor Brushes...........................................................................382
		Inspection..............................................................................383
			Figure 7-50: Motor Brush, Typical Location..........................................383
		Replacement.............................................................................384
		Motor Brush Spring Tension..............................................................385
			Figure 7-51: Motor Brush Spring Tension Inspection..................................385
		Commutator..............................................................................386
			Figure 7-52: Mica Undercutting......................................................386
		Terminal Nuts...........................................................................387
			Figure 7-53: Motor Terminal Nuts....................................................387
		Motor Overheating.......................................................................388
	Electric Motor Tests........................................................................389
		Figure 7-54: Motor Circuits.............................................................389
		Motor Types.............................................................................389
		Open Circuit Motor Test.................................................................389
		Grounded Motor Test.....................................................................390
		Short Circuited Armature or Field Winding...............................................391
	Drive Motor.................................................................................392
		Removal.................................................................................392
			Figure 7-55: Drive Unit Mounting Plate Bolts (Qty. 6)...............................392
			Figure 7-56: Drive Motor Lifting Tool...............................................392
		Installation............................................................................392
		Drive Motor Data........................................................................393
	Lift Motor..................................................................................394
		Removal.................................................................................394
			Figure 7-57: Lift Motor/Pump, Side View.............................................394
			Figure 7-58: Lift Pump to Reservoir Hose Installation...............................395
	Traction Power Amplifier....................................................................397
		Figure 7-59: Traction Power Amplifier...................................................397
		Exterior Cleaning.......................................................................397
		Removal.................................................................................397
		Installation............................................................................398
	Lift Power Amplifier........................................................................399
		Figure 7-60: Lift Power Amplifier.......................................................399
		Exterior Cleaning.......................................................................399
		Removal.................................................................................399
		Installation............................................................................400
	Fuses.......................................................................................401
		Figure 7-61: Fuses in Upper Electrical Compartment......................................401
		Test/Inspection.........................................................................401
			Figure 7-62: Fuses in Lower Electrical Compartment..................................401
	Operator Display............................................................................402
		Figure 7-63: Operator Display...........................................................402
		Removal.................................................................................402
		Installation............................................................................402
		Hour Meter..............................................................................403
		Battery Discharge Indicator.............................................................403
	Temperature Sensors (Lift And Traction Motor)...............................................404
	Brush Wear Sensors..........................................................................405
		Figure 7-64: Brush Wear Sensor Connector Location.......................................405
	Tractor Interface Card......................................................................406
		Figure 7-65: Tractor Interface Card Mounting............................................406
		Removal.................................................................................406
		Installation............................................................................406
	Display Card................................................................................407
		Figure 7-66: Display Card Location......................................................407
		Removal.................................................................................407
			Figure 7-67: Display Card Mounting..................................................407
		Installation............................................................................407
	Light Assemblies............................................................................408
		Overhead Guard Lights (Optional)........................................................408
		Flashing or Rotating Light (Optional)...................................................409
	Fan Assemblies..............................................................................410
		Operator Fan (Optional).................................................................410
		Upper Electrical Compartment Fan........................................................411
			Figure 7-68: Front Mounting Bolts...................................................411
	Height Indicator (Optional).................................................................412
		Figure 7-69: Height Indicator Components................................................412
		Mast Switch1 (S6) Calibration...........................................................412
			Figure 7-70: Height Indicator Operator Display......................................414
		Height Indicator Display................................................................414
		Height Indicator Sensing Unit Components................................................415
		Height Indicator Encoder................................................................416
		Height Indicator Cable..................................................................417
		Height Indicator Pulley.................................................................417
	Hydraulics..................................................................................418
	Hydraulic Fluid.............................................................................419
		Hydraulic Fluid Selection...............................................................419
		Changing Hydraulic System Fluid.........................................................419
		Draining the System.....................................................................419
			Figure 7-71: Diagnostic Fitting.....................................................420
			Figure 7-72: Bleeder/Fill Cap.......................................................420
	Hydraulic Filter............................................................................421
		Figure 7-73: Hydraulic Filter Removal...................................................421
		Removal.................................................................................421
			Figure 7-74: Hydraulic Filter Assembly/Disassembly..................................421
		Installation............................................................................421
	Hydraulic Filter Adapter....................................................................422
		Figure 7-75: Hydraulic Filter Adapter...................................................422
		Removal.................................................................................422
		Installation............................................................................422
	Hydraulic Reservoir.........................................................................423
		Removal.................................................................................423
		Installation............................................................................423
	Bleeding the Hydraulic System...............................................................425
	Control Valve...............................................................................426
		Removal.................................................................................426
			Figure 7-76: Control Valve..........................................................426
			Figure 7-77: Mounting Bolts.........................................................426
		Installation............................................................................426
