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

SERVICE MANUAL 4,500 lb. Powered Pallet Walkie Model 7HBW23

Serial No. 24,501 and up

00700-CL340-05, Issued: 2 May 2005

©2005 by Toyota Industrial Equipment.

All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electroinc retrieval or transfer, or recording without the written permission of the publisher.

Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual.

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Toyota Model 7HBW23 Service Manual

Table of Contents

Table of Contents How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Static Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Control Handle Display and Programming . . . . . . . . . . . . . . . . . . . . . 5-9 Service Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Programmable Maintenance Tool (PMT) . . . . . . . . . . . . . . . . . . . . . . 5-26 List of Troubleshooting Charts/Tables . . . . . . . . . . . . . . . . . . . . . . . 5-29 Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . 5-39 Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Component Locator Photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Tractor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Horn (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Power Amplifier (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Master Control Relay (K4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

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Table of Contents

Toyota Model 7HBW23 Service Manual

Electromagnetic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Pallet Forks and Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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How To Use

Toyota Model 7HBW23 Service Manual

Section 1. How To Use This Manual

Section 1. How To Use This Manual

00700-CL340-05, Issued: 2 May 2005

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Section 1. How To Use This Manual

Toyota Model 7HBW23 Service Manual

Map of the Manual

Map of the Manual How to Use This Manual

Map of the Manual

Manual Design Safety

Start Page Systems Overview

Vehicle Specifications

General System Data Scheduled Maintenance Theory of Operations

Electrical & Hydraulic T.S. Guidelines

Trouble Shooting

Definitions Component Procedures

Alphabetical List of Component Procedures Fault Codes Component Location Photos

Appendix Programmable Maintenance Tool

Index

Troubleshooting Charts and Symptom Tables

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00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 1. How To Use This Manual Manual Design

Manual Design

• “TS1: START TROUBLESHOOTING” on page 5-31 will guide you to the individual troubleshooting symptom chart you need.

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

• When you are familiar with the symptoms listed, you may instead find the symptom chart from the “List of Troubleshooting Charts/Tables” on page 5-29.

• When you complete a troubleshooting procedure, make sure to follow the steps in the “END1: End of Troubleshooting Procedure” on page 5-33.

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)

•

• Frequency of attention • Physical attachment (example: brake must be removed before drive motor)

We suggest you get in the habit of turning to the START page first when you use this manual.

• Functional relation (for example: drive motor and drive unit components are grouped together)

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.

Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order that considers:

To find a component procedure, you may use one of three methods: • Look up the component name. See “Component Procedures” on page 6-1.

• Find the component. See “Component Locator Photo” on page 6-3.

• Look up the component name in the Index. See “Index” on page I-1.

•

Appendix contains reference information such as torque values, lubricants, and schematics.

•

Index lists subjects alphabetically.

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.

00700-CL340-05, Issued: 2 May 2005

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Section 1. How To Use This Manual

Toyota Model 7HBW23 Service Manual

Manual Design

1-4

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 1. How To Use This Manual START Page

Section 1. How To Use This Manual

START Page START:

To review safety precautions?

Why are you here?

Yes

Go to Section 2 "Safety"

Yes

Go to Section 3 "Systems Overview"

Yes

Go to Section 4 "Scheduled Maintenance"

Yes

Go to Section 5 "Troubleshooting"

No

To examine specifications or theory of operations?

No

To do scheduled maintenance?

No

To troubleshoot a problem?

List of Troubleshooting Charts No

Go to Chart START-2

START Troubleshooting

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00700-CL340-05, Issued: 2 May 2005

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Section 1. How To Use This Manual

Toyota Model 7HBW23 Service Manual

START Page

START2

To test, inspect, adjust, remove/install a component?

Yes

Go to Section 6 "Component Procedures"

Alphabetical List of Component Procedures

No

To find general reference information?

Component Locator Yes

Go to the "Appendix"

No

To locate an object or procedure by name?

Go to the Index Yes

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Safety

Toyota Model 7HBW23 Service Manual

Section 2. Safety

Section 2. Safety

00700-CL340-05, Issued: 2 May 2005

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Section 2. Safety

Toyota Model 7HBW23 Service Manual

Definitions

Definitions Throughout this manual, you will see two kinds of safety reminders:

Warning means a potentially hazardous situation exists that, if not avoided, could result in death or serious injury.

Caution means a potentially hazardous situation exists that, if not avoided, could result in minor or moderate injury or in damage to the truck or nearby objects.

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00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 2. Safety General Safety

General Safety

1864 002.eps

Do not operate or work on this truck unless you are trained, qualified, and authorized to do so and have read the Owner/Operator Manual.

Know the truck’s controls and what they do.

1808 003.eps

Operate this truck only from the operator’s position.

1808 004.eps

Before working on this truck, always press the red OFF key (O) on the keypad and disconnect the truck’s battery connector (unless this manual tells you otherwise).

1808 002.eps

Do not operate this truck if it needs repair or if it is in any way unsafe.

1864 067.eps

Do not wear watches, rings, or jewelry when working on this truck.

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Section 2. Safety

Toyota Model 7HBW23 Service Manual

General Safety

schedmnt.eps

Follow the scheduled lubrication, maintenance, and inspection steps.

spills.eps

Clean up any hydraulic fluid, oil, or grease that has leaked or spilled on the floor.

1808 005.eps

Follow exactly the safety and repair instructions in this manual. Do not take “shortcuts.”

Always park this truck indoors.

23L6S012.eps

Do not use an open flame near the truck.

Do not use gasoline or other flammable liquids for cleaning parts.

2-4

Do not park this truck in a cold storage area overnight.

Do not wash this truck with a hose.

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 2. Safety General Safety

Do not add to or modify this truck until you contact your local Toyota Industrial Equipment Dealer to receive written manufacturer approval.

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Section 2. Safety

Toyota Model 7HBW23 Service Manual

Battery Safety

Battery Safety

As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Make sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury.

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. If any electrolyte comes in contact with your clothing or skin, flush the area immediately with cold water. If the solution gets on your face or in your eyes, flush the area with cold water and get medical help immediately.

04G6S059.eps

Make sure a shower and eyewash station are nearby in case there is an accident.

23L6S012.eps

A battery gives off explosive gases. Never smoke, use an open flame, or use anything that gives off sparks near a battery.

04G6S058.eps 25L6SO16.eps

Wear personal protective equipment to protect eyes, face, and skin when checking, handling, or filling batteries. This equipment includes goggles or face shield, rubber gloves (with or without arm shields), and a rubber apron.

2-6

Keep the charging area well-ventilated to avoid hydrogen gas concentration.

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 2. Safety Battery Safety

Press the red OFF key (O) on the keypad before disconnecting the battery from the truck at the battery connector. Do not break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

27Y7S013.tif

Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks.

Vent Hole

04G6S057.eps

Do not lay tools or metal objects on top of the battery. A short circuit or explosion could result.

09G6S047.tif

Keep filler plugs firmly in position at all times except when the electrolyte level is checked, when water is added to the cells, or when the specific gravity is checked.

Make sure the vent holes in the filler plugs are open to permit the gas to escape from the cells.

Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks.

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Section 2. Safety

Toyota Model 7HBW23 Service Manual

Battery Safety

25L6S014.eps

Do not permit cleaning solution, dirt, or any foreign matter to enter the cells.

Follow the charging procedures in the Battery Instruction Manual and in the Battery Charger Instruction Manual.

Make sure you install the correct size battery. A smaller or lighter weight battery could seriously affect truck stability. See the truck’s specification plate for more information.

1808 006.eps

Never plug a battery charger into the truck’s battery connector. Plug the battery charger only into the battery connector from the battery.

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00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 2. Safety Jacking Safety

Jacking Safety

NOTE: After working on a vehicle, test all controls and functions to assure correct operation.

When it is necessary to jack the truck off the floor to perform maintenance procedures, observe the following safety precautions: 1. Lower the forks completely. Remove any load.

2. Position all controls in neutral.

3. Block the wheels to prevent movement of the vehicle.

4. Press the red OFF key (O) on the keypad and disconnect the battery connector.

5. Position the jack under the designated jacking points.

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck.

After the truck is jacked, position solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck.

Fork Section 1. Using the lift button, raise the forks to maximum height.

2. Block the fork section. The tractor section will remain on the floor.

3. Lower the forks on the blocks.

4. Press the red OFF key (O) on the keypad and disconnect the battery connector.

Tractor Section 1. Position the jack in the designated jacking position.

2. Jack one side of the truck so that the drive tire is off the floor no more than 1 in.

(25.4 mm).

3. Block that side of the truck in place.

4. Jack the other side of the truck level with the first side.

5. Block that side of the truck in place.

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Section 2. Safety

Toyota Model 7HBW23 Service Manual

Towing

Towing To safely tow this truck: 1. Lower the forks and remove any load.

2. Press the red OFF key (O) on the keypad and disconnect the battery connector.

3. Using a suitable towing vehicle, lift the tractor end of the truck until the drive tire is no more than 1 in. (25.4 mm) off the floor.

4. Tow the truck slowly in the tractor-first direction.

NOTE: If a suitable towing vehicle is not available, the electromagnetic brake must be disabled to move this truck. See “Mechanically Releasing the Brake” on page 6-34.

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00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 2. Safety Welding Safety

Welding Safety

Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke and vapors. Prior to performing flame cutting or welding operations, it is recommended that the coating be removed in the vicinity where the operation(s) will be performed.

Coating removal may be by mechanical methods, chemical methods or a combination of methods. Flame cutting and/or welding operations must be carried out only in well ventilated areas using local exhaust if necessary.

1808 004.EPS

•

Disconnect the battery before you attempt to inspect, service, or repair the lift truck.

Discharge residual charge in the power amplifier by connecting a load across the power amplifiers B+ and B– (such as a contactor coil or by pressing the horn button).

•

Do a test for shorts to frame. See “Checking for Shorts from Components to Truck Frame” on page 5-3. If any shorts are detected, remove them before you proceed with the welding operation.

•

Clean the area to be welded.

•

Protect all truck components from heat, weld spatter, and debris.

•

Attach the ground cable as close to the weld area as possible.

•

Do not perform any welding operations near the electrical components.

•

If welding must be done near the battery compartment, remove the battery from the truck.

•

When you are finished welding, perform all ground tests and electrical inspections before the vehicle is operated.

04GSO59.eps

Before working on this truck, make sure that: •

Fire protection equipment is nearby.

•

You know where the nearest eyewash station is located.

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Section 2. Safety

Toyota Model 7HBW23 Service Manual

Static Safety

Static Safety

Wrist straps are available in quantities of 25, as part number 00590-04848-71.

Electronic circuit boards and devices used on this truck can be damaged by the discharge of static electricity, called electrostatic discharge.

A wrist strap tester is available as part number 00590-04850-71.

Static charges can accumulate from normal operation of the truck as well as movement or contact between non-conductive materials (plastic bags, synthetic clothing, synthetic soles on shoes, styrofoam coffee cups, etc.).

Contact your authorized Toyota Dealer for information.

Wrist Strap

Static-Dissipative Work Surface

Accumulated static can be discharged through human skin to a circuit board or component by touching the parts. Static discharge is also possible through the air when a charged object is placed close to another surface at a different electrical potential. Static discharge can occur without you seeing or feeling it.

Whenever working on or near static-sensitive electronics, always use static discharge precautions.

1. Place a static discharge wrist strap around your wrist. Connect the ground lead to the wrist strap connector.

2. Connect the ground strap to an unpainted, grounded surface on the truck frame.

Ground Cord Figure 2-1.

Anti-Static Kit With Wrist Strap and Mat

3. If you are removing or installing static-sensitive components, place them on a correctly grounded static mat.

4. To transport static-sensitive components, including failed components being returned, place the components in an anti-static bag or box (available from your Toyota Dealer).

The wrist strap and associated accessories should be tested monthly to verify they are working correctly. A defective static discharge wrist band will not alert you that it is bad.

Figure 2-1 shows the components of the Toyota anti-static field service kit, part number 00590-04849-71. The kit includes a wrist strap, ground cord and static-dissipative work surface (mat). Follow the instructions packaged with this kit.

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00700-CL340-05, Issued: 2 May 2005

Systems Overview

Toyota Model 7HBW23 Service Manual

Section 3. Systems Overview

Section 3. Systems Overview

00700-CL340-05, Issued: 2 May 2005

3-1

Section 3. Systems Overview

Toyota Model 7HBW23 Service Manual

Truck Model Identification

Truck Model Identification

Figure 3-1. Model 7HBW23 Pallet Truck

1581 001.tif

Vehicle Specifications

The total weight of the load must include the pallet and the container or the device holding the load.

Category

3-2

Maximum Load Capacity

4,500 lb. (2,041 kg)

Upright Height

50.8 in. (129.1 cm)

Overall Length (Handle Raised)

up to 81.8 in. (207.8 cm)

Overall Width

28.0 in. (711 mm)

Maximum Lift Height

8.65 in. (219.7 mm)

Regular Speed, Maximum

3.9 mph (6.3 kph)

Stopping Distance

6 ft. (1.83 m)

Battery Compartment Width

7.8 or 9.0 in. (198 or 228 mm)

Battery Voltage

24V

Minimum Battery Weight

200 lb. (91 kg)

Maximum Battery Weight

660 lb. (299 kg)

Truck Weight Without Battery

800 lb. (362 kg)

Wheel: Drive

10 x 5 in. Rubber

Wheel: Load

3.25 x 5 in. Polyurethane (2)

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 3. Systems Overview General Information

General Information

Control Handle Page 6-14

Battery Page 6-4

Drive Unit Page 6-27

Pallet Forks and Load Wheels Page 6-45

Figure 3-2. Model 7HBW23 General Information

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Section 3. Systems Overview

Toyota Model 7HBW23 Service Manual

Special Tools

Special Tools Programmable Maintenance Tool

Service Key

27y7s021.tif

Figure 3-3. Programmable Maintenance Tool

Figure 3-4. Service Key

The optional Programmable Maintenance Tool (PMT) (P/N 00590-49981-71) permits you to test and diagnose the power amplifier in the truck. See Figure 3-3.

Use the optional Service Key (P/N 00590-42683-71) directly on the truck to troubleshoot and program the truck service parameter settings. See “Parameters (P)” on page 5-17.

The PMT is powered by the host power amplifier through the four-pin connector installed at the bottom of the power amplifier.

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00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 3. Systems Overview Theory of Operation

Theory of Operation Truck Starting

•

hydraulic pressure in the lift cylinder raises the forks.

To start the truck, the battery is plugged in, the Master Control ON/OFF switch is in the ON position, the PIN-key code is entered in the keypad, and the green ON (|) key pressed (or optional key switch is ON). See “Service Display” on page 5-21.

•

lift limit switch (S36) transmits a lift limit signal to the power amplifier which removes power to the lift motor when the forks reach a preset lift limit.

Lift/Lower

When the lift button is released: •

the pump contactor coil (K30) is de-energized. This stops the lift motor and pump. The forks are held in position by hydraulic fluid trapped in the cylinder by the check valve, the static position of the relief valve, and the closed lowering solenoid valve (Y10).

•

the relief valve opens if the hydraulic pressure exceeds the preset limit.

The lift/lower system consists of an electrically operated hydraulic pump assembly and related components.

The hydraulic pump assembly consists of a positive displacement rotary gear pump with reservoir mounted to an adapter. A DC electric motor is mounted to the opposite side of the pump adapter. An adjustable relief valve, check valve, and a solenoid operated lowering valve are installed within the adapter.

Lower When the battery is connected, the truck is ON, and the lower button is pressed:

With the forks elevated, the normally closed solenoid valve and the check valve prevent hydraulic fluid from returning to the reservoir.

•

lower signal is detected via hall effect sensors, converted into the lower instruction, and transmitted via the CAN to the power amplifier.

Lift

•

lowering solenoid valve (Y10) opens.

•

hydraulic fluid in the lift cylinder returns to the hydraulic reservoir through the lowering valve and the flow control valve.

The lowering speed is regulated by the flow control valve.

•

the forks lower.

When the battery is connected, the truck is ON, and the lift button pressed: •

a lift signal is detected via hall effect sensors, converted into the lift instruction, and transmitted via the Controller Area network (CAN) to the power amplifier.

•

the lift pump contactor (K30) closes, applying B+ to the lift pump motor (M3) causing the lift pump to operate.

•

hydraulic fluid is drawn into the lift pump.

•

as the pump rotates, oil is forced out the pressure port through the lift hose to the lift cylinder. Oil cannot return to the reservoir because of the closed pressure relief valve and closed lowering solenoid valve.

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Direction/Speed Control The following descriptions assume the battery is charged and connected, the truck is ON, and main contactor (K10) is energized.

Control Handle Positioning When the control handle is in the full upright position, the parking brake is engaged. When the control handle is positioned from 6 to 46° of the full upright position, the brake disengages e

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Toyota Model 7HBW23 Service Manual

Theory of Operation (when travel is requested), Arm Angle B switch (S25) closes and enables slow speed travel.

When the control handle is placed beyond 46° from the full upright position, Arm Angle A switch (S24) also closes, enabling fast speed travel. When the control handle is placed in the bottom 8° of its operating range, Arm Angle B switch opens, activating the parking brake.

Travel Request, Forks Trailing

•

the ETAC verifies that switch S25 (Arm Angle B) is engaged for slow speed mode

•

the ETAC verifies that both switch S24 (Arm Angle A) and switch S25 (Arm Angle B) are engaged for fast speed mode.

•

the voltage at M– of the drive motor will vary from 24V to 1V. The voltage is proportional to the position of the thumb controls.

•

the drive wheel starts to rotate in reverse direction at a speed proportional to the voltage at M–.

When the thumb controls are rotated in the forward direction (tractor-first) from neutral: •

•

a forward travel signal is detected via hall effect sensors, converted into a travel instruction in the ETAC (See “Electronic Tiller Arm Card (ETAC)” on page 3-7.) and transmitted via the Controller Area network (CAN) to the power amplifier. the ETAC verifies that the emergency reverse button is not activated before supplying the travel command to the power amplifier.

•

the ETAC verifies that switch S25 (Arm Angle B) is engaged for slow speed mode.

•

the ETAC verifies that both switch S24 (Arm Angle A) and switch S25 (Arm Angle B) are engaged for fast speed mode.

•

the voltage at M– of the drive motor will vary from 24V to 1V. The voltage is proportional to the position of the thumb controls.

•

the drive wheel starts to rotate in forward direction at a speed proportional to the voltage at M–.

