TOYOTA Forklift 7LOP10CW, 7LOP10CF z wozka 7LOP Szkolenie technikow serwisu PDF

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TOYOTA Forklift 7LOP10CW, 7LOP10CF z wozka 7LOP Szkolenie technikow serwisu – PDF DOWNLOAD

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TOYOTA Forklift 7LOP10CW, 7LOP10CF z wozka 7LOP Szkolenie technikow serwisu – PDF DOWNLOAD

Language : English
Pages : 206
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

TOYOTA Forklift 7LOP10CW, 7LOP10CF z wozka 7LOP Szkolenie technikow serwisu – PDF DOWNLOAD

1- Contents 1-1
2- Technical data 2-1
21Tightening torques 2-5
22General tightening torques 2-6
3- Maintenance 3-1
31Safety rules during maintenance work 3-1
32Cleaning and washing 3-3
321 External cleaning 3-3
322 Cleaning the motor compartment 3-3
323 Electric components 3-3
33Safe lifting 3-4
34Lifting the truck 3-5
35Maintenance schedule 3-6
36Lubrication schedule 3-11
37Oil and lubricant specifications 3-12
4- Tools 4-1
41Super Seal connectors 4-1
42AMP connectors 4-2
421 AMP Connectors, 040 series 4-3
422 AMP connectors CPC 4-4
43Molex connectors 4-5
44Grease guns 4-6
45Other tools 4-7
5- Electric drive motor – 1760 5-1
51General 5-1
52Mechanical design 5-1
53Disassembly of the motor from the truck 5-2
54Assembly of the motor in the truck 5-2
55Service and repairs 5-3
551 Disassembly of the motor 5-3
552 Disassembly, N side 5-4
553 Disassembly, D side 5-4
554 Wearing parts 5-4
555 Cleaning 5-5
6- Driving unit/gear – 2550 6-1
61Included components 6-2
62Disassembly/Assembly Leakage from top cover 6-3
Assembly is done in reverse 6-3
63Replacing the drive axle jointing ring 6-4
631 Disassembly 6-4
632 Assembly 6-5
64Replacing the wheel bolt 6-6
7- Electromagnetic brake – 3370 7-1
71Included components 7-2
72Disassembly 7-2
721 Inspection 7-2
2 Service Manual 7LOP10CW, 7LOP10CF © TIEE SARL
T-code Valid from serial number Date Order number
787, 788 931876- 2006-04-10 232370-040
73 Assembly 7-3
74Manual release of the brake 7-3
75Adjustment 7-3
751 Adjusting the play 7-3
8- Support wheels – 3500 8-1
81Main components 8-1
811 Replacing the wheel 8-2
Disassembly 8-2
Assembly 8-2
812 Replacing the wheel bearings 8-2
9- Electrical steering system – 4300 9-1
91General 9-1
911 Electrical steering servo 9-2
92Component overview 9-3
93Adjustment 9-5
931 Reference sensor 9-5
932 Calibration 9-5
Parameter 36 9-5
Parameter 37 9-5
94Disassembly/assembly of pushbuttons 9-6
941 Replacing the hornbutton/switch 9-6
942 Replacing the lifting/lowering pushbutton 9-7
943 Replacing the pushbutton 9-7
95Replacing the potentiometer 9-8
96Replacing the inductive brake sensor 9-11
97Replacing the viscous damper 9-14
10- Electrical systems – 5000 10-1
101General 10-1
1011 Software/hardware order numbers 10-1
1012 Nomenclature 10-2
102Electrical equipment overview 10-3
1021 Electric component overview 10-5
103Electrical wiring diagram 10-8
1031 Symbol list 10-8
1032 Overview 10-9
1033 Detailed wiring diagram 10-10
104Functional description 10-19
1041 Description of steering system 10-24
1042 Spider expansion unit (SEU) 10-25
1043 Speed limitation 10-26
1044 Hour meter and battery condition 10-27
1045 TLS – Truck log system (optional) 10-28
General 10-28
Registration 10-28
