Toyota Forklift 7HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 24501 and up – PD DOWNLOAD

Description

Toyota Forklift 7HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 24501 and up – PD DOWNLOAD

FILE DETAILS:

Toyota Forklift 7HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 24501 and up – PD DOWNLOAD

Language : English
Pages : 159
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift 7HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 24501 and up – PD DOWNLOAD

Manual Design:

The Toyota Model 7HBW23 Service 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 following:
• Name of the manual
(Toyota Model 7HBW23 Service Manual)
• Current chapter title
(example: this page How to Use This
Manual)
• Current topic
(example: 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 correct chapter.
• How to Use This Manual explains the manual format and design and contains the 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 theory of operation information.
• Planned Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently.
• Troubleshooting is a set of “decision-tree” charts and symptom tables designed to take you from a symptom to a specific sequence of tests in order to isolate a bad component.

TABLE OF CONTENTS:

Toyota Forklift 7HBW23 4,500 lb. Powered Pallet Walkie Service Manual SN 24501 and up – PD DOWNLOAD

R/M: 7HBW23 SN: 24,501 and up.......................................................................  1
	Table of Contents...............................................................................  3
	Section 1. How To Use This Manual...............................................................  6
		Map of the Manual...........................................................................  7
		Manual Design...............................................................................  8
		START Page.................................................................................. 10
	Section 2. Safety............................................................................... 13
		Definitions................................................................................. 14
		General Safety.............................................................................. 15
		Battery Safety.............................................................................. 18
		Jacking Safety.............................................................................. 21
			Fork Section............................................................................ 21
			Tractor Section......................................................................... 21
		Towing...................................................................................... 22
		Welding Safety.............................................................................. 23
		Static Safety............................................................................... 24
			Figure 21. Anti-Static Kit With Wrist Strap and Mat.................................... 24
	Section 3. Systems Overview..................................................................... 26
		Truck Model Identification.................................................................. 27
			Figure 3-1. Model 7HBW23 Pallet Truck................................................... 27
		Vehicle Specifications...................................................................... 27
		General Information......................................................................... 28
			Figure 3-2. Model 7HBW23 General Information............................................ 28
		Special Tools............................................................................... 29
			Programmable Maintenance Tool........................................................... 29
				Figure 3-3. Programmable Maintenance Tool........................................... 29
			Service Key............................................................................. 29
				Figure 3-4. Service Key............................................................. 29
		Theory of Operation......................................................................... 30
			Truck Starting.......................................................................... 30
			Lift/Lower.............................................................................. 30
			Direction/Speed Control................................................................. 30
			Power Amplifier......................................................................... 32
			Electronic Tiller Arm Card (ETAC)....................................................... 32
	Section 4. Planned Maintenance.................................................................. 35
		Maintenance Guidelines...................................................................... 36
			Maintenance Manual...................................................................... 36
			Planned Maintenance Schedule............................................................ 36
			Time Requirements....................................................................... 36
			General Truck Operation................................................................. 36
			Daily................................................................................... 37
			Every Two Months or 250 Operating Hours................................................. 38
			Annually or Every 1500 Operating Hours.................................................. 39
			Grease Fittings......................................................................... 39
				Figure 4-1: Load Wheel Axle (Cold Storage and Corrosion Protection Options only).... 39
	Section 5. Troubleshooting...................................................................... 42
		How to Use This Chapter..................................................................... 43
		Electrical Troubleshooting Guidelines....................................................... 44
			Checking for Shorts from Battery to Truck Frame......................................... 44
			Checking for Shorts from Components to Truck Frame...................................... 44
		Hydraulic Troubleshooting Guidelines........................................................ 46
		Definitions................................................................................. 47
			Acceleration............................................................................ 47
			Arm Angle Switches...................................................................... 47
				Figure 5-1. Arm Angle Switches and Brake Actuation.................................. 47
			Continuity.............................................................................. 47
			Creep Speed............................................................................. 47
			Current Limiting........................................................................ 47
			Deceleration............................................................................ 47
			Emergency Reverse....................................................................... 47
			ETAC (Electronic Tiller Arm Card)....................................................... 47