Emergency Reverse If the emergency reverse button (belly button) is closed with the control handle lowered in travel mode, the control system provides an immediate, rapid acceleration in the reverse (forks-first) direction. The following occurs: •

the emergency reverse signal is converted into a reverse travel instruction and transmitted via the CAN-bus to the power amplifier.

•

travel and speed inputs are ignored.

•

the power amplifier provides maximum torque immediately after the emergency reverse button is activated.

•

maximum reverse travel continues until the emergency reverse button is released.

Travel Request, Forks-First When the thumb controls are rotated in the reverse direction (forks-first) from neutral: •

reverse travel signal is detected via hall effect sensors, converted into a travel. instruction in the ETAC, and transmitted via the CAN-bus to the power amplifier.

•

the ETAC verifies that the emergency reverse button is not activated before supplying the travel command to the power amplifier.

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Toyota Model 7HBW23 Service Manual

Section 3. Systems Overview Theory of Operation

Power Amplifier The basic functions of the power amplifier includes: •

the direction control section that controls the drive motor direction by manipulating the drive motor field polarity according to the directional signal inputs from the ETAC.

•

the speed control section that controls the drive motor speed and torque by monitoring the position change of the Arm Angle A and Arm Angle B switches.

Variable motor speed is accomplished by separate control of field and armature currents.

•

the emergency reverse circuitry in the ETAC which provides the directional travel control commands to the power amplifier.

•

the control circuit section which controls all truck inputs and outputs (excluding handle head inputs).

Electronic Tiller Arm Card (ETAC) The programmable motor control functions are performed by the electronic circuitry housed within the control handle [Electronic Tiller Arm Card (ETAC)]. The basic functions of the ETAC include: •

monitoring relative positioning of the thumb controls to eighteen hall effect sensors for speed and direction control

•

monitoring the position of the emergency reverse button for emergency reversing of the truck direction

•

monitoring truck performance and providing input data and commands to the service display

•

providing lift/lower input commands to the power amplifier

•

monitor horn switches S18-1 and S18-2 for horn operation

•

monitoring and defining truck performance parameters

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Section 3. Systems Overview

Toyota Model 7HBW23 Service Manual

Theory of Operation

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Planned Maintenance

Toyota Model 7HBW23 Service Manual

Section 4. Planned Maintenance

Section 4. Planned Maintenance

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Section 4. Planned Maintenance

Toyota Model 7HBW23 Service Manual

Maintenance Guidelines

Maintenance Guidelines

planned maintenance tasks are completed. Labor and parts for repairs should be calculated as part of the standard truck maintenance costs, separate from the planned maintenance charges.

Following a planned maintenance program: •

Promotes maximum truck performance

•

Prolongs truck life

•

Reduces costly down time

•

Avoids unnecessary repairs

Planned maintenance includes: •

Lubrication

•

Cleaning

•

Inspection

•

Service

Perform all of the scheduled checks and maintenance during the suggested intervals.

The intervals given in this guide are based on normal operating conditions. When operating under abnormal or severe conditions, perform these services more often as necessary to keep the unit in good operating condition.

Time Requirements Performing Planned Maintenance will require approximately 0.75 hour.

General Truck Operation •

Operate all functions of the truck and check for any abnormal operation

•

Talk to the operator to see if any problems were noticed

•

Check to see if all the safety and operational decals are in place and legible

•

List repairs required

See “Lubrication Equivalency Chart” on page A-2. Refer to the manufacturer’s supplements for components not listed on the following pages.

Maintenance Manual Use this manual as required to perform all repair procedures listed in the Planned Maintenance Schedule.

Planned Maintenance Schedule Perform all inspections and lubrication in accordance with the Planned Maintenance Schedule. See “Lubrication Equivalency Chart” on page A-2.

NOTE: Daily (8 hour) inspections should be performed by an authorized Owner-Employee.

All listed repairs should be scheduled for a convenient time between an authorized Customer Representative and the Qualified Service Technician. All repairs should be carried out AFTER the

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Toyota Model 7HBW23 Service Manual

Section 4. Planned Maintenance Maintenance Guidelines

Daily Perform the daily checks and report any faults or abnormal conditions to your supervisor.

Item

Daily or Eight-Hour Checklist

Battery

Check cleanliness and exterior condition. See “Battery Maintenance” on page 6-5.

Check the charge.

Check the weight.

Check the “free play” of the battery. Make sure the battery does not move more than 0.5 in. (13 mm) in any direction.

Battery Connector

Check the connector. Make sure all powered functions shut down when disconnected.

Make sure the battery is properly installed.

General Operation

Check that the horn operates when you press the horn button. (Battery must be connected and the Master Control ON/OFF switch must be ON.) Check the speed and thumb controls.

Check the steering operation.

Check the lifting and lowering functions.

Check the operation of the emergency reverse button.

Check the operation of the Master ON/OFF Switch.

Note any unusual noise during operation, and report it to your supervisor or maintenance personnel.

Brake/Control Handle Decals

Hydraulic System Wheels/Tires

Verify the drive motor does not run while the brake is applied.

Check that the control handle returns to the vertical position when released.

Warning/Safety/Operational decals must be in position and legible.

Contact your local authorized Toyota Industrial Equipment Dealer if any decal is damaged or missing.

Check for oil leaks.

Check the condition of the drive wheel and load wheels. Remove any steel chips and foreign material to prevent damage to the wheels.

Check for gouging and chunking of the surface. If damaged, report to your supervisor or maintenance personnel.

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Section 4. Planned Maintenance

Toyota Model 7HBW23 Service Manual

Maintenance Guidelines

Every Two Months or 250 Operating Hours Perform daily checks plus the following: Item Grease Fittings Forks Lubrication Points Lift Cylinder

Every Two Months or Every 250 Operating Hours Lubricate all grease fittings.

Check the lift-limit switch for lift motor cut-out. Adjust if necessary Lubricate all levers, shafts ,and linkage points.

Check the lift cylinder for leaks. Repair or replace cylinder if necessary. See “Hydraulic Cylinder” on page 6-47.

Hydraulic System

Check for correct fluid level with the forks fully lowered to within 1 in. (25.4 mm) of filler plug. Add fluid if necessary. See “Lubrication Equivalency Chart” on page A-2.

Check hydraulic connections and mountings.

Check the tightness of the pump and motor hardware.

Check hoses, tubes, and fittings for leaks. Replace hoses or seals.

Clean the fill/vent plug. See “Hydraulic Unit” on page 6-49.

General

Check for loose hardware. Tighten if necessary.

Check the tightness of the drive unit mounting bolts. Tighten if necessary.

Electrical System

Visually inspect all cables for damage. Replace if necessary. See “Power Cables” on page 6-10.

Check for electrical shorts to frame. See “Checking for Shorts from Battery to Truck Frame” on page 5-3.

Master Control Relay

Check contacts for welded condition. See “Inspection/Test” on page 6-21.

Drive Wheel

Check the tightness of the mounting bolts on the drive wheel.

Torque to 55 ft. lb. (75 Nm).

Drive Unit

Check for oil leaks. If leaks are found, check the oil level. If the oil level is low, determine the cause. See “Drive Unit” on page 6-27.

Check the transmission pivot bearing.

Motor Brushes

Check the condition of brushes, springs, and holders.

Check that the brush length exceeds the minimum length.

• Drive motor - 0.59 in. (15 mm) • Hydraulic pump motor - 0.35 in. (9 mm)

Arm Angle Switches Load Wheel

4-4

Check adjustment.

Check the load wheel bearings and linkage.

Brake

Check the brake disc for wear. Adjust or replace if necessary. See “Electromagnetic Brake” on page 6-33.

Battery System

Clean the battery and the truck. See “Battery Maintenance” on page 6-5.

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Toyota Model 7HBW23 Service Manual

Section 4. Planned Maintenance Maintenance Guidelines

Annually or Every 1500 Operating Hours Perform Every Two Month checks plus the following: Item Drive Housing

Annually or Every 1500 Hours Change the oil in the drive housing.

See “Drive Housing Lubrication” on page 6-30.

Grease Fittings

Figure 4-1:

Load Wheel Axle (Cold Storage and Corrosion Protection Options only)

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Section 4. Planned Maintenance

Toyota Model 7HBW23 Service Manual

Maintenance Guidelines

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Troubleshooting

Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

How to Use This Chapter

How to Use This Chapter This section uses “decision-tree” charts and symptom tables designed to take you from a symptom to a specific sequence of tests in order to isolate a failing component.

•

Use the “TS1: START TROUBLESHOOTING” on page 5-31 to guide you to the individual symptom chart you need.

•

When you’re familiar with the symptoms listed, you may instead simply look up the symptom chart from the “List of Troubleshooting Charts/Tables” on page 5-29.

As you work with a troubleshooting symptom table, you may be instructed to test various electrical connector pins.

Every time you complete a troubleshooting procedure, make sure you follow the steps in the “END1: End of Troubleshooting Procedure” on page 5-33.

If the troubleshooting symptom tables do not isolate the problem, or if the symptoms are not consistent or repeatable, go to “GEN1: General Troubleshooting” on page 5-31. This chart will help you approach the problem in a systematic and logical manner.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Electrical Troubleshooting Guidelines

Electrical Troubleshooting Guidelines Many problems are caused by a faulty or dirty battery. Make sure the battery is clean. Check the electrolyte level and state-of-charge. See “Battery” on page 6-4. Block the truck whenever a troubleshooting procedure requires turning the key switch ON. This avoids accidents caused by unexpected truck travel.

Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can cause damage to the ohmmeter.

Save time and trouble by looking for simple causes first.

Visually inspect all wiring and electrical components for: •

loose connections or connectors

•

loose or broken terminals

•

damaged terminals, blocks, or strips

•

broken wiring and shorted conditions (especially those that are close to metal edges or surfaces)

Use an ohmmeter to check for wiring continuity and shorts.

For information on pin, connector, and harness connections, see “Wiring Harness” on page 6-11 and “List of Electrical Symbols” on page 5-8.

Checking for Shorts from Battery to Truck Frame 1. Press the red OFF (O) key on the keypad and disconnect the battery connector.

2. Using a voltmeter set on a 50 VDC scale. attach the leads as follows: • negative (–) lead to an unpainted, grounded surface on the truck frame

• positive (+) lead to the positive battery terminal The voltmeter must show no more than 3V. 3. Now attach the leads as follows: • negative (–) lead to the negative battery terminal • positive (+) lead to an unpainted, grounded surface on the truck frame The voltmeter must show no more than 3V. 4. If you get more than a 3V reading in Steps 2 or 3: a. Remove the battery from the truck. See “Battery” on page 6-4. b. Thoroughly clean the battery. See “Battery Maintenance” on page 6-5. c. Reinstall the battery. d. Repeat steps 2 and 3 to see if this has eliminated the problem. e. If excessive voltage is still found, have the battery checked for internal leakage.

Checking for Shorts from Components to Truck Frame 1. Press the red OFF (O) key on the keypad and disconnect the battery connector.

2. Use an ohmmeter and measure the resistance to an unpainted, grounded surface on the frame at B+, B–, and all fuses.

A resistance reading of less than 1000 ohms indicates a serious short to frame. If this condition exists, find the source of low resistance or short to frame using step 6. Do not continue until this condition is corrected.

3. Remove the battery from the truck. See “Battery” on page 6-4.

4. Connect the battery lead to the truck.

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Toyota Model 7HBW23 Service Manual

Electrical Troubleshooting Guidelines 5. Use an ammeter to measure the leakage current to an unpainted, grounded surface on the frame at B+, B–, all fuses, and all motors. If the current is less than 0.001 ampere (1mA), the truck system passes. If the current exceeds 1mA, go to step 6.

6. To find the cause of the low resistance, disconnect the power cables from each motor or major subassembly one at a time, to determine if that item is causing the low resistance.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Hydraulic Troubleshooting Guidelines

Hydraulic Troubleshooting Guidelines When you check voltage at solenoids, make sure hydraulic lines and components are fully installed.

Use an ohmmeter to check for wiring continuity to solenoids.

Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can cause damage to the ohmmeter.

Visually inspect all hydraulic lines and components for: •

Leaking connections or connectors

•

Loose or broken fittings

•

Damaged tubing, hoses, vents, or seals

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Definitions

Definitions

Continuity

Acceleration

A continuous and uninterrupted path between two or more locations in an electrical circuit, typically having a resistance of less than 1 ohm.

The process where the truck’s acceleration characteristic is determined when the truck starts from a stop. This is a operator parameter (Acceleration). The range is from 30% to 90% in increments of 5%. Default is 80%. A lower number gives less aggressive acceleration. See “Parameters (P)” on page 5-17.

Arm Angle Switches The Arm Angle Switches (S24 and S25) determine brake activation and truck travel speed. Each switch is activated by the control handle. The control handle must be positioned between 6° of vertical and 8° of horizontal for the switches to be closed. See Figure 5-1.

8° 1820 001.EPS

Arm Angle Switches and Brake Actuation

When the control handle is in the full upright position, the parking brake engages. When the control handle is positioned from 6° to 46° of the full upright position, the brake disengages (when travel is requested), Arm Angle B switch (S25) closes and enables slow speed travel. See Table 5-2. When the control handle is placed beyond 46° from the full upright position, Arm Angle A switch (S24) also closes, enabling fast speed travel. When the control handle is placed within 8° of horizontal, Arm Angle switch B opens, activating the parking brake.

Table 5-2. Control Handle/Switch Positions Position Top 6°

6° to 46° 46° plus Bottom 8°

5-6

A Switch Open Open Closed Closed

B Switch Open Closed Closed Open

Creep speed is a service parameter that defines speed at low throttle positions. Creep speed range is adjustable from –10 to 10. The factory default value is –5. A negative number enhances low speed maneuverability. A positive number makes the truck more responsive. See “Parameters (P)” on page 5-17.

Current Limiting A protective function of the power amplifier that prevents excessive current levels from damaging drive components.

Deceleration

6°

Figure 5-1.

Creep Speed

Function Brake Applied Slow Speed Fast Speed Brake Applied

The process where the truck’s braking (regenerative) characteristic is determined by any reduction in throttle, including neutral.

This is a operator parameter (Deceleration). See “Parameters (P)” on page 5-17. The range is from 40% to 90% in increments of 5%. Default is 65%. A lower number gives less aggressive deceleration.

Emergency Reverse Emergency Reverse is activated when the emergency reverse button is pressed while the control arm is in a drive position. After the button is released, normal operation is resumed.

ETAC (Electronic Tiller Arm Card) Programmable motor control functions are performed by the electronic circuitry (ETAC) housed within the control handle. See “Electronic Tiller Arm Card (ETAC)” on page 3-7.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Definitions

Fault Codes

Speed Limiting

The ETAC provides fault information by displaying fault codes via the LED display built into the handle head. See “Power Amplifier Fault Codes” on page 5-24.

The ETAC limits maximum speed: •

“Max speed, Slow Mode” parameter determines the maximum speed value sent by the ETAC to the power amplifier (max.

PWM) for both directions of travel while in Slow. This is a programmable parameter.

•

“Max speed, Fast Mode” parameter determines the maximum speed value sent by the ETAC to the power amplifier (max.

PWM) for both directions of travel while in Fast. This is a programmable parameter.

Open Circuit A lack of a continuous path between two or more electrical connections; usually greater than one megohm resistance.

Overvoltage Cutoff Occurs when there is very high voltage (greater than 34V) at the power amplifier B+ connection.

Code C42 or E142 may be displayed and the truck must be restarted.

PIN-Key Code Trucks produced with a standard handle mounted keypad are protected from unauthorized operation by Personal Identification Number (PIN) keypad entry codes.

Up to 10 operators can be assigned their own individual PIN-key code (of one to four digits) for access to the truck. Each operator can also set individual driver parameters. The default operator PIN-key code is number 1.

Short Circuit or “Short” A short circuit is an unspecified path in a circuit that provides unwanted full or partial continuity between two or more locations in an electrical circuit.

Example 1: Two insulated wires are physically next to each other and the insulation has worn off each of the wires. The conductors are now touching each other, causing a short circuit.

Example 2: The insulation has worn away on a power cable from the battery to a junction post in the truck. The wire conductors are touching the tractor frame, causing a short circuit of the battery cable.

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Thermal Cutback (Power Amplifier) Thermal cutback of the power amplifier is below –13°F (–25°C) or above 185°F (85°C). At 185°F to 203°F (85°C to 95°C), the PWM drive current limit is linearly decreased from full set current down to zero. At –13°F to –40°F (–25°C to –40°C), the current limit is reduced to approx. half the set current, resulting in reduced travel speed. Below –40°F (–40°C) or above 203°F (95°C), the allowed PWM is 0%.

Tractor The body section of the truck that contains the motors, drive unit, controls, and handle.

Truck Off Delay (Keypad only) Sets the truck OFF delay time (energy saving feature). If this time delay passes while the truck is in a brake position and the truck is idle (no inputs requested), the ETAC powers the truck OFF. Driver parameter settings are 0 to 20 minutes. When the parameter is set to 0, or the truck has the key switch option, the truck never powers OFF.

Undervoltage Cutoff Occurs when there is very low voltage (less than 13V) at power amplifier B+ connection. Code C41 is displayed and the truck must be restarted.

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Toyota Model 7HBW23 Service Manual

List of Electrical Symbols

List of Electrical Symbols Refer also to electrical schematics found in the Appendix and wiring harness component procedures.

Table 5-3. List of Symbols Symbol

Description

Function

Remark

A1

Power Amplifier

Drive motor controller

A2

Electronic tiller arm card

Vehicle controller

A6

Operator display

Displays various functions

A17

Keypad

PIN inputs and access maintenance modes

Trucks with keypad

B+

Battery

Positive

24V

B–

Battery

Negative

24V

CB1

Circuit Breaker

Drive/Pump motor circuit

110 amp

F50

Fuse

Keypad and tiller arm card

10 amp

F51

Fuse

Main control

10 amp

H1

Horn

J11

Wire Connection

Handle stem base

J41

Wire Connection

Service key (CAN)

K4

Relay

Main

K10

Contactor

Main

K30

Contactor

Pump motor

M1

Motor

Drive

M3

Motor

Pump

R1

Resistor

Pre-charge PTC

S17

Switch

Key

S18

Switch

Horn

S21

Switch

Master Control ON/OFF

S24

Switch

Arm Angle A

S25

Switch

Arm Angle B

S36

Switch

Lift limit

Y1

Coil

Brake

Y10

Coil

Lower valve

5-8

Trucks with key switch

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Control Handle Display and Programming

Control Handle Display and Programming 3. Choose the desired time to be displayed by pressing the thumb controls:

The display located on the top of the control handle displays the operator and machine-specific register.