			Figure 7-78: Solenoid Electrical Connections........................................427
	Reach/Tilt/Sideshift Manifold...............................................................428
		Figure 7-79: Auxiliary Function Manifold................................................428
		Removal.................................................................................428
		Installation............................................................................428
	Solenoids...................................................................................429
		Figure 7-80: Solenoid Removal, Typical..................................................429
		Removal.................................................................................429
			Figure 7-81: Solenoids, Main Manifold...............................................429
			Figure 7-82: Solenoids, Auxiliary Function Manifold.................................429
	Lift Pump...................................................................................430
		Removal.................................................................................430
			Figure 7-83: Lift Pump Assembly.....................................................430
		Installation............................................................................430
	Freelift Cylinder Repair....................................................................431
		Figure 7-84: Freelift Cylinder Components...............................................431
		Figure 7-85: Freelift Cylinder Rod Inspection...........................................432
	Staging Cylinder Repair.....................................................................434
		Figure 7-86: Staging Cylinder Components................................................434
		Staging Cylinder Repair.................................................................435
			Figure 7-87: Staging Cylinder Rod Inspection........................................435
	Tilt Cylinder (3500 lb. Reach)..............................................................437
		Figure 7-88: Tilt Cylinder (3500 lb. Reach).............................................437
	Tilt Cylinder (4500 lb. Reach)..............................................................441
		Figure 7-89: Tilt Cylinder (4500 lb. Reach).............................................441
		Removal.................................................................................442
		Disassembly.............................................................................442
		Inspection..............................................................................443
		Assembly................................................................................443
		Installation............................................................................444
	Reach Cylinder..............................................................................446
		Figure 7-90: Reach Cylinder Components..................................................446
		Removal.................................................................................447
		Disassembly.............................................................................447
		Inspection..............................................................................448
		Assembly................................................................................449
		Installation............................................................................450
	Lift/Auxiliary Pressure Relief..............................................................452
		Figure 7-91: Lift/Aux. Relief Pressure Adjustment.......................................452
	Velocity Fuses..............................................................................453
		Figure 7-92: Flow Controls (Velocity Fuses).............................................453
		Staging Velocity Fuse...................................................................453
		Freelift Velocity Fuse..................................................................453
	Mast........................................................................................454
	Main Mast Assembly..........................................................................455
		Figure 7-93: Main Mast Assembly Components..............................................455
		Removal.................................................................................456
			Figure 7-94: Mast Mounting Bolt Locations...........................................457
	Mast Roller Bearings........................................................................462
		General.................................................................................462
		Shimming................................................................................462
	Lift Chains.................................................................................465
		Main Lift Chain Adjustment..............................................................465
		Freelift Chain Adjustment...............................................................465
		Condition-Cause Chart...................................................................466
		Lubrication.............................................................................467
		Freelift Chain Removal..................................................................467
		Freelift Chain Installation.............................................................468
		Staging Chain Removal...................................................................470
	Freelift Chain Anchors......................................................................473
		Upper (Adjustable) Chain Anchor.........................................................473
			Figure 7-95: Freelift Chain Adjustment..............................................473
	Staging Chain Anchors.......................................................................475
		Upper (Adjustable) Chain Anchor.........................................................475
	Over the Mast Hose/Cable....................................................................477
		Adjustment..............................................................................477
	Reach Carriage Assembly.....................................................................479
		Figure 7-96: Reach Carriage Assembly Components (3500 lb. Reach Illustrated)............479
		Maintenance.............................................................................481
		Repair (with reach carriage still in the mast)..........................................482
		Front Frame (3500 lb. Reach)............................................................483
		Front Frame (4500 lb. Reach)............................................................483
			Figure 7-97: Side Hose Clamp Location...............................................483
			Figure 7-98: Top Hose Clamp Location................................................484
			Figure 7-99: Roll Pin Locations.....................................................484
			Figure 7-100: Removing Mounting Pin.................................................484
			Figure 7-101: Front Frame Shim Installation.........................................485
			Figure 7-102: Roll Pin Hole Alignment...............................................485
		Outer Arm (3500 lb. Reach)..............................................................486
		Outer Arm (4500 lb. Reach)..............................................................487
			Figure 7-103: Roll Pin Location in 3-3/4 in. Nut....................................487
		Inner Arm (3500 lb. Reach)..............................................................488
		Rear Frame (3500 lb. Reach).............................................................489
		Reach Carriage Assembly.................................................................490
			Figure 7-104: Hoist Chain Attachment................................................490
			Figure 7-105: Freelift Chain Detachment.............................................490
			Figure 7-106: Hose/Cable Routing, Over Pulley.......................................493
			Figure 7-107: Hose/Cable Routing, Tractor Side......................................493
			Figure 7-108: Hose/Cable Connection at Bottom of Mast...............................493
	Reach Carriage Hose Routing.................................................................494
		Figure 7-109: Tilt/Sideshift Manifold...................................................494
		Figure 7-110: Hose Clamp/Hose Routing...................................................494
		Figure 7-111: Side Clamp Location.......................................................495
		Figure 7-112: Disconnect Tilt and Sideshift Hoses.......................................495
	Reach Carriage Wear Strip...................................................................496
		Removal.................................................................................496
		Installation............................................................................496
	Carriage Roller Bearings....................................................................497
		Figure 7-113: Carriage Roller Bearings..................................................497
		Removal.................................................................................497
		Installation............................................................................497