Logging in/out SD16 10-28
Logging in/out S16 10-28
Collision sensor 10-29
Settings 10-29
1046 ID unit (optional) 10-30
General 10-30
Installation 10-30
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 3
Settings 10-31
105Parameters & adjustments 10-33
1051 General 10-33
1052 Displaying parameters – without the CAN service key 10-33
1053 Adjusting operator parameters – without the CAN service
key 10-34
1054 Displaying & changing parameters – CAN service key connected 10-34
Changing a parameter 10-35
1055 List of operator parameters 10-36
1056 Description of operator parameters 10-37
#1 – Speed, Fork direction 10-37
# 2 – Speed, Drive wheel direction 10-37
# 3 – Acceleration 10-37
# 4 – Neutral braking force 10-37
# 5 – Travel speed, cabin > 05 m 10-37
# 6 – Travel speed, walking at side 10-37
# 7 – Neutral braking, walking at side 10-37
1057 List of Service parameters 10-38
1058 Description of Service parameter 10-39
# 10 – PIN code 10-39
To enter a new PIN-code: 10-40
To remove an existing PIN-code: 10-40
# 11 – Reverse braking force 10-41
# 14 – Creep speed 10-41
#15 – Non-configurable options 10-41
Setting Non-configurable options 10-41
#16 – Configurable option #1 10-42
#17 – Configurable option #2 10-42
#19 – Configurable option #4 10-42
# 20 – Hour meter selection 10-43
# 21 – Battery size 10-44
# 22 – Machine type 10-45
# 23 – Function selection 10-45
# 24 – Special request 10-45
# 25 – Service interval 10-45
# 28 – Button selection 10-45
# 35 – Automatic log-off 10-46
# 36 – Steer servo calibration 10-46
# 37 – Steering offset 10-47
# 39 – Log-in method & operator parameter access 10-47
Extended keypad – General 10-48
Extended keypad – Programming 10-48
1059 Configurable “Option” parameters 10-50
General 10-50
Parameter #16 to #19 configurable options 10-51
Setting Configurable options 10-52
106Diagnostic and troubleshooting 10-63
1061 General 10-63
1062 Fault code history 10-64
1063 List of fault codes 10-64
1064 Transistor regulator troubleshooting and error codes 10-70
General 10-70
Transistor regulator errors 10-71
Resetting errors 10-72
Safety 10-72
4 Service Manual 7LOP10CW, 7LOP10CF © TIEE SARL
T-code Valid from serial number Date Order number
787, 788 931876- 2006-04-10 232370-040
1065 Built-in Test Function 10-73
Digital inputs/outputs test mode 10-74
1066 Transistor regulator inputs 10-74
Transistor regulator outputs 10-75
Digital input of logic card [A2] 10-75
Digital input/output to expansion unit [A36] 10-76
Digital input/output to expansion unit [A36] (Option) 10-76
Extra functions 10-77
1067 Display test mode 10-77
107Technical specifications – Curtis 1243 10-78
11- Hydraulic system – 6000 11-1
1117LOP10CW 11-1
1111 General 11-1
1112 Hydraulic drawing and symbol list 11-2
Symbol list 11-2
1113 Description 11-3
Lift 11-3
Lowering 11-3
Operating pressure 11-3
Relief valve 11-3
Pressure sensor 11-3
1127LOP10CF 11-4
1121 General 11-4
1122 Hydraulic drawing and symbol list 11-5
Symbol list 11-6
1123 Description 11-6
Cabin lifting 11-6
Cabin lowering 11-6
Initial forks 11-7
Initial forks lowering 11-7
Operating pressure 11-7
Relief valve 11-7
Check valve for the cabin / forks cylinders (3) 11-7
Pressure sensors, B10/B11 11-7
113Adjustments 11-8