5

Explanation of Symbols:

A

A

E E Figure 5-4.

A = Numerical Field

D

C

B

D

C

B

B = Hour Meter Indicator C = Parameter Control D = Battery Indicator E = Error Indicator

Control Handle Display

Special Truck Mode To enter a special truck mode: 1. Press and hold the horn button (S18). At the same time turn the key switch ON, or enter the operator-specific PIN-key code on the keypad, then press the green ON (I) key on the keypad.

2. Continue to hold the horn button while the display (see Figure 5-4) cycles through the following functions: • • • •

H = Hour Meter E = Error Codes P = Parameters Pn = Hardware and Software Part Numbers

3. Release the horn button at the selected display.

Hour Meter (H) To change Hour Meter settings: 1. Enter the special truck mode.

2. Continue to hold the horn button until “H” is displayed. The hour meter indicator (hourglass icon) is illuminated. See Figure 5-4.

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• A. = key time • b. = activity time (drive, lift, lower) • c. = drive motor time • d. = pump motor time • s. = time to service Press the thumb control to step between the different functions. The display shows the number of hours for each function. See “Parameter 20” on page 5-20.

4. Press the red OFF (O) key on the keypad to end the hour meter display.

Error Codes (E) When an error occurs, a code is displayed. See “Caution and Error Codes” on page 5-10.

Error Code History To access Error Code History: 1. Enter the special truck mode. See “Special Truck Mode” on page 5-9.

2. Press and hold the horn button until “E” is displayed. The error indicator (wrench icon) is illuminated. See Figure 5-4.

• Use the thumb control to scroll through the last 50 error codes. The latest fault is shown first. The display first shows the error code and then the hour the fault occurred.

• The error codes are divided into two groups C = caution and E = error.

• The C error codes are not stored. It is only a caution and is highlighted on the display as long as the fault exists.

• For example, if you only have one fault registered in the memory, the second empty place is shown like this: Fault: E - - - and time: - - - -.

3. End displaying the error code history by pressing the red OFF (O) key on the keypad.

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Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Caution and Error Codes Code C14 - Arm Angle Reference Warning Reason

Control handle was not in up position at power ON or after the truck has not been used for a time.

Performance Limits

Travel is not allowed until code is cleared.

How to Clear Code

Code is cleared when tiller arm is moved to upright (Top Brake) position.

Possible Causes and Corrective Actions

Control handle stuck in down position a. Check up-stop Arm angle input stuck ON a. Check arm angle switch “A” and “B” for correct operation. Repair or replace as necessary. b. Check input to power amplifier.

Code C19 - Default parameter warning Reason

Parameter(s) out-of-range, or incompatible with software version.

Performance Limits

Truck functions are not allowed until after this code is cleared.

How to Clear Code

Parameter area is automatically corrected and then code is cleared.

Possible Causes and Corrective Actions

ETAC parameter area is bad.

If the code does not clear after 10 seconds, try restarting the truck.

Cycle the truck OFF then ON. If the code does not automatically clear, replace the ETAC.

Code C20 - Thumb Control Warning Reason

Thumb control was not in neutral position at power ON, or a throttle position sensor failure was detected. See “Code E160 - Error In Reversing Circuit” on page 5-15.

Performance Limits

Truck functions are not allowed until code is cleared.

How to Clear Code

Code is cleared after problem is corrected.

Possible Causes and Corrective Actions

Thumb control is stuck in drive position.

ETAC is bad.

Check the mechanical portions of the throttle controller. Give special attention to the magnet arm alignment with the ETAC sensors and to the non-metallic parts of the emergency reverser.

Code C28 - Master Control ON/OFF Switch Warning

5-10

Reason

Power amplifier could not be reset via the CAN-bus at power ON, or power amplifier reports Master Control ON/OFF switch is open.

Performance Limits

Truck functions are not allowed after this code has been set.

How to Clear Code

This code can only be cleared after the problem is resolved and truck is cycled OFF/ON.

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Section 5. Troubleshooting Control Handle Display and Programming

Code C28 - Master Control ON/OFF Switch Warning Possible Causes and Corrective Actions

• Master Control ON/OFF switch activated • Low voltage to power amplifier (especially while lifting or driving) due to over-current or short-circuit.

• Try a known-good battery • PTC R1 missing, faulty, or tripped (very high resistance, due to excessive current while main contactor is open; should automatically recover).

• Carefully check to see if R1 is hot (tripped). If so, unplug battery and allow it to cool. Locate low impedance path that tripped R1 and correct.

• Wire #24 at 0V due to J5 not connected, blown fuse, or bad wiring.

• Check for 24 V at J5-16 • Short or open circuit in CAN wiring, or electrical noise in CAN wiring due to bad connection or outside interference, both at power ON. • Check CAN wiring • Try operating truck in different environment • Bad power amplifier

Code C29 - Time To Service Warning Reason

See Service Parameter 25 on page 5-19.

Performance Limits

None

How to Clear Code

See Service Parameter 25 on page 5-19.

Possible Causes and Corrective Actions

Time to perform service or service counter not reset after last service.

Code C41 - Battery Undervoltage Warning Reason

Voltage at power amplifier B+ connection less than 17V. Note: Low voltage can also cause problems such as electrical components not powering up/staying activated and CAN errors.

Performance Limits

Truck functions are allowed unless the voltage was below 13V. If voltage was below 13V, the truck must be restarted. (Code C28 may be displayed)

How to Clear Code

Code is cleared when voltage recovers.

Possible Causes and Corrective Actions

Battery voltage less than 17V • Time to charge battery • Check for correct voltage Battery parameter not adjusted correctly.

Circuit breaker open due to overloading, or short circuit (a misadjusted brake may have caused overloading leading to an open circuit breaker).

Open circuit to power amplifier B+ connection.

• Check cabling Bad power amplifier

Code C42 - Battery Overvoltage Warning Reason

High voltage (greater than 30V) at power amplifier B+ connection.

Performance Limits

When 34V is exceeded, overvoltage cutoff occurs and no truck functions are allowed. Truck may need to be restarted (Code E142 may be displayed)

How to Clear Code

Code is cleared when voltage recovers.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming Code C42 - Battery Overvoltage Warning Possible Causes and Corrective Actions

High battery voltage.

• Check for correct voltage • Battery may be overcharged Extreme regenerative braking.

Battery charger attached to truck.

Code C43 - Power Amplifier Thermal Cutback Reason

High or low temperature (above 185°F [85°C] or below –13°F [–25°C]) at power amplifier heat sink.

Performance Limits

Truck functions may be allowed.

How to Clear Code

Code is cleared when power amplifier heat sink temperature recovers.

Possible Causes and Corrective Actions

Operating in extreme environment.

Excessive load on vehicle.

• Check brake adjustment • Reduce the value of parameters 2, 3, and/or 4 to help decrease motor temperature.

Incorrect power amplifier mounting.

Bad power amplifier.

Code C44 (“hot” is displayed) - Traction Motor Thermal Cutback Reason

High traction motor temperature detected.

Performance Limits

Truck functions are allowed, but maximum speed value sent to power amplifier is reduced.

How to Clear Code

Code is cleared when temperature recovers.

Possible Causes and Corrective Actions

Operating in extreme environment, Excessive load on vehicle.

• Check brake adjustment • Reduce the value of parameters 2, 3, and/or 4 to help decrease motor temperature.

Airflow to motor restricted.

Bad motor wiring, or bad motor.

Code C46 - Severe Traction Motor Thermal Cutback Reason

Very high traction motor temperature or extreme operation detected.

Performance Limits

Truck functions are allowed, but maximum speed value sent to power amplifier is reduced.

How to Clear Code

Code is cleared when temperature recovers.

Possible Causes and Corrective Actions

Operating in extreme environment, Excessive load on vehicle.

• Check brake adjustment • Reduce the value of parameters 2, 3, and/or 4 to help decrease motor temperature.

Airflow to motor restricted.

Bad motor wiring, or bad motor.

NOTE: For 100 series error codes, throttle is not allowed, outputs are off (brake is engaged), and main contactor is

5-12

dropped. Code is cleared when problem is resolved and truck is cycled OFF/ON (unless otherwise noted).

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Control Handle Display and Programming

Code E101 - Power Amplifier Does Not Correspond with the Type of Truck Reason

Power amplifier is not compatible with ETAC software.

Possible Cause/ Corrective Action

Replace power amplifier with correct power amplifier.

Code E104 - Brake Output Error Reason

Power amplifier could not detect presence of brake coil.

Possible Cause/ Corrective Action

Open circuit due to brake or wiring; check brake and wiring.

Brake may not be releasing or stuck on motor end bell.

Master control relay missing or stuck open.

Main contactor open circuit (especially after it has closed).

Communication error due to Programmable Maintenance Tool (PMT).

Unplug PMT and allow to completely reboot before turning truck ON. Bad power amplifier.

Code E106 - Digital Output or Field Overcurrent Reason

Power amplifier attempted to deliver more current than allowed to main contactor coil, traction motor field winding, or digital output.

Possible Cause/ Corrective Action

Check main contactor coil, traction motor field winding, digital outputs, and associated wiring.

Replace power amplifier.

Code E107 - Contactor Off Reason

Contactor probably present but controller could not close it successfully.

Possible Cause/ Corrective Action

Problem with main contactor tips.

• If contactor clicks prior to displaying this code, polish contactor tips. If this is unsuccessful, replace contactor.

Low voltage.

• Try closing contactor with a known-good battery.

Short in contactor coil wiring.

• Replace contactor.

Code E108 - Contactor Welded or Missing Reason

Main contactor tips probably welded or missing.

Possible Cause/ Corrective Action

Main contactor tips welded.

Open or short circuit in contactor circuit.

• Check contactor, wiring (coil), and cabling.

Bad power amplifier.

Code E110 - Braking System Fault Reason

Power amplifier detected problem with braking functions.

Possible Cause/ Corrective Action

Short-circuit in brake circuit.

• Check brake and wiring.

Bad power amplifier.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming Code E112 - Arm Angle Sequence Fault Reason

Incorrect sequence of arm angle inputs.

Possible Cause/ Corrective Action

Arm angle input stuck on or off.

Problem with arm angle input wiring.

Problem with tiller arm. Check for correct sequence of arm angle switches.

Communication error due to power amplifier PMT; allow PMT to reboot before turning truck ON.

Code E114 - Traction Motor Speed Fault Reason

Controller detected stalled traction motor.

Possible Cause/ Corrective Action

Traction motor stalled.

Excessive traction motor load at low speed. Brake may not be releasing or stuck on motor endbell. Check brake adjustment.

Power amplifier may be bad.

Code E140 - Checksum Error Reason

ETAC software detected that checksum was invalid.

Possible Cause/ Corrective Action

Internal ETAC fault (Control handle head).

Bad software. Try downloading new software.

Code E141 - Software Problem Reason

ETAC found problem with software.

Possible Cause/ Corrective Action

Internal ETAC fault (Control handle head).

Bad software. Try downloading new software.

Code E142 - Power Amplifier Disable Error Reason

Power amplifier detected a major fault.

Possible Cause/ Corrective Action

Severe overvoltage (especially at main contactor close); check for correct voltage.

High current through a digital output. Check power amplifier outputs and wiring.

Open circuit in traction motor field circuit wiring or windings.

Replace power amplifier.

Code E150 - Drive Communication Error

5-14

Reason

ETAC did not receive CAN data from the power amplifier.

Possible Cause/ Corrective Action

Short or open circuit in CAN wiring.

Electrical noise in CAN wiring caused by bad connection, outside interference, or low voltage. Check CAN wiring. Try driving with a known-good battery or in a different environment.

Bad power amplifier; ETAC internal error.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Control Handle Display and Programming

Code E151 - Drive Communication Tx Error Reason

ETAC could not send CAN data to the power amplifier.

Possible Cause/ Corrective Action

Short or open circuit in CAN wiring.

Electrical noise in CAN wiring caused by bad connection, outside interference, or low voltage (especially while lifting or driving) possibly caused by over-current or short-circuit. Check CAN wiring. Try driving with a known-good battery or in a different environment.

Bad power amplifier; ETAC internal error.

Code E157 - CAN-bus Off Error Reason

ETAC detected problem with the CAN-bus.

Possible Cause/ Corrective Action

Short or open circuit in CAN wiring.

Electrical noise in CAN wiring caused by bad connection, outside interference, or low voltage. Check CAN wiring. Try driving with a known-good battery or in a different environment.

Bad power amplifier; ETAC internal error.

Code E159 - Over Run Error Reason

ETAC detected problem with the CAN-bus.

Possible Cause/ Corrective Action

Short or open circuit in CAN wiring.

Electrical noise in CAN wiring caused by bad connection, outside interference, or low voltage. Check CAN wiring. Try driving with a known-good battery or in a different environment.

Bad power amplifier; ETAC internal error.

Code E160 - Error In Reversing Circuit Reason

ETAC detected problem with throttle position sensors, including the sensor used to initiate emergency reversing. See “Code C20 - Thumb Control Warning”.

Possible Cause/ Corrective Action

Check the mechanical portions of the throttle controller. Give special attention to the magnet arm alignment with the ETAC sensors and to the non-metallic parts of the emergency reverser.

Bad ETAC.

Code E161 - Lower Valve Error Reason

Power amplifier could not detect presence of lower valve coil.

Possible Cause/ Corrective Action

Lower valve missing.

Open or short circuit in lower valve or wiring; master control relay missing or stuck open; main contactor open circuit (especially after it has closed); communication error due to PMT. Allow PMT to reboot before turning truck ON. Bad power amplifier.

Code E200 - Field Open Reason

Power amplifier detected open field.

Possible Cause/ Corrective Action

Open circuit in traction motor field circuit. Check traction motor field wiring and field windings in motor.

Harness broken. Bad power amplifier.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming Code E201 - M– Error Reason

Power amplifier detected a drive circuit fault.

Possible Cause/ Corrective Action

Traction motor cabling bad; bad power amplifier.

Code E202 - Power Amplifier Sensor Error Reason

Power amplifier reported an armature current sensor fault.

Possible Cause/ Corrective Action

Abnormal vehicle operation.

Low battery voltage or undersized battery.

Bad power amplifier.

Code E214 - Power Amplifier CAN Time-out

5-16

Reason

Power amplifier did not receive CAN data from the ETAC, or power amplifier selftest failed.

Possible Cause/ Corrective Action

Short or open circuit in CAN wiring.

Electrical noise in CAN wiring caused by bad connection, outside interference, or low voltage. Check CAN wiring. Try driving with a known-good battery or in a different environment.

Bad power amplifier; Bad ETAC.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Control Handle Display and Programming

Parameters (P)

change or view. See Table 5-5. Release the thumb control to neutral when the desired parameter number is shown.

4. Press the horn button once to access the parameter. The parameter symbol on the display starts flashing.

Modifying specific truck parameters will change the driving characteristics of the truck.

5. Change the parameter value by pressing the thumb control up or down. Release the thumb control to neutral when the desired parameter number is shown.

Programming Truck Parameters

6. Press the horn button again to confirm the change. The parameter symbol on the display stops flashing and remains illuminated.

To program the trucks operating parameters follow directions below (also see “Setting Individual PIN-key codes” on page 5-18): 1. Enter special truck mode. See “Special Truck Mode” on page 5-9.

2. Release the horn button when the “P” is displayed. The parameter control indicator (wheel icon) is illuminated. See Figure 5-4.

3. Use the thumb control to scroll to the desired truck parameter you want to Table 5-5. Truck Parameters Parameter Name

7. End programming by pressing the red OFF (O) key on the keypad.

The truck parameter change is complete. The next time the truck is started, the new parameter is in effect.

Unit

Range

Step

Default

Description

01

Max speed, slow mode

%

10 to 40

2

20

Max Speed, slow mode 10: low speed 40: full speed

02

Max speed, fast mode

%

70 to 98

2

94

Max speed, fast mode 70: low speed 98: full speed

03

Acceleration

%

30 to 90

5

80

30: low acceleration 90: full acceleration

04

Deceleration

%

40 to 90

5

65

Defines motor speed reduction force when thumb control goes to neutral position.

40: low reduction force 90: full reduction force

05

Truck off delay (keypad only)

min

0 to 20

1

0

The time until the truck is powered OFF (truck with key-pad only). Time is counted while the truck is idle and brake is applied.

Programming Service Parameters 1. Connect the service key at J41. See “Special Tools” on page 3-4.

2. Enter Special Truck Mode. See “Special Truck Mode” on page 5-9.

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3. Press and hold the horn button until “P” is displayed. The parameter control indicator (wheel icon) is illuminated. See Figure 5-4.

4. Use thumb control to scroll to the desired service parameter to be changed. See Table 5-6.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming NOTE: All parameters can be viewed; however, not all parameters can be changed.

Individual operator parameters (1 through 5) may or may not be accessed, depending on the value of parameter 39.

Service Parameter Display When parameters 1 thru 5, and 10 are viewed with the service key, both the parameter number (left side of display) and the 1st operator number (right side of display) are shown.

As the service parameter number display progresses through parameters 1, 2 ..., 10 the display will roll over to the next operator (the operator number increases). If a parameter is changed, it is valid only for the operator shown.

After all operators and operator parameters are scrolled through, service parameters 11 thru 40 are displayed.

To quickly display/access a service parameter rotate the thumb control away from the forks (sequence backwards through the parameters/operators).

Setting Individual PIN-key codes 1. Connect the service key at J41. See “Special Tools” on page 3-4. Make sure that the Master Control ON/OFF switch is ON. 2. Enter Special Truck Mode. See “Special Truck Mode” on page 5-9.

3. Press and hold the horn button until “P” is displayed. The parameter control indicator (wheel icon) is illuminated. See Figure 5-4.

If the horn button is released at the wrong time, turn the truck OFF and start over.

4. Use the thumb control to scroll through the service parameters. While the thumb control is held and briefly after it is released, both the parameter number (on the left side of the display) and the operator number (on the right-this only occurs if the service key is connected) are displayed. Stop (release the thumb control) at parameter 10 (PIN-key code) (See “Parameter 10” on page 5-20.) for the 1st

5-18

operator; the default value of “1” will be displayed.

5. Press the horn button once to access this parameter. The parameter symbol on the display flashes. Now you can make changes to the value of the 1st operator’s PIN-key code.