	Reach Carriage Lubrication Points...........................................................498
		Figure 7-114: Reach Assembly Lubrication (Deep Reach Shown).............................498
	Fork Carriage Pivot Pins....................................................................499
	Sideshift Carriage..........................................................................500
		Figure 7-115: Sideshift Assembly Components.............................................500
		Installation............................................................................501
		Removal.................................................................................501
		Pad Replacement.........................................................................501
		Cylinder................................................................................502
	Mast Guard..................................................................................503
		Figure 7-116: Mast Guard Mounting Bolt Locations........................................503
		Removal.................................................................................503
		Installation............................................................................503
	Carriage Bumpers............................................................................505
	Forks.......................................................................................506
		Figure 7-117: Fork Latch................................................................506
		Adjustment..............................................................................506
			Figure 7-118: Fork Wear Calipers....................................................506
		Fork Inspection.........................................................................506
			Figure 7-119: Fork Wear Inspection..................................................507
			Figure 7-120: Fork Latch............................................................507
		Removal (with Tilt and Sideshift).......................................................507
			Figure 7-121: Fork Removal (with Tilt and Sideshift)................................507
		Installation (with Tilt and Sideshift)..................................................507
		Removal (with Tilt and no Sideshift)....................................................508
		Installation (with Tilt and no Sideshift)...............................................508
	Load Wheels.................................................................................509
		Figure 7-122: Tandem Load Wheel Assembly................................................509
		Tandem Load Wheels......................................................................509
	Load Wheel Toe Plate Box....................................................................511
		Removal.................................................................................511
		Installation............................................................................511
			Figure 7-123: Single Load Wheel Assembly............................................512
		Single Load Wheel.......................................................................512
	Load Backrest...............................................................................514
		Removal.................................................................................514
			Figure 7-124: Mounting Bolts........................................................514
		Installation............................................................................514
Theory of Operation.............................................................................516
	Electrical Functions........................................................................517
		Operating Description Overview..........................................................517
		Start Up................................................................................517
	Braking System..............................................................................518
		Brake Switch/Pot Operation..............................................................518
		Proportional Plugging and Pedal Up/Down Transition Point................................518
			Figure 8-1: Pedal Pot Voltages......................................................519
	Steering System.............................................................................520
		180 Steering...........................................................................520
		360 Steering (optional)................................................................521
	Traction System.............................................................................522
		Forward Travel Requested................................................................522
		Reverse Travel Requested................................................................522
		Plugging................................................................................523
	Lift/Lower System...........................................................................524
		Lift....................................................................................524
		Lower...................................................................................524
	Auxiliary Hydraulic Functions...............................................................525
		Reach...................................................................................525
		Retract.................................................................................525
		Sideshift Right.........................................................................526
		Sideshift Left..........................................................................526
		Fork Tilt Up............................................................................526
		Fork Tilt Down..........................................................................527
	Indicators and Switches.....................................................................528
		Traction Motor Brush Wear Indicator.....................................................528
		Lift Motor Brush Wear Indicator.........................................................528
		180 Sensor.............................................................................528
		Drive Wheel Position Proximity Sensor A and Sensor B....................................528
		Drive Motor Speed/Direction Indicators..................................................528
		Wheel Direction Indicator (360 Steer)..................................................528
		Mast Switch 1 (S6) (Speed Limiting).....................................................529
		Lift Limit Switch (S4)..................................................................529
		Platform (Right Foot) Switch (S7).......................................................529
		Staging Switch (S8).....................................................................529
		Pressure Transducer (Weight) - Option...................................................529
Appendix........................................................................................530
	Lubrication Equivalency Chart...............................................................531
		Figure 1-1: Lubrication Equivalency Chart...............................................531
	Torque Chart - Standard (Ferrous)...........................................................533
		Figure 1-2: Torque Chart - Standard.....................................................533
	Torque Chart - Standard (Brass).............................................................535
		Figure 1-3: Torque Chart - Standard Brass...............................................535
	Torque Chart - Metric.......................................................................536
		Figure 1-4: Torque Chart - Ferrous Metric...............................................536
		Figure 1-5: Torque Chart - Brass Metric.................................................536
	Decimal Equivalent Chart....................................................................537
		Figure 1-6: Decimal Equivalent Chart....................................................537
	Standard/Metric Conversions.................................................................539
	Electrical Schematics.......................................................................542
		Figure 1-1: Electrical Schematic (180 Steering) - Part 1 of 2..........................543
		Figure 1-2: Electrical Schematic (360 Steering) - Part 1 of 2..........................545
	Electrical Schematic Legend.................................................................547
	Hydraulic Schematic - 7BRU18/7BRU23.........................................................548
		Figure 1-3: 7BRU18/7BRU23...............................................................548
	Hydraulic Schematic - 7BDRU15...............................................................549
		Figure 1-4: 7BDRU15.....................................................................549
	Hydraulic Schematic - 7BSU20/25.............................................................550
		Figure 1-5: 7BSU20/7BSU25...............................................................550
Index...........................................................................................552

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