TOYOTA Forklift 7LOP12, 7LOP12P, 7LOP25, 7LOP25P Service Manual PDF

Description

TOYOTA Forklift 7LOP12, 7LOP12P, 7LOP25, 7LOP25P Service Manual – PDF DOWNLOAD

FILE DETAILS:

TOYOTA Forklift 7LOP12, 7LOP12P, 7LOP25, 7LOP25P Service Manual – PDF DOWNLOAD

Language : English
Pages : 260
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

TOYOTA Forklift 7LOP12, 7LOP12P, 7LOP25, 7LOP25P Service Manual – PDF DOWNLOAD

1- Table of contents 3
2- Technical data 11
21 Specific tightening torques 15
22 General tightening torques 16
221 Galvanised, non-oiled bolts 16
222 Untreated, oiled bolts 16
3- Maintenance 17
31 Safety rules during maintenance work 17
32 Cleaning and washing 19
321 External cleaning 19
322 Cleaning the motor compartment 19
323 Electric components 19
33 Safe lifting 20
34 Lifting the truck 21
35 Maintenance schedule 22
7LOP12, 7LOP12P 28
7LOP25, 7LOP25P 29
36 Lubrication schedule 30
37 Oil and grease specification 32
4- Tools 33
41 Super Seal connectors 33
42 AMP connectors 34
421 AMP connectors, Multilock series 040 35
43 Molex connectors 35
44 Other tools 36
5- Fork carriage – 0380 39
51 7LOP12, 7LOP12P 39
511 Component overview 39
512 Verifying lateral play 40
513 Disassembly of the fork carriage 41
514 Roller replacement 41
52 7LOP25, 7LOP25P 42
521 Included components 42
522 Disassembly of the fork carriage 44
523 Roller replacement 45
6- Electric drive motor – 1760 47
61 Component parts 47
62 Removing the motor from the truck 49
63 Refitting the motor in the truck 50
64 Service and repairs 50
641 Cleaning 50
7- Drive unit/gear – 2550 51
71 General 51
72 Included components 52
73 Disassembly of the drive unit from the truck 53
74 Assembly of the drive unit in the truck 53
75 Oil inspection or changing oil 54
751 Oil inspection/replenishment 54
752 Changing oil 54
76 Replacing the gasket ring 54
761 Disassembly 54
762 Assembly 55
77 Leakage from top cover 55
78 Pin bolt replacement 56
8- Electromagnetic brake – 3370 57
81 Component overview 57
82 Disassembly 58
821 Inspection 58
83 Assembly 59
84 Manual release of the brake 59
85 Adjustment 59
851 Adjusting the play 59
9- Swivel wheel – 3540 61
91 General 61
92 Component overview 62
93 Maintenance 63
931 Swivel wheel height inspection 63
932 Swivel wheel height adjustment 65
Adjust the swivel wheel 65
Adjustment 65
933 Replacing the swivel wheel 65
Disassembly of the swivel wheel assembly 65
934 Replacing the wheel 66
Disassembly 66
Assembly 66
935 Replacing the wheel bearing 66
10- Electrical steering system – 4300 67
101 General 67
1011 Electrical steering servo 68
102 Component overview 69
103 Adjustment 71
1031 Reference sensor 71
1032 Calibration 71
Parameter 36 71
Parameter 37 71
104 Disassembly/assembly of pushbuttons 72
1041 Replacing the hornbutton/switch 72
1042 Replacing the lifting/lowering pushbutton 73
1043 Replacing the pushbutton 73
105 Replacing the potentiometer 74
106 Inspection and replacement of the lateral movement line (Ergo version) 77
107 Replacing the inductive brake sensor 79
108 Replacing the viscous damper 82
11- Electrical systems – 5000 85
111 General 85
1111 Software/hardware order numbers 85
1112 Nomenclature 86
112 Electrical equipment overview 87
1121 Electric component overview 90
113 Electrical wiring diagram 93
1131 Symbol list 93
1132 Overview 94
1133 Detailed wiring diagram 7LOP12 95
1134 Detailed wiring diagram 7LOP12P102
1135 Detailed wiring diagram 7LOP25110
1136 Detailed wiring diagram 7LOP25P116
114 Functional description123
1141 Description of the steering servo system135