Changing the 1st operator’s PIN-key code will alter default operation. You will not be able to press “1” and green ON (I) to power the truck unless a operator’s PIN-key code is set to a value of “1.”

6. Rotate the thumb control in fork direction to increase the PIN-key code value, or in operator direction to decrease the value.

Holding the thumb control in a direction for a time will help quickly advance to larger numbers (for example, codes greater than 100). The PIN-key code can be from one to four digits long. Release the thumb control when the desired value is reached.

7. Press the horn button again to confirm the new PIN-key code value. The parameter symbol on the display stops flashing.

8. To enable additional operators; rotate the thumb control in the fork direction to roll over to the 2nd operator, and stop at parameter 10. The default value of “0” will be displayed. Follow the previous steps for the desired number of different PIN-key codes you want to set up. There are a total of ten operators.

NOTE: Disabling all operators (all PIN-key code values = 0) prohibits truck operation without the service key.

NOTE: Use unique PIN-key codes to avoid confusion. If two operators have the same PIN-key code, the higher number operator’s parameters will be used. For example if both the 1st and 2nd operator PIN-key code is 1111, and the 1st operator’s max speed is 80% and the 2nd operator’s max speed is 90%, when someone logs in with 1111 the max speed used will be 90%.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Control Handle Display and Programming

Table 5-6. Service Parameters Parameter Name Unit

Range

Step

Default

Description

10

PIN-key code

0 to 9999

1

1

Capability to assign up to 10 PIN-key codes (for 10 different operators)

14

Creep speed

–10 to 10

1

–5

Defines how much output the power amplifier gives when you reach the first speed sensor.

–10 = low speed when reaching first speed sensor 10 = high speed when reaching first speed sensor

20

Hour meter selection

1 to 5

1

2

1 (A.) = key time 2 (b.) = activity time 3 (c.) = drive 4 (d.) = lift 5 (s.) = time to service

21

Battery size

1 to 20

1

8

Battery size selection

25

Service interval

0 to 2000

50

0

Sets/resets service timer. C29 displays when time is up. To reset timer, access this parameter without changing the value.

39

Access code

1 to 4

1

3

Defines what access level service personnel have to parameters.

1 = key switch/operator parameters open, 2 = key switch/operator parameters closed, 3 = keypad/operator parameters open, 4 = keypad/operator parameters closed (when closed, Service Key is required to access truck parameters).

hours

Parameter Description

Parameter 4

Parameter 1

Auto-Plug Braking in Neutral - Defines the truck’s automatic plug-braking characteristic when throttle is reduced (including to neutral).

A lower number gives less aggressive deceleration.

Maximum speed value sent to the power amplifier while in Slow mode except during Turtle Torque (gives torque boost if high load is encountered).

Parameter 2 Top Speed - Reduces speed value sent from the ETAC to the power amplifier while in Fast mode (all throttle positions).

Parameter 3 Acceleration - Defines the truck’s acceleration characteristic when the truck starts from a stop. A high number gives maximum acceleration, a lower number gives less aggressive acceleration.

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Parameter 5 Automatic Time Off Interval (touch pad only)The time until the truck is switched OFF (energy saving feature) when the truck is idle and the brake is applied. Time is counted from when the latest power output is requested. If truck has key switch option, the truck never powers OFF. Range is from 1 minute to 20 minutes (a setting of ‘0’ disables automatic time off).

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming Parameter 10 All trucks with a touch pad have a temporary key code set at the factory. By default the 1st operator’s PIN-key code is the single digit number “1” and all other operator’s PIN-key codes are “0” which disables that operator. The key code logic has ten (10) registers for individual operator key codes. To add additional operators, change these PIN-key codes to numbers other than “0.” See “Setting Individual PIN-key codes” on page 5-18. A Service Key is required to assign up to 10 operators their own PIN-key code (one to four digits) for access to the truck.

Parameter 14 Defines the speed at low throttle positions. A negative number enhances low speed maneuverability. A positive number makes the truck more responsive.

Parameter 20 You choose the hour meter you want to display.

•

1 = A. (key time)

•

2 = b. (activity time)

•

3 = c. (drive motor time)

•

4 = d. (pump motor time)

•

5 = S. (time to service)

Parameter 21 Data must be provided about the battery installed in the truck.

The battery state-of-charge reset voltage is 25.2V and the lift cutout occurs when the display shows 0% state-of-charge.

To adjust the disconnection point of the battery discharge indicator, measure: •

•

5-20

the acid concentration of a fully-charged battery (must be between 1.27 and 1.29 SG) at lift cutout, acid concentration should be about 1.14 SG.

NOTE: Acid concentration varies with different battery brands.

Make sure that you have the correct parameter setting. Otherwise the battery can be destroyed.

Parameter 25 With this parameter you can set a time limit to next service from 0 to 2000 hours in steps of 50 hours. When it is time for service, you will get caution 29 (C29) on the display. To disable the service timer, set this parameter to 0. To reset the service timer, simply access this parameter without changing the value.

Parameter 39 This parameter determines whether the truck has a key switch or keypad and what access level service personnel will have to the operator parameters. This parameter is adjustable: •

1 = key switch connected, driver parameters open.

•

2 = key switch connected, driver parameters must be opened with service key.

•

3 = keypad connected, driver parameters open.

•

4 = keypad connected, driver parameters must be opened with service key.

Display Part Numbers (Pn) 1. Enter the special truck mode.

2. Press and hold the horn button until “Pn” is displayed.

3. Use the thumb control to scroll and display the following information: • HPn = Hardware part number • HSn = Hardware serial number • SPn = Software part number 4. End displaying the part number by pressing the red OFF (O) key on the keypad.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Service Display

Service Display

Digital Inputs/Outputs from Power Amplifier

•

Connect the service key (see “Special Tools” on page 3-4) in connection point J41 and press the green ON key (I) to start the lift truck.

•

The battery status is displayed and the symbol “D” is lit continually.

•

Press horn button (S18) to toggle between display modes. See table below:

The first most significant figure active (marked with arrow).

Power amplifier inputs A

A E

D

C

B

A E

Flashing Symbol

D

C

B

F

G

E

Displayed Data

B

Figure Segments

C DP

B

Speed reference value sent to power amplifier.

D

C

Digital inputs/outputs from power amplifier and ETAC. See “Digital Inputs/Outputs from Power Amplifier”. * See explanation following

Figure Segment A

BC

Battery voltage (V) at ETAC

B

Input (J5-14): Arm Angle B

D

Armature current (A)

C

Input (J5-15): Lift limit

BD

Field current (A)

D

Input (J5-12): Arm Angle A

CD

Armature PWM in %

E

BCD

Status of power amplifier.

See “Typical Statuses of Power Amplifier” on page 5-23.

Input (J5-2): Lower valve (lit if valve is present and not powered)

E

Field resistance (Ohms), used for thermal cutback.

Function

F G

Input (J5-5): Brake (lit if brake is present and not released)

DP

* They are displayed by highlighting the segments of three of the figures (A).

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Service Display The second most significant figure active (marked with arrow).

The third most significant figure active (marked with arrow).

Power amplifier outputs

Digital input from ETAC control sensors

A A

E

D

C

B E

D

C

B

A F

G

E D

B

A Figure Segments

F

C DP

G

E D

Figure Segment

Function

A

Figure Segments

C DP

Figure Segment

Function

A

B C

B

B Output (J5-2): Lower valve

D

C D

ETAC input: lift forks

E

Output (J5-4): Main contactor interlock

E

ETAC input: lower forks

F

Output (J5-7): Horn

F

(not used)

G

Output (J5-5): Brake

G

(not used)

DP

Output (J5-6): Pump contactor

DP

ETAC input: horn

5-22

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Service Display

Typical Statuses of Power Amplifier Status

Comments

13

No Activity: Main contactor open because no output requested for 30 seconds or an error occurred.

24

Passive restraint (transitional)

16

Passive restraint

1

Motor drive, plug, or active neutral braking

17

Active restraint while driving (overspeed)

10

Regen

11

Regen taper (transitional)

4

Field reversal (transitional)

74

Emergency reverse (regen)

65

Emergency reverse (drive)

6

Disable (major fault, such as severe overvoltage)

129

Emergency shutdown while in drive

144

Emergency shutdown while in passive restraint

NOTE: The system mode shows details of power amplifier activity, including normal operation. It is different than, and does not correspond to, the code from the power amplifier status LED. See “Power Amplifier Fault Codes” on page 5-24.

Throttle requests are not allowed for any system mode of 32 and over.

Truck is in emergency shutdown for any system mode of 128 and over.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Power Amplifier Fault Codes

Power Amplifier Fault Codes An internal microcontroller automatically checks the function of the power amplifier.

When this microcontroller detects a fault, the status LED on the bottom of the power amplifier flashes the appropriate code. See Table 5-7.

Under normal operation, the LED flashes a single flash (heartbeat) at approx. one flash every five seconds. A double flash indicates a fault has been detected by the microcontroller.

Table 5-7 describes the fault codes that are shown on the status LED or read using the Programmable Maintenance Tool (PMT). See “Programmable Maintenance Tool (PMT)” on page 5-26. Correct faults by following the “Troubleshooting Flowcharts” on page 5-31.

Table 5-7. Fault Codes Fault Code

PMT Display

Possible Cause

Explanation Power amplifier does not have voltage at +24Vdc logic power supply input.

LED OFF

N/A

Open circuit at power amplifier +24Vdc logic input due to wire, fuse, or bad power amplifier.

Solid ON

N/A

Bad power amplifier.

Power amplifier is not functioning correctly.

Normal “heartbeat”, everything is okay.

Single flash

¤

NO KNOWN FAULTS

N/A

1, 1

¤¤

CURRENT SHUNT FAULT

See “Code E202 - Power Amplifier Sensor Error” on page 5-16.

See “Code E214 - Power Amplifier CAN Time-out” on page 5-16 if ETAC is keyed ON.

Power amplifier is reporting that it is not receiving CAN messages from the ETAC, or that selftest failed.

1, 2

¤ ¤¤

HW FAILSAFE

Otherwise, the controller is reporting it is not receiving CAN messages from the ETAC, which is normal when the truck is not turned ON.

1, 3

¤ ¤¤¤

M– SHORTED

See “Code E201 - M– Error” on page 5-16.

1, 4

¤ ¤¤¤¤

SRO

Bad power amplifier or ETAC.

2, 1

¤¤ ¤

THROTTLE FAULT 1

2, 2

¤¤ ¤¤

EMR REV WIRING

2, 3

¤¤ ¤¤¤

HPD

Bad power amplifier or ETAC.

2, 4

¤¤ ¤¤¤¤

THROTTLE FAULT 2

Bad power amplifier.

3, 1

¤¤¤ ¤

CONT COIL/FLD SHORT

See “Code E106 - Digital Output or Field Overcurrent” on page 5-13.

3, 2

¤¤¤ ¤¤

MAIN CONT WELDED

Bad power amplifier or ETAC.

3, 3

¤¤¤ ¤¤¤

FIELD OPEN

See “Code E200 - Field Open” on page 5-15.

5-24

Bad power amplifier.

Power amplifier is not setup or functioning properly.

Power amplifier is not setup or functioning properly.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Power Amplifier Fault Codes

Table 5-7. Fault Codes Fault Code

PMT Display

Possible Cause

Explanation Power amplifier is not setup or functioning properly.

3, 4

¤¤¤ ¤¤¤¤

MISSING CONTACTOR

Bad power amplifier or ETAC.

4, 1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

See “Code C41 - Battery Undervoltage Warning” on page 5-11.

4, 2

¤¤¤¤ ¤¤

OVERVOLTAGE

See “Code C42 - Battery Overvoltage Warning” on page 5-11.

4, 3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

See “Code C43 - Power Amplifier Thermal Cutback” on page 5-12.

4, 4

¤¤¤¤ ¤¤¤¤

ANTI-TIEDOWN

Bad power amplifier or ETAC.

00700-CL340-05, Issued: 2 May 2005

Power amplifier is not setup or functioning properly.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Programmable Maintenance Tool (PMT)

Programmable Maintenance Tool (PMT)

The Main Menu is the starting point for the PMT. The main menu displays menu titles: • Program (not used) • Monitor • Faults

Data Inc/Dec Key

• Functions • Information • Programmer Setup

Bookmark Keys

If there are no entries within a Menu, then the Menu title will not be displayed.

Connector Menu Navigation Key 1665 037.tif

Figure 5-8.

Programmable Maintenance Tool

The optional Programmable Maintenance Tool (P/N 00590-49981-71) permits you to test and diagnose the power amplifier in this pallet truck.

The PMT is powered by the power amplifier through a four-pin connector at the bottom of the power amplifier. See Figure 5-9.

The Menu Navigation Key moves the screen curser up or down through the Menu list (top or bottom arrow), and opens or closes Sub-Menus (right or left arrows).

The Data Inc/Key changes the value of the parameter indicated by the curser.

The Bookmark Keys allow you to quickly go back to your favorite selections without having to navigate back through the Menu.

•

To select a position in the menu, hold a Bookmark Key down for three seconds until the bookmark set screen is displayed.

•

To jump to a selected Bookmark position, press the appropriate Bookmark Key.

NOTE: The Bookmarks are not permanently stored in the PMT. They are cleared when the PMT is unplugged.

5-26

1665 037.tif

Figure 5-9.

Connecting PMT to Power Amplifier

Monitor Mode Real-time status information is displayed in the Monitor mode for various inputs, outputs, temperature, etc. This information can be helpful in troubleshooting many problems and is useful for checking out the operation of the controller during initial installation.

1. Press the red OFF (O) key on the keypad.

2. Remove the tractor cover.

3. Connect the PMT to the power amplifier.

Wait for the PMT to “boot up” before proceeding to the next step.

4. Enter the PIN key code and press the green ON (I) key on the keypad or turn key switch ON. 5. Use the Menu Navigation Key to select Monitor.

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Section 5. Troubleshooting Programmable Maintenance Tool (PMT)

6. Press the right arrow on the Menu Navigation Key to enter the sub-menu.

7. Use the Up and Down Button arrows to scroll through the sub-menu list of monitor variables.

8. Use the right arrow to select and view a single variable.

9. To change the value of the parameter use the Data Inc/Dec Key. Alternately, you can press the right arrow Menu Navigation Key once more and enter the detail screen. A bar graph appears as well as min and max data points. Change the parameter value by pressing the Data Inc/Dec Key. The new value is set as soon as the Data Inc/Dec Key is released.

To close a Monitor Menu, sub-menu, or detail screen, press the left arrow on the Navigation Key.

Faults Mode In System Faults mode, currently active faults detected by the controller are displayed.

In Faults History mode, the controller’s diagnostic history file is displayed. This field includes a list of all faults observed and recorded by the controller since the history was last cleared.

NOTE: Each fault is listed only once, regardless of the number of times it occurred.

7. Use the Up and Down Buttons arrows on the Menu Navigation Key to scroll through list of multiple faults.

Clear After you have diagnosed and corrected the problem, clear the diagnostic history file. This permits the power amplifier to accumulate a new file of faults. By checking the new history file at a later date, you can easily determine whether the problem was completely fixed.

1. To clear the fault history of the unit, use the Menu Navigation Key to select Faults -> Clear Fault History.

2. Press the increment arrow (+) for yes and the decrement arrow (-) to cancel and not clear the fault history.

Table 5-10 on page 5-28 lists possible messages you may see displayed when the PMT is operating in either System Faults or Fault History mode.

Information Mode The Information Menu provides access to product information describing the basic revision level of the PMT. To view, use the Menu Navigation Key to select Information in the Main Menu. Remember to press the right arrow to select a Menu. Press the left arrow to exit.

1. Press the red OFF (O) key on the keypad.

2. Remove the tractor cover.

Programmer Mode

3. Connect the PMT to the power amplifier.

Wait for the PMT to “boot up” before proceeding to the next step.

Programmer mode permits you to perform a variety of tasks.

4. Enter the PIN key code and press the green ON (I) key on the keypad or turn key switch ON. 5. To view the present status of the unit, use the Menu Navigation Key to select Faults -> System Faults 6. To access the log, use the Menu Navigation Key to select Faults -> Fault History.

1. Press the red OFF (O) key on the keypad.

2. Remove the tractor cover.

3. Connect the PMT to the power amplifier.

Wait for the PMT to “boot up” before proceeding to the next step.

4. Enter the PIN key code and press the green ON (I) key on the keypad or turn key switch ON. 5. Use the Menu Navigation Key to select Programmer.

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Programmable Maintenance Tool (PMT) 6. Press the right arrow on the Menu Navigation Key to enter the sub-menu.

7. Use the Up and Down arrows on the Navigation Key to scroll through the sub-menu list of Programmer displays.

8. Use the right arrow to select and view a single variable.

Change the parameter value by pressing the Data Inc/Dec Key. The new value is set as soon as the Data Inc/Dec Key is released.

Table 5-10. Test Mode Menu Test Mode Display

Explanation

THROTTLE%

Throttle reading, in % of full throttle

ARM CURRENT

Motor armature current, in amps

FIELD CURRENT

Motor field current, in amps

ARM PWM

Armature duty cycle (PWM) - applied as %

FIELD PWM

Motor field duty cycle (PWM) - applied as %

BATT VOLTAGE

Battery voltage (B+ and B– connection) at key switch input

CAP VOLTAGE

Voltage of power amplifier B+ (bus bar)

HEAT SINK TEMP

Heat sink temperature - °C

FORWARD INPUT

Forward switch: on/off

REVERSE INPUT

Reverse switch: on/off

MODE

Power Amplifier operating mode: 1 to 4

INTRLCK INPUT

Interlock (brake/deadman) switch: on/off

PEDAL INPUT

(not used)

EMR REV INPUT

Emergency reverse button: on/off

MOTOR RPM

(not used)

MAIN CONT

Main contactor: on/off

AUX CONT

(not used)

REV OUTPUT

(not used)

BRAKE OUTPUT

(not used)

FAULT 1 OUTPUT

(not used)

FAULT 2 OUTPUT

(not used)

CONTROL STATE

(not used)

MODSEL 1

Mode select 1 switch: on/off

MODSEL 2

Mode select 2 switch: on/off

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting List of Troubleshooting Charts/Tables

Section 5. Troubleshooting

List of Troubleshooting Charts/Tables Troubleshooting Charts TS1: START TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-33

Hydraulic Symptom Tables No Lift, Lift Motor Does Not Run, Travel is OK. . . . . . . . . . . . . . . . . . . . 5-35 No Lift or Slow Lift, Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . 5-36 No Lower, Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Load Drifting/Settling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 No Lift or Lower. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Travel Symptom Tables Slow Travel, Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . . 5-39 Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Green/Red LED on Keypad Not Illuminated When Key Pressed . . . . . . . 5-40 No Fast Travel Mode. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 No Travel Mode. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Horn Does Not Sound When Horn Button Pushed. No Fault Codes . . . . 5-41

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List of Troubleshooting Charts/Tables

5-30

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Troubleshooting Flowcharts

Section 5. Troubleshooting

TS1: START TROUBLESHOOTING

Troubleshooting Flowcharts TS1: START TROUBLESHOOTING

Is a Message or Fault Code displayed?