			Fault Codes............................................................................. 48
			Open Circuit............................................................................ 48
			Overvoltage Cutoff...................................................................... 48
			PIN-Key Code............................................................................ 48
			Short Circuit or “Short”................................................................ 48
			Speed Limiting.......................................................................... 48
			Thermal Cutback (Power Amplifier)....................................................... 48
			Tractor................................................................................. 48
			Truck Off Delay (Keypad only)........................................................... 48
			Undervoltage Cutoff..................................................................... 48
		List of Electrical Symbols.................................................................. 49
		Control Handle Display and Programming...................................................... 50
			Figure 54. Control Handle Display...................................................... 50
			Special Truck Mode...................................................................... 50
			Hour Meter (H).......................................................................... 50
			Error Codes (E)......................................................................... 50
			Parameters (P).......................................................................... 58
			Display Part Numbers (Pn)............................................................... 61
		Service Display............................................................................. 62
		Power Amplifier Fault Codes................................................................. 65
		Programmable Maintenance Tool (PMT)......................................................... 67
			Figure 5-8. Programmable Maintenance Tool............................................... 67
			Figure 5-9. Connecting PMT to Power Amplifier........................................... 67
			Monitor Mode............................................................................ 67
			Faults Mode............................................................................. 68
			Information Mode........................................................................ 68
			Programmer Mode......................................................................... 68
		List of Troubleshooting Charts/Tables....................................................... 70
			Troubleshooting Charts.................................................................. 70
			Hydraulic Symptom Tables................................................................ 70
			Travel Symptom Tables................................................................... 70
		Troubleshooting Flowcharts.................................................................. 72
		Symptom Tables: Lift/Lower System........................................................... 76
		Symptom Tables: Travel (Forward/Reverse) System............................................. 80
	Section 6. Component Procedures................................................................. 85
		Component Locator Photo..................................................................... 87
			Figure 6-1. Tractor Interior............................................................ 87
		Battery..................................................................................... 88
			Swingout Battery Pack................................................................... 88
				Figure 6-2. Multiple Battery Wiring Hookup.......................................... 88
			Maintenance-Free Batteries.............................................................. 89
			Battery Maintenance..................................................................... 89
				Figure 6-3. Battery Filler Plugs and Vent Holes..................................... 89
		Tractor Covers.............................................................................. 93
			Figure 6-4. Top Cover Removal (decals omitted).......................................... 93
		Power Cables................................................................................ 94
			Figure 6-5. Power Cables................................................................ 94
		Wiring Harness.............................................................................. 95
			Figure 6-6. Wiring Harness.............................................................. 95
		Fuses....................................................................................... 96
			Figure 6-7. Fuse/Circuit Breaker Location............................................... 96
		Circuit Breaker............................................................................. 97
			Test/Inspection......................................................................... 97
				Figure 6-8. Circuit Breaker Location................................................ 97
		Control Handle.............................................................................. 98
			Control Handle Disassembly.............................................................. 99
				Figure 6-9. Horn Button Removal..................................................... 99
				Figure 6-10. Lift/Lower Button Removal..............................................100
				Figure 6-11. Push Button Removal....................................................100
			Control Handle Stem.....................................................................100
				Figure 6-12. Removing Cover.........................................................100
				Figure 6-13. Cover Removed..........................................................100
				Figure 6-14. Allen Head Cap Screws..................................................101
		Horn (H1)...................................................................................102
			Figure 6-15. Horn Location..............................................................102
		Power Amplifier (A1)........................................................................103
			Figure 6-16. Power Amplifier Location...................................................103
		Contactors..................................................................................104
			Main Contactor (K10)....................................................................104
				Figure 6-17. Main Contactor K10.....................................................104
			Lift Motor Contactor (K30)..............................................................104
				Figure 6-18. Lift Motor Contactor K30...............................................104
		Master Control Relay (K4)...................................................................105
			Inspection/Test.........................................................................105
				Figure 6-19. Master Control Relay (K4)..............................................105
		Switches (General)..........................................................................107
