Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD

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Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD

Language : English
Pages : 150
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD

3- Introduction Maintenance – P1:

• All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter.
• The operator may adapt them to local conditions, but it is important that the intervals comply with TOYOTA’s minimum requirements.
• The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations.

The following running times have been used when calculating the intervals:
-Day time:08.00-17.00 (20 hr./week)
-2-shifts:06.00-14.00, 14.00-22.00 (40 hr./week)
-3-shifts:06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)

• Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.
• Only use TOYOTA approved spare parts when service and repair work are carried out.

3.1 Safety regulations with maintenance work:
Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.
•Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so
•Keep the area where you carry out the service clean. Oil or water makes the floor slippery
•Never wear loose objects or jewellery when working on the truck

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD

1- Table of contents......................................................................  3
2- Technical data - M4.................................................................... 11
3- Introduction Maintenance - P1.......................................................... 15
	3.1 Safety regulations with maintenance work.......................................... 15
	3.2 Cleaning and washing.............................................................. 16
		3.2.1 External cleaning........................................................... 17
		3.2.2 Cleaning the motor compartment.............................................. 17
		3.2.3 Electrical components....................................................... 17
	3.3 Safe lifting...................................................................... 18
4- Preventive maintenance - P2............................................................ 19
	4.1 Maintenance schedule.............................................................. 19
	4.2 Lubrication schedule.............................................................. 24
5- Oil and grease specifica tion - P3..................................................... 25
6- Tools - P4............................................................................. 27
	6.1 Super Seal connectors............................................................. 27
	6.2 AMP connectors.................................................................... 28
		6.2.1 AMP Connectors, 040 series.................................................. 29
	6.3 Molex connectors.................................................................. 29
	6.4 Other tools....................................................................... 30
7- Engine suspension- 0450................................................................ 31
	7.1 Component parts................................................................... 31
		7.1.1 Component List.............................................................. 32
8- Electric drive motor - 1760............................................................ 33
	8.1 Component parts................................................................... 33
		8.1.1 Dismantling/assembling of motor from truck.................................. 34
		8.1.2 Assembling.................................................................. 35
	8.2 Service/Repairs................................................................... 35
		8.2.1 Dismantling of motor........................................................ 35
		8.2.2 Assembling of motor......................................................... 36
		8.2.3 Cleaning.................................................................... 37
	8.3 Technical data.................................................................... 38
9- Mechanical drive gear unit - 2550...................................................... 39
	9.1 Component parts................................................................... 40
		9.1.1 Technical data.............................................................. 41
	9.2 Leakage from top cover............................................................ 42
		Dismantling....................................................................... 42
		Assembling........................................................................ 42
	9.3 Changing of the drive shaft’s sealing ring........................................ 42
		Dismantling....................................................................... 42
		Assembling........................................................................ 43
10- Electro magnetic brake - 3370......................................................... 45
	10.1 Main components.................................................................. 45
	10.2 Maintenance...................................................................... 46
		10.2.1 Exchange of brake disc..................................................... 46
11- Electro magnetic brake - 3370......................................................... 47
	11.1 Main components.................................................................. 47
	11.2 Maintenance...................................................................... 48
		11.2.1 Basic Adjustment of gap.................................................... 48
			Adjustment:................................................................... 48
		11.2.2 Exchange of brake disc..................................................... 49
12- Steering system - 4000................................................................ 51
	12.1 Component parts, tiller arm...................................................... 51
	12.2 Adjustments...................................................................... 52
		12.2.1 Adjusting of brake microswitch............................................. 52
	12.3 Tiller arm handle................................................................ 53
		12.3.1 Dismantling/Assembling..................................................... 54
			Change from ignition key to keyboard (2)...................................... 55
			Change from keyboard to ignition key (2)...................................... 55
			Changing of signal button/switch (9, 10)...................................... 56
			Changing of lift/lowering button (13)......................................... 56
			Changing of pushbutton (16)................................................... 57
13- Electrical System - 5000.............................................................. 59
	13.1 Electrical components............................................................ 59
	13.2 Symbol List and Wiring Diagram................................................... 61
		13.2.1 Wiring diagram 1(5)........................................................ 63
		13.2.2 Wiring diagram 2(5)........................................................ 64
		13.2.3 Wiring diagram 3(5)........................................................ 65
		13.2.4 Wiring diagram 4(5)........................................................ 66
		13.2.5 Wiring diagram 5(5)........................................................ 67
		13.2.6 Wiring diagram 1(5)........................................................ 68
		13.2.7 Wiring diagram 2(5)........................................................ 69
		13.2.8 Wiring diagram 3(5)........................................................ 70
		13.2.9 Wiring diagram 4(5)........................................................ 71
		13.2.10 Wiring diagram 5(5)....................................................... 72
	13.3 Operating description............................................................ 73
		13.3.1 Starting truck............................................................. 73
		13.3.2 Driving speed £ 6 km/h..................................................... 73
		13.3.3 Braking in neutral mode.................................................... 73
		13.3.4 Braking in neutral mode on a slope......................................... 73
		13.3.5 Braking.................................................................... 74
		13.3.6 Lifting the forks.......................................................... 74
		13.3.7 Lowering the forks......................................................... 74
		13.3.8 Horn....................................................................... 74
	13.4 Hour meter....................................................................... 74
	13.5 Error codes...................................................................... 75
	13.6 Parameters....................................................................... 89
		13.6.1 Operator parameters........................................................ 89
		13.6.2 Parameter description...................................................... 90
			Parameter 1................................................................... 90
			Parameter 2................................................................... 90
			Parameter 3................................................................... 90