Yes

Find Message or Code in Chapter 5

No

Is symptom listed in Symptom Tables in Chapter 5?

No

Go to Chart GEN-1

Yes

Follow Symptom Table directions in Chapter 5

TS-1.wmf

GEN1: General Troubleshooting

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Troubleshooting Flowcharts

GEN1: General Troubleshooting

Gather as much information as you can about the problem.

Eliminate unlikely causes.

What is the problem?

Where did it happen?

When did it happen?

Select and prioritize the most likely causes.

What functions are affected?

What conditions trigger the problem?

Talk directly to the operator or foreman.

Check each likely cause, using the tests in this manual.

Operate the truck yourself.

Check all other truck functions before returning the truck to service.

Using the schematics if necessary, identify all components which could cause the problem.

Gen1.wmf

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Section 5. Troubleshooting Troubleshooting Flowcharts

END1: End of Troubleshooting Procedure

END1:

End of Troubleshooting Procedure

Make sure ALL wires, hoses, and cables that you removed have been re-attached correctly.

Operate the truck as it was being operated when the problem occurred. Verify the problem does not recur.

Make sure all panels are properly reinstalled.

Have the driver operate the truck. Verify the problem does not recur.

Make sure any component that was drained has been refilled with the correct level of fluid.

Fill out any required forms.

Create the same conditions that occurred when the problem first happened.

If you contacted Field Service to discuss the problem, call them again to let them know what fixed the problem.

This is especially important if the solution you found is not in the troubleshooting chart.

End of Troubleshooting

End1.wmf

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Troubleshooting Flowcharts

5-34

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Symptom Tables: Lift/Lower System

Section 5. Troubleshooting

Symptom Tables: Lift/Lower System NOTE: If it is determined that a component failed as a result of hydraulic fluid contamination, replace the failed component and flush, fill, and bleed the hydraulic system. See “Hydraulic Fluid” on page 6-52.

NOTE: Reference electrical schematics beginning on Page A-9 and hydraulic schematic beginning on page A-12.

No Lift, Lift Motor Does Not Run, Travel is OK Possible Cause

Action

Bad lift pump contactor

With Master Control ON/OFF switch ON, the PIN-key code entered, the green ON (I) key on the keypad pressed and lift switch depressed, does main contactor (K10) and pump contactor (K30) energize (click)? If not, measure voltage between pump contactor coil terminals. If B+ voltage is present, replace the pump contactor.

Bad control handle card (A2)

With Master Control ON/OFF switch ON, the PIN-key code entered, the green ON (I) key on the keypad pressed and lift switch depressed, does pump contactor (K30) energize (click)? If not, check for lift signal input at CAN. (See “Service Display” on page 5-21.) If no signal is detected, replace control handle card (A2).

NOTE: Check for mechanical problems in the handle head before replacing control handle card.

Bad wiring continuity or wiring shorts

With Master Control ON/OFF switch OFF and battery disconnected, check for continuity and wiring shorts in wiring harness or cables.

Bad lift-limit switch

With Master Control ON/OFF switch OFF, battery disconnected and forks lowered, check continuity through the lift-limit switch.

Replace if necessary.

Bad lift pump motor brushes...

With Master Control ON/OFF switch ON, the PIN-key code entered, the green ON (I) key on the keypad pressed and the lift switch depressed, does pump contactor (K30) energize (click)? If YES, measure voltage between B– and lift pump motor terminal. If OK, check lift motor brushes...

...or bad lift pump motor...

...if brushes are OK, test the pump motor.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Symptom Tables: Lift/Lower System

No Lift or Slow Lift, Lift Motor Does Run Possible Cause

Action

Battery problems

Replace battery with fully-charged good battery.

Mechanical binding in lift mechanism

Repair lift mechanism.

Low hydraulic pressure or relief valve setting

Check hydraulic pressure setting and adjust if necessary. See “Adjusting Hydraulic Pump Pressure Relief Valve” on page 6-53.

Relief valve contaminated or bad.

(Unable to get the correct hydraulic pressure)

With Master Control ON/OFF switch OFF and battery disconnected, remove the pressure relief valve. Check for damage or contamination. Replace valve or flush system and replace the hydraulic fluid. See “Hydraulic Fluid” on page 6-52.

Bad lift pump motor or brushes

Check the lift pump motor brushes. If OK, replace the pump.

Contamination found in the pump

Flush the system and replace hydraulic fluid.

Bad pump

If lift motor is OK, remove motor from pump and rotate pump by hand. Replace pump if not OK.

No Lower, Lift and Travel OK

5-36

Possible Cause

Action

Bad lower solenoid valve...

With the Master Control ON/OFF switch ON, cycle the lower switch. Does the lower solenoid valve energize (click)? If YES, disconnect the battery, then slowly loosen, but DO NOT REMOVE the hydraulic line at the hydraulic pump assembly. Permit the forks to slowly lower. Have rags and drain pan ready to catch fluid.

... if the forks do not lower, check for mechanical binding in lift cylinder or fork mechanism...

Replace lift cylinder or repair lift mechanism.

...if the forks lower, remove and inspect the solenoid valve...

Inspect for free movement and for signs of contamination. Clean the solenoid valve or flush the system, clean the filter and replace hydraulic fluid.

If no contamination is found, repair or replace the solenoid valve or pump assembly.

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Section 5. Troubleshooting Symptom Tables: Lift/Lower System

Possible Cause

Action

...check for bad control handle (ETAC) card

With Master Control ON/OFF switch ON, the PIN-key code entered, the green ON (I) key on the keypad pressed, and the lower button depressed, check for lower signal input at CAN. (See “Service Display” on page 5-21.) If no signal is detected, replace control handle card (A2). NOTE: Check for mechanical problems in the handle head before replacing control handle card.

Unable to Pick Up a Load Possible Cause

Action

Load too large for lift truck capacity

Check load weight. Check lift pressure setting.

Battery problems

Replace battery with fully-charged good battery.

Incorrect lift pressure adjustment

Check and adjust lift pressure setting.

Contaminated or bad pressure relief valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system. Clean the relief valve.

If no contamination is found, replace relief valve.

Bad lift pump or motor

Replace lift pump or motor.

Slow Lower Possible Cause

Action

Bad lift/lower solenoid valve or wiring

Repair or replace the solenoid valve or wiring.

Plugged or malfunctioning flow control valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system and clean the relief valve.

If no contamination is found, replace the flow control valve.

Contamination in lowering solenoid valve

Inspect solenoid for contamination or binding.

Mechanical binding in lift mechanism

Adjust or replace mechanism.

Bad or misadjusted lift-limit switch

Adjust or replace lift-limit switch (pump should not hit relief if lift-limit switch is operating properly).

NOTE: If the pump hits relief and lower is attempted, lowering will be slow. Release the lower button momentarily, then continue to lower. Normal lower speed should resume.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Symptom Tables: Lift/Lower System

Load Drifting/Settling Possible Cause

Action

Incorrect lift pressure adjustment

Check and adjust lift pressure setting.

Contaminated or bad check valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system. Clean the check valve.

If no contamination is found, replace check valve.

Leaking or contaminated lowering solenoid valve

Check for contamination in hydraulic fluid.

If contamination is present, flush, fill and bleed the hydraulic system. Clean the solenoid valve.

If no contamination is found, replace the solenoid valve.

Load too large for lift truck capacity

Check load weight. Check lift pressure setting.

No Lift or Lower. No Fault Codes '

5-38

Possible Cause

Action

Throttle magnet-actuator arm (in control handle) out of adjustment

Check with service display and repair as needed.

Bad ETAC. If no other problems are noted but the ETAC does not detect the presence of the magnet, replace the ETAC.

Lift contactor missing, open or short circuit in lift circuit (contactor, wiring, motor), Bad power amplifier

Perform standard electrical troubleshooting procedures in the lift circuit.

Incorrect ETAC software installed.

Note: this is only possible if ETAC was recently replaced.

Lowering may not occur if incorrect software was inadvertently installed (drive function will also not function correctly). Check for correct software part number and replace ETAC if not correct.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Symptom Tables: Travel (Forward/Reverse) System

Symptom Tables: Travel (Forward/Reverse) System NOTE: Reference electrical schematics beginning on Page A-9 and hydraulic schematic beginning on Page A-12.

Slow Travel, Lift/Lower OK. No Fault Codes Possible Cause

Action

Truck configured for slow acceleration

Check truck configuration.

Battery problems

Replace battery with fully-charged good battery.

Binding drive wheel assembly/drive motor

Jack and block truck. Disable brake.See “Mechanically Releasing the Brake” on page 6-34. Check that drive wheel spins freely. If not, repair or replace.

Binding brake disc

Check “Air Gap Adjustment” on page 6-33

Bad drive motor (may test OK with no load, but fail under load) or worn brushes

Repair or replace drive motor or brushes.

Truck Does Not Accelerate Correctly Possible Cause

Action

Truck configured for slow acceleration

Check truck configuration.

Battery problem

Verify a correct, fully-charged good battery (24V) is installed in truck.

Binding or mechanical problem

Jack and block truck. Turn Master Control ON/OFF switch ON. Check brake, wheel bearings and load wheels to see if there is a mechanical problem. Repair or replace.

Bad motor brushes or motor

With Master Control ON/OFF switch OFF and battery disconnected, check drive motor brushes and motor. See “Drive Motor Brush Inspection” on page 6-35. Repair or replace.

Bad power amplifier

If all other possible causes check out, replace power amplifier.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Symptom Tables: Travel (Forward/Reverse) System

Green/Red LED on Keypad Not Illuminated When Key Pressed Possible Cause

Action

No power supplied to the ETAC.

Check for open circuit in wires or connectors in tiller arm, F50 open, keyswitch jumper not connected.

Faulty Connectors

Repair and replace faulty connectors (check connector J11 at control handle arm base, connector into ETAC, and connector J5 to motor controller).

F50 Open

Ensure control fuse has not tripped.

Key switch jumper not connected

Connect keyswitch jumper.

Bad LED(s)

Check LED(s) if truck functions normally but LED(s) not lighting correctly.

No Fast Travel Mode. No Fault Codes Possible Cause

Action

Open Arm Angle Switch

Check for correct operation of arm angle switch “A” and correct if necessary, check wiring, power amplifier, and switch adjustment. Arm Angle switch A is open-circuited. See “Arm Angle Switches” on page 5-6.

No Travel Mode. No Fault Codes

5-40

Possible Cause

Action

Open Arm Angle Switch

Check arm angle switch adjustment, wiring, power amplifier. Arm Angle switch A or B is open-circuited. See “Arm Angle Switches” on page 5-6.

Throttle magnet-actuator arm (in control handle) out of adjustment

Check with service display and repair as needed.

Bad ETAC. If no other problems are noted but the ETAC does not detect the presence of the magnet, replace the ETAC.

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Toyota Model 7HBW23 Service Manual

Section 5. Troubleshooting Symptom Tables: Travel (Forward/Reverse) System

Horn Does Not Sound When Horn Button Pushed. No Fault Codes Possible Cause

Action

Bad horn switch/wiring in handle head

Repair or replace as necessary.

Bad horn

Replace horn.

Bad power amplifier

Check fuse and replace if necessary.

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Section 5. Troubleshooting

Toyota Model 7HBW23 Service Manual

Symptom Tables: Travel (Forward/Reverse) System

5-42

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Component Procedures

Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures

Section 6. Component Procedures A

H

Arm Angle Switches ............................ 6-24

Horn ................................................... 6-18 Hydraulic Components Cylinder ........................................ 6-47 Fluid ............................................. 6-52 Hydraulic Unit .............................. 6-49 Filter Screen ............................ 6-50 Pump ...................................... 6-51 Relief Valve Adjustment ........... 6-53 Reservoir ................................. 6-50 Solenoid .................................. 6-49 Suction Tube ........................... 6-50

B Battery ................................................. 6-4 Adding Water .................................. 6-7 Charging ........................................ 6-6 Exterior Cleaning ............................ 6-5 Maintenance Free ........................... 6-8 Specific Gravity .............................. 6-7 Storage ........................................... 6-8 Voltage Check ................................. 6-7 Battery Pack Swingout ........................................ 6-4 Brake ................................................. 6-33

K Key Switch (Optional) ......................... 6-26

C

L

Circuit Breaker .................................. 6-13 Contactors ......................................... 6-20 Control Handle ................................... 6-14 Cover, Tractor ...................................... 6-9

Lift Motor ........................................... 6-51 Lift-Limit Switch ................................. 6-25 Load Wheel Pull Rod Adjustment ..................... 6-45 Load Wheels ....................................... 6-45 Lubrication Drive Housing ............................... 6-30

D Drive Unit .......................................... 6-27 Brake, Electromagnetic ................. 6-33 Drive Housing Lubrication ............ 6-30 Drive Motor .................................. 6-42 Drive Wheel .................................. 6-31 Transmission Assembly ................ 6-27 Drive Wheel ........................................ 6-31

E Electromagnetic Brake ....................... 6-33

F Fuses ................................................. 6-12

G

M Master Control ON/OFF Switch .......... 6-23 Motors Brush Spring Tension ................... 6-36 Brushes ........................................ 6-35 Commutator ................................. 6-36 Drive ............................................. 6-42 General ......................................... 6-35 Lift ................................................ 6-51 Tests ............................................. 6-39

P Power Amplifier .................................. 6-19 Power Cables ...................................... 6-10 Pump, Hydraulic ................................ 6-51

Gear Oil ............................................. 6-30

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

S Switches Arm Angle .....................................6-24 General .........................................6-49 Key Switch (Optional) ....................6-26 Lift-Limit .......................................6-25 Master Control ON/OFF ................6-23

W Wheels Load ..............................................6-45 Wiring Harness ...................................6-11

6-2

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Section 6. Component Procedures Component Locator Photo

Component Locator Photo Section 6. Component Procedures

Battery Connector Main Contactor page 6-20

Hydraulic Cylinder page 6-47

Power Amplifier page 6-19

Fill/Vent Plug

Master Control Relay page 6-21

Hydraulic Reservoir page 6-50

Horn page 6-18

Drive Unit page 6-27

Figure 6-1. Tractor Interior

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Battery

Battery The pallet truck may be equipped with a multiple (swingout) battery pack or a maintenance-free battery and charger.

Before working on the battery, batteries can weigh more than 500 pounds. Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting. See “Battery Safety” on page 2-6.

Swingout Battery Pack NOTE: For replacement parts information refer to Parts Catalog.

1790 001.eps

Removal (single battery) 1. After the truck is stopped and the handle is returned to the full up position, press the red OFF (O) key on the keypad.

2. Disconnect the battery connector found at the top of the tractor cover. Remove the battery cover.

3. Lift up on the top battery frame to get access to the lower two batteries.

4. As the frame is lifted, swing the battery toward the center of the forks.

5. The cables may now be disconnected from the battery terminals and the batteries may be serviced or replaced if necessary.

See Figure 6-2.

Figure 6-2. Multiple Battery Wiring Hookup

Installation (single battery) 1. Position the fully-charged and tested batteries in the battery pack.

2. Reconnect the battery cables to the battery terminals in accordance with the battery wiring hookup shown on the decal in the battery frame.

3. Reconnect the battery connector, reinstall the battery cover, press the green ON (I) key on the keypad, and test the operation of the pallet truck.

Removal (entire battery pack) 1. Press the red OFF (O) key on the keypad.

2. Disconnect the battery connector found at the top of tractor cover.

3. Position the battery replacement device above the battery and attach it to the battery manufacturer’s designated lift points.

4. Remove the battery with the lifting device.

5. Put the discharged battery on the charging stand.

6-4

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Section 6. Component Procedures Battery

Installation 1. With a fully charged and tested battery on the lifting device, position the lifting device in accordance with the manufacturer’s recommendations.

Cable Vent Hole

2. Position the battery in the compartment.

Make sure the battery has no more than 1/2 in. (13 mm) of “free play” movement in the battery compartment in any direction.

3. Remove the lifting device from the area.

4. Reconnect the battery connector, turn the key switch ON, and test the operation of the truck.

Filler Plug 09g6s047.tif

Figure 6-3. Battery Filler Plugs and Vent Holes

Maintenance-Free Batteries NOTE: For replacement parts information refer to Parts Catalog.

The truck may be equipped with a maintenance-free battery and charger pack.

The specific gravity need not be measured on a maintenance-free battery. Please follow manufacturer’s recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery must be kept clean and dry and may be washed to remove any accumulated foreign matter. See “Exterior Cleaning” on page 6-5.

Battery Maintenance Exterior Cleaning 1. Inspect the battery. a. Make sure the cables are not frayed or loose. b. Make sure there is no foreign material inside the connector. c. Make sure the filler plugs are tight and the vent holes in the filler plugs are open. See Figure 6-3.

00700-CL340-05, Issued: 2 May 2005

2. Keep the top of the battery clean and dry.

Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create grounds.

Do not clean the top of the battery with the soda solution while it is installed in the truck. Water will seep into the electrical compartments and cause serious damage.

3. Disconnect the battery connector, and remove the battery from the truck before you clean it.

4. Tighten the battery filler plugs.

5. Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb. (0.45 kg) of baking soda added to 1/2 gal (1.9 liters) of hot water.

6. Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized.

7. Rinse the battery with clean water.

8. Dry the battery completely before re-installing it.

9. Apply a thin coat of petroleum jelly to the battery posts and cable terminals.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Battery

Charging To charge a battery, direct current is passed through the battery cells in the direction opposite to that of discharge. Charging time is 5% to 20% longer than discharge time.

The most important element in battery service and prolonging battery life is correct charging.

Make sure you follow the approved method for each application, following the battery and battery charger manufacturers’ instructions.

The vent holes in the filler plugs must be open to permit hydrogen gas to escape from the cells. When you charge the battery, make sure the polarity connections are correct. The positive lead of the charger must be connected to the positive terminal, and the negative lead must be connected to the negative terminal.