			Test/Inspection.........................................................................107
			Master Control ON/OFF Switch............................................................107
				Figure 6-20. Master Control ON/OFF Switch Location..................................107
			Arm Angle Switches......................................................................108
				Figure 6-21. Arm Angle Switches.....................................................108
				Figure 6-22. Arm Angle Switch Screws................................................108
				Figure 6-23. Control Handle Cover Installed.........................................108
			Lift-Limit Switch.......................................................................109
				Figure 6-24. Lift-Limit Switch......................................................109
			Key Switch (Optional)...................................................................110
		Drive Unit..................................................................................111
			Transmission Assembly...................................................................111
				Figure 6-25. Control Handle Assembly Removal........................................111
				Figure 6-26: Terminal Block.........................................................111
				Figure 6-27. Transmission Assembly, Exploded View...................................113
			Drive Housing Lubrication...............................................................114
				Figure 6-28. Transmission Assembly Fill/Drain Plugs.................................114
			Drive Wheel.............................................................................115
				Figure 6-29. Drive Wheel Nuts.......................................................115
				Figure 6-30. Tire Replacement.......................................................115
		Electromagnetic Brake.......................................................................117
			Brake Disc Location.....................................................................117
				Figure 6-31. Brake Location.........................................................117
			Air Gap Adjustment......................................................................117
				Figure 6-32. Brake Gap Adjustment...................................................117
			Friction Disc Replacement...............................................................118
				Figure 6-33: Friction Disc Replacement..............................................118
			Mechanically Releasing the Brake........................................................118
		Motors, General.............................................................................119
			Drive Motor Brush Inspection............................................................119
				Figure 6-34. Drive Motor Brush, Typical Location....................................119
			Drive Motor Brush Spring Tension........................................................120
				Figure 6-35. Motor Brush Spring Tension Inspection..................................120
			Motor Commutator........................................................................120
				Figure 6-36. Mica Inspection........................................................120
			Terminal Nuts...........................................................................123
				Figure 6-37. Motor Terminal Nuts....................................................123
			Electric Motor Tests....................................................................123
				Figure 6-38. Motor Circuits.........................................................123
		Drive Motor.................................................................................126
			Figure 6-39: Drive Motor Brush Shield...................................................126
		Pallet Forks and Load Wheels................................................................129
			Load Wheels.............................................................................129
				Figure 6-40. Removing Set Screw.....................................................129
			Load Wheel Pull Rod.....................................................................129
				Figure 6-41. Wheel Fork Set Screw Location (top view)...............................129
			Carrier Frame Linkage...................................................................130
				Figure 6-42: Lower Links............................................................130
		Hydraulic Components........................................................................131
			General Guidelines......................................................................131
			Hydraulic Cylinder......................................................................131
				Figure 6-43. Remove Retaining Clip..................................................131
				Figure 6-44. Hydraulic Cylinder (shown extended with retaining clip removed)........131
				Figure 6-45. Hydraulic Cylinder Disassembly.........................................132
			Hydraulic Solenoid......................................................................133
				Figure 6-46. Hydraulic Solenoid.....................................................133
			Hydraulic Unit..........................................................................133
				Figure 6-47. Hydraulic Unit.........................................................134
			Hydraulic Reservoir.....................................................................134
			Filter Screen and Inlet Tube............................................................134
				Figure 6-48. Cleaning Filter Screen.................................................135
			Hydraulic Pump..........................................................................135
			Lift Motor..............................................................................135
			Hydraulic Fluid.........................................................................136
				Figure 6-49. Hydraulic Connections..................................................136
			Adjusting Hydraulic Pump Pressure Relief Valve..........................................137
				Figure 6-50. Checking Relief Valve Pressure.........................................137
		Cold Storage Conditioning...................................................................139
		Lubrication Equivalency Chart...............................................................143
		Torque Chart - Standard.....................................................................144
		Torque Chart - Metric.......................................................................145
		Decimal Equivalent Chart....................................................................146
		Standard/Metric Conversions.................................................................148
			Figure A-1. Electrical Schematic - Sheet 1 of 2.........................................152
			Figure A-2. Electrical Schematic - Sheet 2 of 2.........................................153
			Figure A-3. Hydraulic Schematic.........................................................154
	Index...........................................................................................156

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