			Parameter 4................................................................... 90
			Parameter 5................................................................... 90
		13.6.3 Service parameters......................................................... 91
		13.6.4 Parameter description...................................................... 92
			Parameter 10.................................................................. 92
			Parameter 14.................................................................. 93
			Parameter 15 - Non-configurable option........................................ 93
			Parameter 16 - Configurable option #1......................................... 93
			Parameter 17 - Configurable option #2......................................... 93
			Parameter 18 - Configurable option #3......................................... 93
			Parameter 19 - Configurable option #4......................................... 93
			Option parameters............................................................. 93
			General....................................................................... 93
			Parameter #15 Non-configurable options........................................ 93
			Changing non-configurable options............................................. 94
			Parameter #16 to 19 configurable optional functions........................... 95
			Changing configurable optional functions...................................... 95
			Parameter 20..................................................................100
			Parameter 21..................................................................100
			Recommendation on parameter setting for freely ventilated batteries...........101
			Instructions for verifying parameter setting..................................102
			Recommendation on parameter setting for valve- controlled batteries (VRLA)....103
			Instructions for verifying parameter setting..................................104
			Parameter 22..................................................................104
			Parameter 25..................................................................104
			Parameter 28..................................................................104
			Parameter 39..................................................................105
			Login method and driver parameter access......................................105
			Expanded keypad - General.....................................................105
			Expanded keypad - Programming.................................................105
			Service indication............................................................107
	13.7 Part number......................................................................110
	13.8 Transistor panel.................................................................110
		13.8.1 General....................................................................110
	13.9 Troubleshooting..................................................................111
		13.9.1 Error codes and troubleshooting............................................111
		13.9.2 Reset error................................................................112
		13.9.3 Safety.....................................................................112
	13.10 Technical specifications - Curtis 1243..........................................113
14- Hydraulic/Pneumatik - 6000............................................................115
	14.1 General..........................................................................115
	14.2 Hydraulic chart and list of symbols..............................................115
		14.2.1 List of Symbols............................................................115
	14.3 Adjustments 7PM18................................................................116
		14.3.1 Adjusting the pressure limit valve.........................................116
		14.3.2 Tools......................................................................117
	14.4 Adjustments 7PM20................................................................118
		14.4.1 Adjusting the pressure limit valve.........................................118
	14.5 Hydraulic chart and list of symbols..............................................119
		14.5.1 List of Symbols............................................................119
	14.6 Adjusting the pressure limit valve...............................................120
15- PowerTrak cylinder - 6680.............................................................121
	15.1 Component parts..................................................................121
	15.2 Dismantling of PowerTrak cylinder................................................122
16- Battery charger (Inbuilt) - 8340......................................................123
	16.1 General..........................................................................123
	16.2 Charging.........................................................................123
	16.3 Troubleshooting and service......................................................124
	16.4 Technical data...................................................................124
	16.5 Charging settings................................................................125
		16.5.1 Freely ventilated batteries................................................125
		16.5.2 Valve regulated batteries..................................................125
17- Control/computer equipment - 8700.....................................................127
	17.1 General..........................................................................127
	17.2 Connection.......................................................................127
	17.3 Layout...........................................................................128
		17.3.1 Main program screen........................................................128
		17.3.2 Nodes......................................................................128
		17.3.3 Icons......................................................................129
		17.3.4 Tool buttons and menu bar..................................................129
		17.3.5 Information window.........................................................130
		17.3.6 Status bar.................................................................130
	17.4 Connection function..............................................................130
	17.5 Disconnection function...........................................................130
	17.6 Downloading program function.....................................................131
		17.6.1 Normal downloading (truck with key)........................................131
		17.6.2 Normal downloading (truck with keypad).....................................131
		17.6.3 Emergency downloading (truck with keypad)..................................132
		17.6.4 Downloading in old versions of logic card..................................132
		17.6.5 Emergency downloading (truck with keypad)..................................132
	17.7 Truck report function............................................................133
	17.8 Parameters function..............................................................134
	17.9 Diagnostics function.............................................................134
		17.9.1 Representation of signal colours...........................................135
		17.9.2 “Tiller arm” tab...........................................................135
		17.9.3 “Drive Controller” tab (transistor regulator - travel).....................136
		17.9.4 “Pump controller” tab (transistor regulator - pump)........................137
		17.9.5 “EPS” steering servo tab...................................................138
	17.10 Other menu functions............................................................139
		17.10.1 Save to file..............................................................139
		17.10.2 Download from file........................................................139
		17.10.3 Reset CAN adapter.........................................................139
		17.10.4 Delete error code log.....................................................139
		17.10.5 Reset hour meter..........................................................139
		17.10.6 Read error code log.......................................................139
		17.10.7 Adjust date and time......................................................140
		17.10.8 Adjusting the hour meter on older cards...................................140
		17.10.9 Help......................................................................140
			About the TruckCom application................................................140
		17.10.10 Exit.....................................................................140
	17.11 Specifications..................................................................140
	17.12 Installation....................................................................141
		17.12.1 Installation on a PC with Windows® 95/98..................................141
		17.12.2 Installation on a PC with Windows XP/ 2000................................142
		17.12.3 Installation on a PC with Windows NT......................................147
		17.12.4 In case of communication problems with CAN................................147
		17.12.5 To uninstall..............................................................147

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