1. Familiarize yourself with the following: • Charging rate, starting rate, and finish rate • Time available for charge • Overheating, excessive gassing, or overcharging • Variations between cell voltage 2. Battery performance varies depending on the type of application. If you use more than one truck, one battery, and one charger, keep the same batteries and charger assigned to each truck. This makes it easier to diagnose any battery or charging problem.

3. Consult your battery and battery charger manufacturer’s manual for specific charging procedures.

4. Wear personal protective equipment, See “Battery Safety” on page 2-6.

5. Press the red OFF (O) key on the keypad, and disconnect the battery.

6. Inspect the battery.

7. Examine the electrolyte level in each cell.

Electrolyte must cover the top of the

6-6

battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. Do not fill to level yet.

Electrolyte level will increase during charging. See “Adding Water” on page 6-7.

8. Using a hydrometer, measure and record the specific gravity of each cell. See “Specific Gravity” on page 6-7.

9. Measure and record the voltage of each cell.

10. To get the maximum use out of each battery, recharge only when effectively discharged. Routinely recharging batteries when only partially discharged will decrease battery life. At maximum recommended discharge, the specific gravity must read 1.140 to 1.160 or less.

11. Make sure that the filler plugs are clean and the vent holes are open. Tighten all filler plugs.

NEVER plug the battery charger into the truck. This will severely damage the truck’s electrical system. Plug the charger ONLY into the connector from the battery.

12. Charge the battery, following specific instructions in your battery and battery charger manufacturer’s manual.

13. Using a hydrometer, measure the specific gravity of each cell. No amount of charging will increase battery capacity or increase specific gravity above its fully charged level (specific gravity 1.280 to 1.300).

14. If, after charging, the electrolyte level is below the fill port, add water to move it to the fill level. Do not overfill the cells or permit electrolyte to spill on the battery case. See “Adding Water” on page 6-7.

In general, a lead-acid battery may be charged at any rate in amperes that does not cause excessive gassing or produce electrolyte temperatures above 110° F (43°C).

Temperatures of 120°F (49° C) are permitted only for short periods of time.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Battery

Adding Water

Procedure

Water must be added to battery cells periodically. Frequency and quantity depend on the water level above the plates and the amount of gassing during charge.

Guidelines: •

Wear personal protective equipment. Use only distilled water or water approved by the battery manufacturer. See “Battery Safety” on page 2-6.

1. Wear personal protective equipment. See “Battery Safety” on page 2-6.

2. Insert the nozzle of the hydrometer into the battery cell and draw enough electrolyte into the tube to permit the float to ride free.

3. Leave the hydrometer nozzle in the battery and read the specific gravity of the cell.

4. If there is not enough electrolyte in the battery to get a hydrometer reading then:

•

Before charging, make sure battery plates are covered with electrolyte. Add water, if necessary, only to cover plates.

• Add just enough water to cover the battery plates

•

Electrolyte level increases during charging.

To prevent overflow, add water to fill port, if necessary, after charging, and after hydrometer and voltmeter readings are taken.

5. Record the specific gravity reading on the battery maintenance chart.

•

Keep the outside of the battery case clean and dry.

Specific Gravity Specific gravity readings for lead acid batteries with electrolyte temperatures at 80° F (27° C) change with the state-of-charge as follows: Charge

Specific Gravity

100%

1.280 to 1.300

75%

1.250 to 1.260

50%

1.200 to 1.210

25%

1.150 to 1.160

0%

1.080

• Charge the battery, then take readings

Voltage Check Take a voltage check on each cell after performing the specific gravity check. Attach a voltmeter to the positive and negative terminals of each cell. Voltage readings will change with the state-of-charge. See “Specific Gravity” on page 6-7.

Charge

Voltage Reading

100%

2.14

75%

2.07

50%

1.95

25%

1.80

Record the voltage reading for each cell on the battery maintenance chart. There must be a difference of less than 0.2V between cells.

Most industrial deep-cell discharge batteries are considered discharged when 20% of the charge remains (specific gravity 1.140).

NOTE: Maintenance-free batteries do not require specific gravity measurements.

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Section 6. Component Procedures

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Battery

Storage Before storing a battery, make sure electrolyte is at the correct level in every cell, filler plugs are tight, and battery is fully charged.

Store the battery in a clean, cool, dry location away from radiators and other sources of heat.

Measure the electrolyte level and the specific gravity every 30 days during storage. Whenever the specific gravity is less than 1.230, charge the battery.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Tractor Covers

Tractor Covers NOTE: For replacement parts information refer to Parts Catalog.

The tractor covers are designed to be easily removed and re-installed for service and maintenance.

Removal 1. Grasp top cover at location shown. Lift cover upward to disengage captivating clasps. See Figure 6-4.

2. Remove two captivating screws located at the top of the cover then remove bottom cover.

Grasp Top Cover Here

Bottom Cover

Figure 6-4. Top Cover Removal (decals omitted)

Installation 1. Install the bottom cover and secure with two captivating screws located at the top of the cover.

2. To install the top cover, slide it back into the original position, and secure by engaging the captivating clasps located on the top of the cover.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Power Cables

Power Cables NOTE: For replacement parts information refer to Parts Catalog.

Power cables are used to connect power from the battery to the drive motor and lift motor.

Examine the power cables for damage, including: •

Evidence of overheating

•

Burned spots in the cable

•

Nicks in the insulation

•

Damaged or overheated terminal lugs

•

Damaged mounting hardware or brackets

Repair or replace damaged cables or mounting hardware as necessary.

Figure 6-5. Power Cables

The terminal lugs must be crimped tightly and securely on the wire. Replace the lug if overheating is evident. Repair or replace bad connectors as necessary.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Wiring Harness

Wiring Harness NOTE: For replacement parts information refer to Parts Catalog.

The wiring harness is designed to connect the electrical components of the pallet truck.

•

Replace terminations with exposed wire visible at the connectors. Damaged terminations, exposed wires, or damaged connectors can cause operational failure of the truck

During troubleshooting and repairs, it is sometimes necessary to unmate a connector, move a harness, cut a cable tie, or remove the wire from a bracket. Note carefully the location of the wire and all protective or securing attachments before moving the harness.

After repair, return or replace all protective and/or securing hardware to its original condition. Protective materials are necessary to provide reliable performance of the interconnect system.

Figure 6-6. Wiring Harness

All wires in the harness are marked with a wire identification number. These numbers correspond to wire identification given in the schematic. All connectors are represented by “J” followed by a number. See “Schematics” on page A-9.

In addition to the wire identification number printed every 1 to 1.5 in. (25.4 to 38.1 mm) on the wire, there is a wire marker at each termination. If the marker is missing or unreadable, remark the wire to permit easier identification.

NOTE: It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to the harness.

Inspection Whenever working on the truck, use care around wiring harnesses.

•

Do not pull on wires

•

Carefully mate and unmate all connectors

•

Do not pry apart connectors with unspecified tools

•

Examine and maintain any added materials used to dress or protect the wire.

This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit, and so forth.

•

Examine harness wires for abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Fuses

Fuses NOTE: For replacement parts information refer to Parts Catalog.

Under extreme operating conditions, fuses (F50, F51) protect the electrical circuits and components from excessive current or voltage overloads.

Test/Inspection Examine each fuse for signs of overheating, discoloration, cracking, or other physical damage. Replace the fuse if you find damage.

See Figure 6-7.

Fuse F50

Fuse F51 1665 031.tif

Figure 6-7. Fuse/Circuit Breaker Location

To test a fuse, remove it or isolate it from the electrical circuit. Do this by removing the fuse from the truck or by removing all the connections from one side of the fuse.

Use an ohmmeter set to Rx1 scale and measure the resistance across the fuse. The resistance must be less than 1 ohm.

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Section 6. Component Procedures Circuit Breaker

Circuit Breaker NOTE: For replacement parts information refer to Parts Catalog.

Under extreme operating conditions the current demand on the battery may exceed the rating for the main circuit breaker (CB1) and force it open. This causes the truck to become inoperable until the circuit breaker automatically resets itself.

Test/Inspection Examine the circuit breaker for signs of overheating, discoloration, or other physical damage. Replace the circuit breaker if you find damage. See Figure 6-8.

Circuit Breaker CB1 Figure 6-8. Circuit Breaker Location

To test a circuit breaker, remove the circuit breaker from the truck or isolate it from the electrical circuit by removing all the connections from one side. Let it cool (or reset itself).

Use an ohmmeter set to Rx1 scale and measure the resistance across the circuit breaker. The resistance must be less than 1 ohm.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Control Handle

Control Handle

NOTE: For replacement parts information refer to Parts Catalog.

20

19 21

18

17

22 23

15

24

14

25

11

13

26

10 27 28

16

30 12

32 29

33 31

35 36 31 34

7 6

35

5

4

3

2

8

6-14

1 9

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Control Handle

Pos

Description

Pos

Description

Pos

Description

1

Screw

13

Electronic circuit board

25

Gasket

2

Keypad

14

Push button (option)

26

Signal button

3

Screw, 2 x M5 x 45 2 x M5 x 60

15

Top cover

27

Push button (option)

4

Handle

16

Display card

28

Wire, hold down

5

Cover, keypad (Optional)

17

Push button

29

Screw

6

Top plate

18

Emergency reverse button

30

Control switch

7

Screw

19

Push button (not used)

31

Sliding bearing

8

Bottom plate

20

Plate

32

Control stop

9

Grommet

21

Holder

33

Arm

10

Screw, M4 x 40

22

Push button, lift/lower

34

Axle

11

Spring

23

Arm

35

Spring holder

12

Lower cover

24

Display glass

36

Spring

Control Handle Disassembly 1. Remove screw [1], then unplug and remove the keypad [2].

2. Remove the four screws [3] that secure the top cover assembly to the handle. Hold the top cover [15] firmly while removing screws.

3. Disconnect the cable connected to the electronic circuit board [13].

Changing Horn Button/Switch [26, 27] 1. Remove the horn button. See Figure 6-9.

Do not use excessive force when prying on the button or you can damage the locking tabs.

4. For access to the electronic circuit board [13], remove the screws [10] securing the lower cover [12].

Static electricity! Risk of static discharge that can damage the electronics. Make sure to take the necessary precautions before working with the electronics.

5. Carefully lift off the lower cover [12].

NOTE: Place your finger between the lower cover [12] and button [18] to hold the control switch [30] in place.

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Figure 6-9. Horn Button Removal

2. Disconnect the connection for the switch on the electronic circuit board [13].

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Control Handle 3. Press out the switch from its mounting in the top cover assembly.

Changing Lift/Lower Button [22]

Control Handle Stem NOTE: For replacement parts information refer to Parts Catalog.

Removal

1. Remove the button by placing a screwdriver in the hole [A]. See Figure 6-10.

1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

2. Remove the hex head cap screw securing the stem mount cover. See Figure 6-12.

3. Disconnect the wiring harness connector and arm angle switch connections. See Figure 6-13.

Cap Screw

A

A

Figure 6-10. Lift/Lower Button Removal

2. Unscrew the holder [21] so that the arm [23] comes loose.

Cover

Changing Push Button [19] 1581 010.tif

1. Press the push button sideways.

2. Insert a screwdriver and carefully pry the button loose. See Figure 6-11.

Figure 6-12. Removing Cover

Wiring Harness Connector

Arm Angle Switch Connections

Figure 6-13. Cover Removed

Figure 6-11. Push Button Removal

3. Unscrew the button’s holder and arm.

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Section 6. Component Procedures Control Handle

Before removing the cap screws in the next step, make sure you are holding the handle. When the cap screws are removed, the handle will fall.

4. Remove the three Allen head cap screws located at the base of the control handle stem. See Figure 6-14.

Allen Head Cap Screws

Figure 6-14. Allen Head Cap Screws

5. Carefully remove the control handle stem and mount.

Reassembly 1. During reassembly, make sure that the brake release cam assembly is in the correct position before installing.

2. Position the control handle mounting base on the pivot assembly.

3. Reinstall the three Allen head cap screws.

4. Thread the wiring harness through the handle base.

5. Reattach the control handle head unit if removed.

6. Reconnect the handle harness connector and arm angle switch connections. Install the cable ties in their original locations on the handle harness.

7. Install the control handle cover.

8. Connect the battery connector. Press the green ON (I) key on the keypad.

9. Test the operation of the truck.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Horn (H1)

Horn (H1) NOTE: For replacement parts information refer to Parts Catalog.

Removal 1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the two wires from the horn.

See Figure 6-15.

Horn (H1)

1665 031.tif

Figure 6-15. Horn Location

4. Remove the horn mounting bolt.

Installation 1. Attach the horn to the electrical panel and tighten the mounting bolt.

2. Attach the two wires.

3. Reconnect the battery connector, press the green ON (I) key on the keypad, and test operation.

4. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

5. Install the tractor cover.

6. Reconnect the battery connector.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Power Amplifier (A1)

Power Amplifier (A1)

Removal

NOTE: For replacement parts information refer to Parts Catalog.

The power amplifier is installed in the tractor compartment. See Figure 6-16.

1. Press the red OFF (O) key on the keypad and disconnect the battery connector.

2. Remove the tractor cover.

3. Discharge the capacitors in the power amplifier by connecting a load (such as a contactor coil or a horn) across the power amplifier’s B+ and B– terminals.

4. Push the locking tab and disconnect the J5 connector from the power amplifier. See Figure 6-16.

Power Amplifier J5 Connector

1665 031.tif

5. Disconnect the three power cables (terminals B+, B– and M–) on the power amplifier. Do not stress the power cable connections. Disconnect wiring harness connectors (terminals F1 and F2).

6. Remove the three hex head cap screws securing the power amplifier to the electrical panel. Remove the power amplifier.

Figure 6-16. Power Amplifier Location

Installation Do not open the power amplifier.

Opening the power amplifier could damage it and will void the warranty.

Cleaning 1. Press the red OFF (O) key on the keypad and disconnect the battery connector.

2. Remove the tractor cover.

3. Discharge the capacitors in the power amplifier by connecting a load (such as a contactor coil) across the power amplifier’s B+ and B– terminals.

NOTE: All power amplifiers are preset to factory default specifications.

1. Secure the power amplifier to the electrical panel with the three previously removed hex head cap screws.

2. Reconnect the three power cables (terminals B+, B– and M–) on the power amplifier. Torque screws to 12 ft. lb.

(16.3 Nm) maximum. Do not stress the cable connections and put strain on internal components.

3. Connect the J5 connector and wiring harness connectors (terminals F1 and F2) to the power amplifier.

4. Clean the power amplifier with a moist rag. Let it dry before connecting the battery.

4. Connect the battery connector and press the green ON (I) key on the keypad.

5. Make sure the power cable connections are tight. Do not stress the cable connections or put strain on internal components.

6. Press the red OFF (O) key on the keypad.

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5. Test operation of the truck.

7. Install the tractor cover.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Contactors

Contactors

4. Install the tractor cover.

NOTE: For replacement parts information refer to Parts Catalog.

5. Connect the battery connector. Press the green ON (I) key on the keypad.

6. Test the operation of the truck.

Contactors (K10 and K30) control the transmission of battery power to the drive and lift motors.

Lift Motor Contactor (K30)

Main Contactor (K10)

Lift Motor Contactor

Removal 1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the wires from the X and Y terminals on the contactor coils. See Figure 6-17.

4. Remove the nuts securing the bus bar and cables to the contactor. Note the location for assembly later. See Figure 6-17.

Figure 6-18. Lift Motor Contactor K30

See “Hydraulic Components” on page 6-47.

5. Remove the two screws holding the contactor assembly to the electrical panel.

X and Y Terminals

Bus Bar

Figure 6-17. Main Contactor K10

Installation 1. Secure the contactor to the electrical panel with the two screws removed earlier.

2. Secure the bus bar and cable to the contactor with the nuts.

3. Connect the wires to the X and Y terminals.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Master Control Relay (K4)

Master Control Relay (K4) The master control relay (K4) should be regularly tested for proper operation.

Inspection/Test 1. Remove the tractor cover.

2. With the battery connected, press the green ON (I) key on the keypad.

3. Use a voltmeter to check the voltage between wire #26 (terminal 4) and wire #24 (terminal 2).

Wire #26

Wire #24

1665 031.tif

Figure 6-19. Master Control Relay (K4)

The voltmeter should read approximately 24V. 4. Move the control handle down into the operating position. The voltmeter should now read 0V. If not, replace the master control relay.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Master Control Relay (K4)

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Section 6. Component Procedures Switches (General)

Inspection

Switches (General) Section 6. Component Procedures

NOTE: For replacement parts information refer to Parts Catalog.

Refer to the schematic in the Appendix to identify the electrical circuit location of the switch. See “Schematics” on page A-9.

Test/Inspection Examine the switch for signs of arcing, overheating, discoloration, cracking, or other physical damage. Replace the switch if you see such damage.

To test a switch, isolate it from the electrical circuit. Do this by removing all the connections from the switch, making sure all wires are labeled and identified for later reconnection.

Use an ohmmeter set to a low resistance scale to measure the resistance across the switch. In the closed position, the switch must have a resistance of less than 1 ohm. In an open position, the switch must show a resistance greater than 10 megohms.

Master Control ON/OFF Switch A Master Control ON/OFF switch (S21) is provided on the truck. In the OFF (O) position, battery power to all control functions is interrupted. In the ON (I) position, battery potential is provided to all control functions via the power amplifier. See Figure 6-20.

1. With the battery plugged in and the Master Control ON/OFF switch in the ON position, battery voltage B+ must be present on the two terminals of the switch.

2. Test the Master Control ON/OFF switch with an ohmmeter after disconnecting the battery and removing the wires from the switch terminals.

In the OFF position, the ohmmeter must read greater than 1 megohm, and in the ON position, the ohmmeter must read less than 1 ohm. If not, replace the switch.

Removal 1. Disconnect the battery connector.

2. Remove the tractor cover.

3. Disconnect the wires from the switch.

4. Remove the Master Control ON/OFF switch.

Installation 1. Install the new Master Control ON/OFF switch.

2. Connect the wires to the new Master Control ON/OFF switch terminals.

3. Reconnect the battery connector and verify operation.

4. Install the tractor cover.

Master Control ON/OFF Switch

1581 004.tif

Figure 6-20.

Master Control ON/OFF Switch Location

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Section 6. Component Procedures

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Switches (General)

Arm Angle Switches The Arm Angle Switches (S24 and S25) determine brake activation and truck travel speed. Each switch is activated by the control handle position. The control handle must be positioned between 5° of vertical and 5° of horizontal in order for the switches to be closed, permitting travel. See “Arm Angle Switches” on page 5-6.