1142 Spider expansion unit (SEU)135
1143 Speed limitation137
1144 Hour meter and battery condition139
1145 TLS – Truck log system (optional)140
General140
Registration140
Logging in/out SD16140
Logging in/out S16140
Collision sensor141
Settings141
1146 ID unit (optional)141
115 Parameters & adjustments142
1151 General142
1152 Displaying parameters – without the CAN service key142
1153 Adjusting operator parameters – without the CAN service key143
1154 Displaying & changing parameters – CAN service key connected144
Changing a parameter144
1155 List of Operator parameters146
1156 Description of operator parameters147
#1 – Speed, Fork direction147
# 2 – Speed, Drive wheel direction147
# 3 – Acceleration147
# 4 – Neutral braking force147
# 5 – Travel speed, platform > 05 m147
# 6 – Travel speed, walking at side147
# 7 – Neutral braking, walking at side147
1157 List of Service parameters148
1158 Description of Service parameter149
# 10 – PIN code149
To enter a new PIN-code:150
To remove an existing PIN-code:150
# 11 – Reverse braking force151
# 14 – Creep speed151
# 15 – Non-configurable options151
Setting Non-configurable options151
#16 – Configurable option #1152
#17 – Configurable option #2152
#18 – Configurable option #3152
#19 – Configurable option #4152
# 20 – Hour meter selection153
# 21 – Battery size154
# 22 – Machine type155
# 23 – Function selection155
# 24 – N/A155
# 25 – Service interval155
# 28 – Button selection156
# 35 – Automatic log-off156
# 36 – Steer servo calibration156
# 37 – Steering offset157
# 39 – Log-in method & operator parameter access157
Extended keypad – General158
Extended keypad – Programming158
1159 Configurable “Option” Parameters161
General161
Parameter #16 to #19 Configurable options162
Setting Configurable options163
116 Diagnostic and troubleshooting172
1161 General172
1162 Fault code history173
1163 List of error codes174
1164 Transistor regulator troubleshooting and error codes180
General180
Transistor regulator errors181
Resetting errors182
Safety182
1165 Built-in Test Function183
Digital inputs/outputs test mode184
Transistor regulator inputs184
Transistor regulator outputs185
Digital input of logic card [A2]185
Digital input/output to expansion unit [A36]186
Extra functions186
1166 Display test mode187
117 Technical specifications – Curtis 1243188
12- Hydraulic system – 6000189
121 Hydraulic component overview189
122 Hydraulic diagrams190
1221 Component overview192
123 Functional description193
1231 Fork lifting193
1232 Fork lowering193
1233 Platform lifting193
1234 Platform lowering193
1235 Operating pressure193
1236 Relief valve194
1237 Platform cylinder check valve194
1238 Pressure sensor194
124 Adjustments195
1241 Adjusting the pressure limiting valve195
125 Tools196
13- Main lift chain system – 7120197
131 General197
132 Checking the chain setting197
133 Chain inspection197
1331 Noise197
1332 Surface rust197
1333 Rusty links197
1334 Stiff links198
1335 Bolt rotation198
1336 Loose bolts198
1337 Outline wear199
1338 Stretching200
1339 Damage200
13310 Damaged discs201
13311 Damaged bolts201
13312 Dirty chain201
134 Cleaning201
135 Lubrication202
14- Platform – 9130203
141 General203
142 Component overview204
143 Adjustment206
1431 Outer side guide207
15- TruckCom209
151 General209
152 Connection210
153 Layout211
1531 Main program screen211
1532 Nodes211
1533 Icons212
1534 Tool buttons and menu bar212
1535 Information window213
1536 Status bar213
154 Connection function213
155 Disconnection function213
156 Downloading program function214
1561 Normal downloading (truck with key)214