Adjusting the pressure limiting valve 11-8
12- Main lift chain system – 7120 12-1
121General 12-1
122Checking the chain setting 12-1
123Chain inspection 12-1
1231 Noise 12-1
1232 Surface rust 12-1
1233 Rusty links 12-1
1234 Stiff links 12-2
1235 Bolt rotation 12-2
1236 Loose bolts 12-2
1237 Outline wear 12-3
1238 Stretching 12-4
1239 Damage 12-5
12310 Damaged discs 12-5
12311 Damaged bolts 12-5
12312 Dirty chain 12-5
124Cleaning 12-5
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 5
125Lubrication 12-6
13- Fork carriage – 7420 13-1
131Included components 13-1
132Dismounting of the mast carriage 13-3
133Adjusting the play 13-3
134Roller replacement 13-3
135Dismounting of the initial fork carriage 13-4
14- TruckCom 14-1
141General 14-1
142Connection 14-1
143Layout 14-2
1431 Main program screen 14-2
1432 Nodes 14-2
1433 Icons 14-3
1434 Tool buttons and menu bar 14-3
1435 Information window 14-4
1436 Status bar 14-4
144 Connection function 14-4
145Disconnection function 14-4
146Downloading program function 14-5
1461 Normal downloading (truck with key) 14-5
1462 Normal downloading (truck with keypad) 14-5
1463 Emergency downloading (truck with keypad) 14-6
1464 Emergency downloading (truck with keypad) 14-6
1465 Downloading in old versions of logic card 14-6
147Truck report function 14-7
148Parameters function 14-8
149Diagnostics function 14-8
1491 Representation of signal colours 14-9
1492 “Tiller arm” tab 14-9
1493 “Drive Controller” tab (transistor regulator driving) 14-10
1494 “Pump controller” tab (transistor regulator pump) 14-11
1495 “EPS” (steering servo tab) 14-12
1496 SEU tab (Extra I/O module) 14-13
1410Other menu functions 14-13
14101 Save to file 14-13
14102 Download from file 14-13
14103 Reset CAN adapter 14-14
14104 Delete error code log 14-14
14105 Reset hour meter 14-14
14106 Read error code log 14-14
14107 Adjust date and time 14-14
14108 Adjusting the hour meter on older cards 14-14
14109 Help 14-14
About the TruckCom application 14-14
141010 Exit 14-14
1411Specifications 14-15
1412Installation 14-15
14121 Installation on a PC with Windows® 95/98 14-15
14122 Installation on a PC with Windows XP/2000 14-16
Changes in Windows® control panel 14-19
14123 Installation on a PC with Windows NT 14-22
6 Service Manual 7LOP10CW, 7LOP10CF © TIEE SARL
T-code Valid from serial number Date Order number
787, 788 931876- 2006-04-10 232370-040
14124 In case of communication problems with CAN 14-22
14125 To uninstall 14-22
15- Destruction instructions 15-1
151General 15-1
152Procedure 15-1
153Abbreviations 15-2
154Sorting 15-2
155Hoods, hatches (0340) 15-3
156Hoods, hatches (0340) 15-4
157Seat, cushions (0620) 15-5
158Wall/floor covering (0670) 15-6
159Electric motors (1700) 15-7
1510Drive assembly/gear (2550) 15-8
1511Wheels (3500) 15-9
1512Steering arm (4110) 15-10
1513General electronic equipment (5100) 15-11
1514Battery cut out connector/contactor (5190) 15-12
1515Expansion unit “SEU”(5730) 15-13
1516Hydraulic unit (6100) 15-14
1517Hydraulic lines chassis (6230) and main lift cylinders (6610) 15-15
1518Frame/chassis (7420) 15-16
1519Charger adaptor (9380) 15-17
1520Other extra equipment, tuck log device (9420) 15-18
1521Other extra equipment, writing table (9500) 15-19

S.V 26/02/2025