Adjustment

Screws 1581 008.tif

The arm angle switches are found at the base of the control handle stem. See Figure 6-21.

1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

Use extreme care when the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck.

After the truck is jacked, DO NOT rely on the jack alone to support the truck. For details, See “Jacking Safety” on page 2-9.

Figure 6-22.

Arm Angle Switch Screws

5. Slide the switch back in until the switch “clicks.” Move the switch out (approx.

1/32 in. [0.7 mm]) until it “clicks” again.

Retighten the screws.

6. Make sure that the cam arm makes solid contact with the switch lever.

7. Verify that the switch “clicks” near the middle of the cam movement.

8. Switch S25 must operate within 5° of the full up or down handle position. Make sure the switch does not bottom out when fully compressed.

9. Install the stem mount cover. See Figure 6-23.

2. Jack the truck and block the frame.

Arm Angle Switches

1581 007.tif

Figure 6-21.

Arm Angle Switches

3. Remove the stem mount cover.

4. Loosen the two screws holding the bracket on the stem mount. Slide the bracket out as far as possible. See Figure 6-22.

6-24

Figure 6-23.

Control Handle Cover Installed

10. Remove the blocks, connect the battery connector and press the green ON (I) key on the keypad.

11. Test the operation of the truck.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Switches (General)

Removal 1. Lower the forks completely.

2. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

3. Remove the stem mount cover.

4. Disconnect the wires on the switch.

Lift-Limit Switch When the forks are fully raised, the lift-limit switch (S36) turns the hydraulic pump motor off. This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. See Figure 6-24.

5. Remove the mounting bracket from the stem mount.

6. Remove the screws holding the switch on the mounting bracket.

Lift-Limit Switch

7. Remove the switch.

Installation 1. Mount the switch to the mounting bracket.

2. Connect the wires to the switch.

3. Install the mounting bracket.

4. Reconnect the battery connector. Press the green ON (I) key on the keypad.

5. Test drive the truck.

6. Adjust the switch if necessary.

7. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

8. Install the stem mount cover.

9. Reconnect the battery connector.

1581 014.tif

Figure 6-24.

Lift-Limit Switch

Adjustment 1. Raise the forks until they reach their fully raised position. If the lift-limit switch does not shut the pump down when the lift cylinder reaches its upper limit, the relief valve on the hydraulic pump will make a high-pitched squeal, indicating that the relief valve is opening.

2. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

3. Loosen the bolt and slide the switch bracket up or down to activate (cut power off) when the lift is 1/2 to 1 in. (13 to 25.4 mm) before the fully raised position.

4. Tighten the bolt.

5. Reconnect the battery connector. Press the green ON (I) key on the keypad. Lower the forks and then lift them until they reach their fully raised position. The lift-limit switch must cut power off to the pump when the lift cylinder reaches 1/2 to 1 in.

(13 to 25.4 mm) before its fully raised position.

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Switches (General)

Key Switch (Optional) A two-position (ON/OFF) key switch (S17), located on the main console, energizes all truck control functions when in the ON position, provided the Master Control ON/OFF switch is in the ON position.

Inspection 1. Remove the tractor cover.

2. With the battery plugged in and the key switch ON, battery voltage B+ must be present on the two terminals of the switch.

3. Turn the key switch to OFF, disconnect the battery and remove the wires from the switch terminals.

4. Test the key switch for continuity with an ohmmeter.

In the OFF position, the ohmmeter must read greater than 1 megohm, and in the ON position, the ohmmeter must read less than 1 ohm. If not, replace the switch.

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Section 6. Component Procedures Drive Unit

Drive Unit Section 6. Component Procedures

5. Remove the three Allen head cap screws that secure the control handle assembly to the drive unit assembly. See Figure 6-25.

The drive unit includes the drive motor, electromagnetic brake assembly, drive wheel, and transmission assembly.

Allen Head Cap Screws

NOTE: For replacement parts information refer to Parts Catalog.

Transmission Assembly Removal 1. Lower the forks, press the red OFF (O) key on the keypad. Disconnect the battery connector.

1665 045.tif

Figure 6-25.

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck.

After the truck is jacked, put solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck. For details, See “Jacking Safety” on page 2-9.

Control Handle Assembly Removal

6. Disconnect the cables/wire from the terminal block on the transmission. See Figure 6-26.

2. Jack the truck and block the frame.

3. Remove the tractor cover.

4. Remove the stem mount cover. Disconnect the handle harness and arm angle sensors.

Terminal Block Connections

Figure 6-26: Terminal Block

7. Remove the ten Allen head bolts that secure the transmission and bearing assembly to the frame.

NOTE: Remove four Allen head bolts to remove only the transmission but not the steer bearing.

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Drive Unit

Assembly Transmission assembly may fall free from mounting after bolts are removed.

1. Install the new bearings in the gear case and cover for the 2nd stage gear set.

2. Install the new bearings, spacer, and seal in the gear case for the drive axle.

8. Remove the transmission and steer bearing assembly by lowering through the pivot-frame mount.

3. Place the case in a fabricated assembly base and carefully press the drive axle in the gear case.

9. Feed the control wiring harness and power cables through the transmission pivot mount.

4. Position the transmission on the work bench with the gear case side up. Install the output gear in the case and secure with the retaining ring.

Disassembly 1. After draining the gear case lubricant, thoroughly clean the outside with solvent or other non-corrosive cleaning fluid. Air dry all parts, and proceed with the disassembly of transmission.

2. Remove the drive wheel. See “Drive Wheel” on page 6-31.

3. Remove the nine hex head cap screws securing the gear case cover. Remove the gear case cover.

5. Install the 2nd stage gear set.

6. Install the drive motor bearing, bearing shim, and seal in the gear case if removed previously.

NOTE: The seal must be installed correctly with its open side and seal ring positioned towards the bearing.

7. Carefully slide the drive motor armature shaft into the gear case if removed previously. See “Drive Motor” on page 6-42.

4. Remove the retaining ring that secures the top (pinion) gear.

5. Remove the top (pinion) gear and Woodruff key attached to the drive motor armature shaft.

6. Remove the drive motor if required. See “Drive Motor” on page 6-42.

7. Remove the drive motor bearing, bearing shim, and seal from the gear case if required.

8. Remove the 2nd stage gear set from the gear case.

Make sure that the motor end cap is installed before proceeding to the next step.

8. Install the pinion gear, woodruff key, and the retaining ring on the armature shaft.

9. Use gasket eliminator (Loctite 515 or GE Weicon Silmate) on the mating surface and install the gear case cover. Torque the cover bolts to 30 ft. lb. (42 Nm).

9. Remove the retaining ring from the drive axle then remove the output gear.

10. Press the drive axle through the inner and outer gear case bearings.

11. Remove the old bearings, spacers, and seals from the gear case. Thoroughly clean the case.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Drive Unit

9

1

21 3

4

5

25

20

17

2 19

12

10

13

16

11

13 18

27 Figure 6-27.

7 W08175b.eps

Transmission Assembly, Exploded View

Legend: 1 2 3 4 5 7 9 10 11 12 13 14

Housing, Gearbox Cover, Gearbox Screw Pinion, Drive 1st Stage Gear Set, 2nd Stage Gear Set, Output Bearing, Steering Outer Race Plug, Fill/Level Plug, Drain Bearing, Sealed Bearing Set, Cup & Cone Bearing, Motor (not shown)

00700-CL340-05, Issued: 2 May 2005

15 16 17 18 19 20 21 22 23 25 26 27

Seal, Motor (not shown) Seal Drive Axle Bearing, Sealed Spacer, Bearing Ring, Retaining Key, Woodruff Cap Screw, Allen Head Hub, Wheel (not shown) Axle, 2nd Stage Key, Output (not shown) Ring, Retaining

6-29

Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Drive Unit

Installation

Drive Housing Lubrication Gear Oil Level

Make sure the Master Control ON/OFF switch is OFF and the battery connector is disconnected before you start.

1. Remove the fill/level plug. See Figure 6-28.

1. Install the steer bearing assembly if removed previously.

2. Reinstall the drive unit assembly through the pivot frame while feeding the harness and cables through the pivot frame mount.

Drain Screw Fill/Level Plug

3. Secure the assembly with the ten Allen head bolts removed previously.

4. Feed the wire harness and power cables through the pivot tube.

5. Reconnect the cables/wire to the terminal block on the transmission.

6. Install the drive wheel. See “Drive Wheel” on page 6-31.

7. Unblock and lower the truck.

8. Install the control handle.

9. Reconnect the wiring harness.

10. Ensure the drive unit is filled to the correct level with gear oil. Install the fill/level plug.

11. Install the stem mount cover and tractor cover.

12. Install the battery, reconnect the battery connector and the turn the Master Control ON/OFF switch ON. Press the green ON (I) key on the keypad.

13. Check the controls for correct operation.

1665 039.tif

Figure 6-28.

Transmission Assembly Fill/Drain Plugs

2. Check the oil level. When the truck is level, the oil must be up to the bottom of the plug opening.

3. If necessary, add the specified oil through the plug opening, but do not overfill.

4. Install the fill/level plug securely.

Changing Gear Oil 1. Remove the drain plug from the bottom of the gear housing and permit the oil to drain. See Figure 6-28.

2. After the oil has drained completely, flush the housing with a suitable solvent and allow it to drain.

3. Install the drain plug.

4. Fill the drive housing with the specified gear oil through the fill/level plug opening in the cover of the transmission.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Drive Unit

Drive Wheel

Tire Replacement

NOTE: For replacement parts information refer to Parts Catalog.

Any misalignment of the tire and hub while the tire is being pressed on the hub can cause damage to the hub. For this reason, chamfers are provided on the outside edge of the hub and on the end of the inside diameter of the tire’s metal insert. The chamfers help to center the hub and tire during pressing and to reduce the possibility of misalignment.

Removal 1. Press the red OFF (O) key on the keypad and disconnect the battery connector.

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck.

After the truck is jacked, put solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck. For details, See “Jacking Safety” on page 2-9.

2. Jack and block the truck under the tractor frame.

3. Remove the five drive wheel mounting nuts. See Figure 6-29.

Drive Wheel Nuts (5)

To prevent damage, the hub must be installed on the circular ram with the chamfered side up.

1. Check the inside surface of the metal insert on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert.

2. Place a circular ram on the press table.

The length of the ram must be longer than the width of the old tire to permit complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub. See Figure 6-30.

1581 007.tif

Figure 6-29.

Drive Wheel Nuts

4. Remove the drive wheel.

tire.pcx

Figure 6-30.

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Tire Replacement

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Drive Unit 3. If the outside edge of the hub is not flush with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. You can use a spacer (slightly smaller in diameter than the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the correct amount of recession.

4. Position the hub assembly with the old tire on top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire on the wheel. The chamfered edge must always be the leading edge when a tire is pressed on the hub.

5. Center the hub assembly on top of the ram and make sure they mate squarely.

6. Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so they are concentric.

7. Begin pressing the new tire on the hub and the old tire off the wheel. Run the press slowly for the first few inches of travel because this is the critical step of the operation. If the tire starts to cock, stop the press immediately and realign the tire. Use a soft-headed mallet to realign the tire on the hub.

NOTE: If the new tire does not press on with a minimum pressure of 5 tons (68,947 kPa), replace the hub.

8. Release the press. Remove the wheel, tire assembly and the old tire from the press table. Inspect the wheel and tire assembly.

9. Install the wheel and tire assembly on the drive axle of the truck. Reinstall the five drive wheel mounting nuts. Torque to 55 ft. lbs. (75 Nm).

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Electromagnetic Brake

Electromagnetic Brake

Air Gap Adjustment

NOTE: For replacement parts information refer to Parts Catalog.

The nominal gap between the coil housing and the pressure plate in the applied position is 0.008 to 0.010 in. (0.2 to 0.25 mm).

Section 6. Component Procedures

1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

Allow the brake to cool completely before servicing.

Brake Disc Location

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck.

After the truck is jacked, Do NOT rely on the jack alone to support the truck. See “Jacking Safety” on page 2-9.

The electromagnetic brake assembly is mounted directly to the drive motor. See Figure 6-31.

2. Jack the truck and block the frame.

3. Remove the drive unit cover.

Electromagnetic Brake

4. Loosen the three 4 mm Allen head brake assembly mounting bolts. See Figure 6-32.

Air gap

Adjusting Screw

0.008 - 0.010 in.

(0.2 - 0.25 mm)

Mounting Bolt

1581 009.tif

Figure 6-31.

Brake Location

Friction Disc

Pressure Plate

Coil Housing 1665 053.tif

Figure 6-32.

Brake Gap Adjustment

5. Turn the adjusting screws while checking the air gap at several points with a 0.008 in. (0.2 mm) feeler gauge.

6. Tighten the mounting bolts to 50 in. lb.

(5.6 Nm). Recheck the gap with the feeler gauge.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Electromagnetic Brake

Friction Disc Replacement

4. Adjust the gap and torque mounting bolts.

See “Air Gap Adjustment” on page 6-33.

Replace the friction disc when its total thickness is reduced to 0.20 in. (5.5 mm).

5. Install the drive unit cover.

1. Loosen and remove the three 4 mm mounting bolts and remove the brake coil assembly. See Figure 6-33.

2. Replace the friction disc on the hub.

Inspect friction plate for wear. Replace the friction plate if the surface is worn unevenly.

3. Install the brake coil assembly on the motor end. Adjust the gap and torque mounting bolts. See “Air Gap Adjustment” on page 6-33.

Adjusting Screw (x3)

Friction Disc

Mounting Bolt (x3)

Brake Coil Assy

Figure 6-33: Friction Disc Replacement

Mechanically Releasing the Brake If the brake cannot be electrically released, perform the following: 1. Remove the drive unit cover.

2. Loosen the three 4 mm Allen head mounting bolts evenly until the clamping force on the friction disc is low enough to allow the truck to roll.

3. Move the truck to the desired location.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Motors, General

Motors, General

you must take this into account when considering brush replacement.

Section 6. Component Procedures

NOTE: For replacement parts information refer to Parts Catalog.

2. Check brush spring tension. See “Drive Motor Brush Spring Tension” on page 6-36.

Drive Motor Brush Inspection

3. Clean brushes and holders. Wipe the commutator with a dry, lint-free cloth. DO NOT USE lubricants of any kind on or around the commutator.

4. Check brush holders for solid connection to the mounting support. Tighten the mounting screws as necessary.

5. Check the cap screws holding the brush cross connectors to the brush holder body.

6. Make sure the motor terminals are secured tightly to the motor frame. Be careful not to strip the threads or crush the insulating parts.

7. Check all the cap screws around the frame for tightness.

8. Keep the outside frame of the motor clean and free from dirt. Maintain a free air passage around the motor to permit heat radiation.

MTRBRUSH.tif

Figure 6-34.

Drive Motor Brush, Typical Location

Conduct a partial inspection of the drive motor after every 1,000 hours of truck operation. If you work in an abnormally severe or caustic environment or if you have a rigorous duty cycle, inspect the motor more frequently.

Set up and rigidly adhere to a strict inspection schedule to obtain the maximum efficiency from the electrical equipment.

Each partial inspection of the motor must include the following: 1. Inspect the brushes for wear and for correct contact with the commutator.

Record the level of wear on the brushes.

This history will give you an indication of whether a brush must be changed or if it can wait until the next inspection. Refer to page 6-36 for acceptable brush length and general motor information.

NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore,

00700-CL340-05, Issued: 2 May 2005

Replacement If one brush needs replacement, always replace the entire set of brushes.

Use only genuine Toyota brushes. Using another type of brush could damage the commutator or cause excessive brush wear.

If the end of the brush is not already contoured to fit the commutator, use the following procedure to seat the brush to the commutator: NOTE: If the motor commutator is not accessible, form the brush contour using a brush seating stone.

1. Move the motor brush springs out of your way.

2. Wrap a piece of 00 sandpaper around the commutator. DO NOT use emery cloth to seat brushes.

3. Move the brushes back down in their holders so that the face of the brushes matches the curve of the commutator.

6-35

Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Motors, General 4. Remove the sandpaper.

5. Blow any dust out of the motor with clean, compressed air at a maximum of 30 psi (207 kPa).

Drive Motor Brush Spring Tension

7. While gently pulling the scale outward, slowly pull the paper strip in the direction that the commutator normally rotates.

8. When the paper strip starts to move freely, the spring scale will read the spring brush tension.

9. Refer to the table below for correct spring tension.

Inspection

Minimum Brush Length

Motor

1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

2. Remove the drive motor cover.

3. Slide the brush up slightly in its holder.

4. Insert a paper strip between the brush face and the commutator. See Figure 6-35.

Drive Motor

Spring Tension

0.59 in.

(15 mm)

20 oz. min.

(568 grams)

10. Repeat steps 3 through 9 for the remaining brushes.

Motor Commutator Inspection The commutator should be inspected for surface condition and high mica. Most armatures have the mica undercut. If the armature on your motor does not, do not attempt to cut it. See Figure 6-36.

coil spring

leather loop

Segments

Mica

NORMAL UNDERCUT

Paper

High Mica

TENSION.tif

Figure 6-35.

Motor Brush Spring Tension Inspection

5. Place a small leather loop around the coil spring for the brush. If the brush spring has a loop at the brush, hook the spring scale directly to the spring.

6. Attach a 5 lb. (2.27 kg) spring scale to the leather loop.

6-36

HIGH MICA 1881 003.tif

Figure 6-36.

Mica Inspection

The commutator must be smooth and clean to provide maximum brush wear. When commutators are not properly maintained, carbon dust can collect in the grooves between the segments. This can lead to a short circuit in the armature.

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Motors, General

Good commutation is indicated by a dark brown polished commutator and an evenly polished brush wearing surface. See Table 6-1, “Commutator Surfaces.”

If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, remove the motor for servicing.

Table 6-1: Commutator Surfaces

Condition

Probable Cause

Good Condition-Light Film

Uniform coloring indicates satisfactory operation of machine and brushes. Film color is largely an effect of thickness; therefore, provided the film is uniform, it is perfectly acceptable.

Satisfactory Condition-Light and Dark Pattern

This is not a good condition, but in our experience it is known that machines having this commutator pattern have operated with satisfactory results for long periods of time. This condition can appear in alternating bars as shown or every 3rd or 4th bar and so on. This is related to the winding design of the armature. Difficulty caused from split windings crossing in the same slot.