1562 Normal downloading (truck with keypad)214
1563 Emergency downloading (truck with keypad)215
1564 Emergency downloading (truck with keypad)215
1565 Downloading in old versions of logic card215
157 Truck report function216
158 Parameters function217
1581 PIN-code218
1582 Hour meters219
159 Diagnostics function219
1591 Representation of signal colours220
1592 “Tiller arm” tab220
1593 “Drive Controller” tab (transistor regulator driving)221
1594 “Pump controller” tab (transistor regulator pump)222
1595 “EPS” (steering servo tab)223
1596 SEU tab (Extra I/O module)224
1510 Other menu functions224
15101 Save to file224
15102 Download from file225
15103 Reset CAN adapter225
15104 Delete error code log225
15105 Reset hour meter225
15106 Read error code log225
15107 Adjust date and time225
15108 Adjusting the hour meter on older cards225
15109 Help225
About the TruckCom application225
151010 Exit226
1511 Specifications226
1512 Installation226
15121 Installation on a PC with Windows® 95/98226
15122 Installation on a PC with Windows XP/2000228
15123 Installation on a PC with Windows NT228
15124 In case of communication problems with CAN228
1513 Installation of the CPC-USB interface229
1514 To uninstall231
16- Destruction instructions233
161 General233
162 Procedure233
163 Abbreviations233
164 Sorting234
165 Hoods, hatches (0340)235
1651 Disassembly235
1652 Material handling235
166 Battery cover (0340)236
1661 Disassembly236
1662 Material handling236
167 Frame/chassis (0300) and fork frame (0380/7000)237
1671 Disassembly237
1672 Material handling237
168 Seat, cushions (0620)238
1681 Disassembly238
1682 Material handling238
169 Wall/floor covering (0670)239
1691 Disassembly239
1692 Material handling239
1610 Internal fittings (0680)240
16101 Disassembly240
16102 Material handling240
1611 Operator protection (0840)241
16111 Disassembly241
16112 Material handling241
1612 Electric motors (1700)242
16121 Disassembly242
16122 Material handling242
1613 Drive assembly/gear (2550)243
16131 Disassembly243
16132 Material handling243
1614 Wheels (3500)244
16141 Disassembly244
16142 Material handling244
1615 Steering unit (4110)245
16151 Disassembly245
16152 Material handling245
1616 General electronic equipment (5100)246
16161 Disassembly246
16162 Material handling246
1617 Battery cut out connector/ contactor (5190)247
16171 Disassembly247
16172 Material handling247
1618 Extra SEU expansion unit (5730)248
16181 Disassembly248
16182 Material handling248
1619 Hydraulic unit (6100)249
16191 Disassembly249
16192 Material handling249
1620 Hydraulic lines chassis (6230) and main lift cylinders (6610)250
16201 Disassembly250
16202 Material handling250
1621 Charger adaptor (9380)251
16211 Disassembly251
16212 Material handling251
1622 Terminal on board (9410)252
16221 Disassembly252
16222 Material handling252
1623 Other extra equipment, tuck log device (9420)253
16231 Disassembly253
16232 Material handling253
1624 Other extra equipment, load support (9500)254
16241 Disassembly254
16242 Material handling254
1625 Other extra equipment, writing table (9500)255
16251 Disassembly255
16252 Material handling255
1626 Other extra equipment, writing table (9500)256
16261 Disassembly256
16262 Material handling256
1627 Other extra equipment, support (9500)257
16271 Disassembly257
16272 Material handling257
1628 Other extra equipment, collision protection (9500)258
16281 Disassembly258
16282 Material handling258
1629 Other extra equipment, working cage (9130)259
16291 Disassembly259
16292 Material handling259

S.V 26/02/2025