Unsatisfactory Condition-Streaky Film With No Commutator Wear

Frequently due to under-loaded operation, machine grossly over-brushed or brush grade incorrect for particular machine application. Atmosphere and environmental conditions can contribute.

Unsatisfactory Condition-Uneven Film

Patchy colors of varying densities and shape. Due to unclean operating conditions or incorrect physical condition of commutator.

Unsatisfactory Condition- Film With Dark Areas

These areas can be isolated or regular.

Commutator out of round. This can be caused by vibration or mechanical deficiencies in equipment operation, bearings, couplings, etc.

Unsatisfactory Condition-Example of Poor Commutator Machining

Bars are low on entry and leaving edges giving rise to the brushes riding on the middle of the bars.

Unsatisfactory Condition-Example of Poor Commutator machining

Bars are low in the middle giving rise to the brushes riding on entry and leaving bar edges. This and the previous illustration indicate the need for better maintenance.

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Commutator Surface

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Motors, General Table 6-1: Commutator Surfaces

Condition

Probable Cause

Unsatisfactory Condition-Streaky Film With commutator Wear

This is a further development of the third example. Brush grade, machine applications, and working environment are all suspect. Earlier corrective action should have been taken.

Unsatisfactory Condition-Double Pole Pitch

Darkening of commutator in sequences two pole pitches apart is due to armature fault, bad coil, riser bars, or equalizer connections.

Unsatisfactory Condition-Brush Contact Mark

Commutator Surface

Storage of machines, for lengthy periods, with brushes in position. This can also result from operation of machine in prolonged stall conditions.

Unsatisfactory Condition-Bar Edge Burning-Cause High Mica

Illustration shows high mica in every slot.

Same effect can occur on one bar only.

Similar conditions can be caused by a high or low bar.

Unsatisfactory Condition-Small Bright Spots

Related to over-loaded machines and low brush pressure. Due to sparking under brush that gives rise to spots being of a random distribution. If not corrected, will result in scored commutator.

Servicing If the commutator requires service, you will need to remove the armature from the motor.

DO NOT use a stone to even out high and low spots on the commutator. Use only a suitable abrasive rubber polisher.

Servicing a motor for an abnormal commutator surface condition and high mica or mica undercutting requires special equipment at a motor rebuilding facility.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Motors, General

Terminal Nuts

Electric Motor Tests

Whenever you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor. Use a second wrench on the stud terminal securing nut to avoid twisting the stud. See Figure 6-37.

Motor Types •

A shunt-wound motor, such as the drive motor, has four external connections: two armature (A) and two field (E). See Figure 6-38.

•

A compound motor, such as the lift motor, has only two external connections because the armature and field windings are connected internally.

Terminal Stud

Shunt-Wound Motor

Motor Cable Securing Nut

Flat Washer

A2

Fiber Washer

Stud Terminal Securing Nut

S2/E2/D2 MD

Motor Housing

A1

S1/E1/D1 Compound Motor A

CABLENUT.eps

Figure 6-37.

Motor Terminal Nuts

Check these torques each time you check motor brushes.

MX

Motor Cable Securing Nut

Stud Terminal Securing Nut

3/8 in.

(M10)

100-120 in. lb.

(11.2-13.6 Nm)

140-160 in. lb.

(15.8-18.1 Nm)

Figure 6-38.

5/16 in.

(M8)

90-110 in. lb.

(10.2-12.4 Nm)

110-140 in. lb.

(12.4-15.8 Nm)

Open Circuit Motor Test

1/4 in.

(M6)

40-50 in. lb.

(4.5-5.6 Nm)

50-60 in. lb.

(5.6-6.8 Nm)

An open circuit is one where the electrical circuit within the motor has been broken. This can be caused by:

Stud Size

S/D Dschem.eps

Motor Circuits

•

Bad brushes or brush springs

•

A broken wire in the field or armature winding

•

A loose or bad connection

Test using the following procedure: 1. Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal stud.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Motors, General 4. If the meter indicates high resistance in the armature, check the condition of the brushes before replacing the motor.

2. With the motor at room temperature, connect the leads of a digital ohmmeter between the individual circuits in the motor.

5. If an open circuit is found in a compound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

3. Observe the measurements given in Table 6-2.

Table 6-2: Motor Resistance Readings

Motor Traction (Drive)

Lift

Acceptable Resistance Readings

Terminals

Unacceptable Resistance Readings

Armature

A1 to A2

0.01 to 0.10 ohms

Greater than 0.10 ohms

Field

E1 to E2 (S1 to S2)

0.8 to 1.7 ohms

Less than 0.5 ohms or Greater than 2.0 ohms

A to S

0.020 to 0.030 ohms

Greater than 0.1 ohms

NOTE: Measure all readings at room temperature.

See Figure 6-38 on page 6-39.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Motors, General

Grounded Motor Test In a grounded motor, an electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused either by direct contact or through conductive foreign material.

The ground may be caused by: •

Insulation breakdown

•

Brush leads touching the motor housing

•

Build-up of carbon dust or other materials

To test a motor for grounds: Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal studs.

Attach one lead of a digital ohmmeter to a motor terminal and the other lead to an unpainted surface of the motor housing. Set the ohmmeter to the highest scale.

If the ohmmeter reads resistance of less than 100,000 ohms, the motor is grounded. Clean, repair, or replace the motor as necessary.

Short-Circuited Winding

•

Severe burning or discoloring on one or two commutator segments every 90° of rotation

These symptoms can also be caused by problems other than the motor itself, such as: •

Brake too tight or dragging

•

Wheel bearings too tight

•

Faulty transmission

•

Binding in an attached pump

Testing a motor for short-circuited windings requires special equipment at a motor rebuilding facility.

Short-Circuited Armature A short circuit in the armature will cause heating, and will probably result in burning of: •

The armature coil

•

Brush wires

•

Commutator segments

Visual inspection may reveal these conditions.

Positive determination of a short-circuited armature requires special equipment at a motor rebuilding facility.

A short-circuited winding is one where the insulation on the field or armature has broken down at two or more points. The breakdown creates a low resistance path, permitting current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and an increase in the current flow.

The severity of the short circuit depends on its location.

A shorted motor may be indicated by: •

Slow or sluggish operation

•

Running faster than normal

•

Overheating

•

Blowing a power fuse

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Drive Motor

Drive Motor NOTE: For replacement parts information refer to Parts Catalog.

Brush Replacement 1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

2. Remove the tractor covers.

3. Remove any shields around the motor end cover to expose the brushes. See Figure 6-39.

Brush Shield

5. Remove the electromagnetic brake assembly by removing the three mounting bolts that secure the assembly to the motor end bell cover.

6. Remove the brake disc from the brake hub.

7. Remove the retaining ring that secures the brake hub. Remove the hub and woodruff key.

8. Remove the four screws and lock washers holding the brush end bell to the housing.

9. Separate the end bell from the motor housing. The armature will come out with the end bell.

10. To remove the end bell from the armature, remove the snap ring that holds the bearing in the end bell. If needed, press off the bearing and replace.

Installation 1. Thoroughly clean all parts with solvent or other non-corrosive cleaning fluid. Air dry all parts.

NOTE: Assemble the drive motor in a dirt-free area.

Figure 6-39: Drive Motor Brush Shield

4. Lift the spring off the brush, pull the brush out of the holder.

5. Follow the brush replacement instructions. See “Drive Motor Brush Inspection” on page 6-35.

6. Replace the shields around the motor end that were removed in step 3.

Motor Disassembly 1. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

2. Remove the tractor covers.

3. Disconnect the power cables from the terminal block on the drive motor, noting their correct position.

4. Follow steps 1 through 5 in “Disassembly” on page 6-28 to remove the top (pinion) gear attached to the motor armature shaft.

6-42

2. If previously removed, install the drive motor bearing, bearing shim, and seal in the gear case.

NOTE: The seal must be replaced any time the motor is removed from the housing.

The seal must be installed correctly with its open side and seal ring positioned towards the bearing.

3. Reinstall the end bell cover, with the brush plate attached, on the motor armature shaft.

4. Carefully slide the drive motor armature in the motor housing.

5. Attach the end bell cover to the motor housing with the four cap screws.

6. Install the pinion gear, woodruff key, and the retaining ring on the armature shaft.

7. Use Permatex gasket eliminator on the mating surface and install the gear case cover.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Drive Motor

8. Make sure the drive unit is filled to the correct level with gear oil. Install the fill/level plug. See “Drive Housing Lubrication” on page 6-30.

9. Install the brake hub and woodruff key, and secure with the retaining ring.

10. Install the brake disc on the hub.

11. Install the brake coil assembly and attach with three hex head cap screws.

12. Reattach the power cables and electromagnetic brake wiring connections to the terminal block.

13. Before testing operation, move the handle from extreme left to right and down into operating position and back several times.

Check for any wire and cable interference.

Repair or adjust as necessary.

14. Install the battery, reconnect the battery connector and the turn the Master Control ON/OFF switch ON. Enter your PIN-key code then press the green ON (I) key on the keypad.

15. Test the operation of the truck.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Drive Motor

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Pallet Forks and Load Wheels

Pallet Forks and Load Wheels Section 6. Component Procedures

NOTE: For replacement parts information refer to Parts Catalog.

Load Wheels

position with a plastic mallet. Make sure the bearing is fully seated in the load wheel.

8. Align the wheel with the holes in the load arm casting.

9. Drive the axle through the load arm casting and wheel. Align the “dimple” in the axle with the set screw hole.

10. Install and tighten the set screw.

Load wheels are installed on each pallet fork and are designed to support the rated load at the forks fully raised height.

Removal and Replacement 1. Lift the forks to maximum height and block them. See “Jacking Safety” on page 2-9.

2. Remove the axle set screw. See Figure 6-40.

Load Wheel Pull Rod Load wheel pull rods are installed on each fork and are designed to transfer the hydraulic cylinder lifting action at the tractor end to the load wheel fork.

Removal and Replacement NOTE: It may be easier to work with the truck upside down. Remove the battery before turning the truck over. Some oil may leak from the hydraulic reservoir.

1. Extend the load wheel forks. Remove the set screw and shaft connecting the wheel fork to the pallet fork. See Figure 6-41.

Axle Set Screw

27y7s173.tif

Figure 6-40.

Removing Set Screw

3. Drive the axle out of the load arm casting with a hammer and brass drift pin.

Wheel fork Set Screw

4. Push the wheel out.

5. If the bearings are to be reused, insert a brass drift pin into each end of the load wheel and knock the bearings out.

6. Install the bearings in the new load wheel with the shields facing out.

7. Place the new load wheel upright on a flat surface. Position the bearing over the load wheel. Put a flat metal plate over the bearing, and hammer the bearing in

00700-CL340-05, Issued: 2 May 2005

Figure 6-41.

Wheel Fork Set Screw Location (top view)

2. Remove the pivot pin locking bolt and drive the pivot pin out with a brass drift pin.

3. With the lower links out of the lift frame channels, the links can be separated and the pull rod removed from the link pin.

Each link has one set screw at opposite

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Pallet Forks and Load Wheels ends. The link can be pulled apart without removing any other set screws.

4. Press new bushings in the pull rods, if necessary.

5. Reassemble the pull rods on the lower links and press the links together so they will fit in the frame channel.

6. Reinstall the pivot shaft and the retaining bolt in the lower links.

7. Reconnect the pull rod to the wheel fork.

8. Place the truck upright and install the battery. Connect the battery. Check the reservoir fluid level. Test the operation of the lift frame.

Carrier Frame Linkage NOTE: For replacement parts information refer to Parts Catalog.

The bushings on the lower links can be replaced by removing the links from one side at a time and pressing in new bushings.

1. To separate the lift and carrier frames, remove all battery connections before removing the links.

2. Remove the upper and lower linkages and lift the lift frame off the carrier frame. See Figure 6-42.

Figure 6-42: Lower Links

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Hydraulic Components

Hydraulic Components

3. Press the green ON (I) key on the keypad.

Leave the control handle in the neutral (vertical) position.

General Guidelines

4. Press the lift button, raise the forks to maximum height and block them. See “Jacking Safety” on page 2-9.

Section 6. Component Procedures

To prolong the life of your Toyota Pallet Truck, follow these guidelines: •

Keep all fittings and connections tight to prevent leaks. Do not over-tighten brass fittings or they may become damaged or distorted.

•

Before you remove any component from the hydraulic system, wash the component and surrounding area with cleaning solvent to prevent foreign matter from entering the system. Cap and plug all openings immediately.

•

Whenever you remove a fitting with a pipe thread, use a sealing compound on the outside of the threads before you reinstall the fitting. (Do not use Teflon® tape.) Make sure all parts are clean.

•

When you install a hose assembly, make sure that it is not twisted when the fittings are tightened. Always use two wrenches on a swivel-type fitting—one to hold the fitting and the other to tighten the hose.

Hydraulic Cylinder Fluid leakage indicates that the seal is worn.

Replace the seal, wiper, and retaining ring when fluid leakage becomes excessive.

Cylinder Removal

Hydraulic Hose

Hydraulic Cylinder

1665 033.tif

Figure 6-44.

Hydraulic Cylinder (shown extended with retaining clip removed)

5. Lower the forks on the blocking to release pressure on the hydraulic cylinder.

Manually press down on the cylinder after the forks come to rest on the blocking to disengage the cylinder from the tractor frame.

6. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

1. Remove the tractor cover.

2. Remove retaining clip (see Figure 6-43).

Retaining Clip

1665 041.tif

Figure 6-43.

Remove Retaining Clip

00700-CL340-05, Issued: 2 May 2005

Hot oil under pressure is present. Make sure truck is safely blocked and pressure is released.

7. Thoroughly clean the outside of the cylinder before removing the hydraulic hose. Remove the hose from the cylinder.

Cap and plug the fittings.

NOTE: Catch hydraulic fluid under the hydraulic cylinder in a suitable container.

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Hydraulic Components 8. Lift the cylinder up and out of the tractor frame. Some spillage of hydraulic oil may occur.

Cylinder Disassembly 1. Thoroughly clean the outside of the cylinder.

2. Pull the rod out until the end of the rod and the retaining ring are visible through the inlet port. See Figure 6-45.

3. Insert a screwdriver into the inlet port and slide the retaining ring into the deep groove in the piston rod assembly.

4. Remove the rod assembly from the barrel.

5. Remove the retaining ring from the piston rod.

6. Remove the wiper and seal from inside the barrel assembly.

2. Install new seal in the barrel. Install new wiper in the barrel with lips facing inward.

3. Install new retaining ring in deep groove of the piston rod end.

4. Oil outside of piston rod and carefully insert rod into barrel.

5. Push rod into barrel until the retaining ring is seen through the inlet port.

6. Insert a screwdriver into the inlet port and slide the retaining ring into the lock position.

7. Extend rod to full out position to make sure the retaining ring is locked in place.

Cylinder Installation 1. Place the new cylinder into position in the tractor frame. Install retaining clip (see Figure 6-43).

NOTE: To prevent air from filling the cylinder, install the cylinder with the rod retracted.

Inlet Port

2. Connect the hydraulic hose.

3. Reconnect the battery connector and press the green ON (I) key on the keypad.

4. Press the lift button to extend the cylinder.

Barrel

5. Check the hydraulic reservoir fluid level. If necessary, add fluid. See “Lubrication Equivalency Chart” on page A-2.

Wiper Seal Retaining Ring Figure 6-45.

Rod

Hydraulic Cylinder Disassembly

Cylinder Inspection 1. Thoroughly clean all parts and remove all nicks and burrs with emery cloth.

6. Remove the blocking. Lift and lower the forks several times. Look for leakage around the fittings and cylinder seal.

7. Recheck the hydraulic reservoir fluid level.

If necessary, add fluid.

8. Install the tractor cover.

2. Inspect the inside surface of the barrel assembly for excessive wear or scoring.

3. Inspect the outside surface of the rod for nicks, scratches, or scoring.

Cylinder Assembly 1. Make sure all parts are cleaned and dried thoroughly. Lightly oil all metal parts before reassembly.

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Section 6. Component Procedures Hydraulic Components

Hydraulic Solenoid

4. Connect the wires to the terminals.

The hydraulic solenoid activates the hydraulic solenoid release valve that releases pressure on the lift cylinder, lowering the forks. See Figure 6-46.

5. Reconnect the battery connector and press the green ON (I) key on the keypad. Test the functions of the truck.

6. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

7. Install the tractor cover.

Hydraulic Unit Draining and cleaning the hydraulic reservoir is important to control the accumulation of condensation and contamination that can damage the hydraulic system.

Condensation is caused by the repeated heating and cooling of hydraulic fluid during normal operation. Contaminants include dirt, rust, scaling and products of fluid deterioration.

Hydraulic Solenoid 1665 033.tif

Figure 6-46.

Hydraulic Solenoid

Removal 1. Make sure that the forks are fully lowered.

2. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

3. Remove the two wires from the terminals on the solenoid.

4. Remove the nut holding the solenoid coil to the solenoid valve.

5. Lift the solenoid coil off the solenoid valve stem.

6. Remove the solenoid valve stem from the manifold.

Installation 1. Inspect the seat where the solenoid valve stem seals against the manifold. The sealing surface must be completely clean and free from any nicks or damage.

Removal Remove the hydraulic unit from the truck in order to separate the pump from the motor.

1. Lower the forks completely.

2. Press the red OFF (O) key on the keypad.

Disconnect the battery connector. Remove the tractor cover.

3. Remove and tag all wires and cables connected to the pump motor. See Figure 6-47.

4. Remove and cap the hydraulic line from the hydraulic unit. Disconnect the solenoid control wires.

5. Remove the bolts that attach the hydraulic unit mounting bracket to the tractor frame.

6. Remove the hydraulic unit from the truck.

2. Thread the solenoid valve body into the manifold. Torque the valve body to 204 to 240 in. lbs (23 to 27 Nm).

3. Install the solenoid coil and tighten the nut. Torque the nut to 48 to 60 in. lbs (5 to 7 Nm).

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Hydraulic Components 9. Check the hydraulic fluid level in the reservoir.

Pump Motor

Hydraulic Reservoir Removal

Lift Motor Solenoid

1. Remove the hydraulic unit from the truck.

See “Removal” on page 6-49.

Adapter Body (Pump)

2. Remove the hose clamp that secures the hydraulic reservoir to the adapter housing.

Hydraulic Solenoid

3. Tap the reservoir lightly to loosen. Wiggle the reservoir sideways while pulling up on the pump and motor at the same time to remove.

4. Remove the reservoir and properly dispose of the old hydraulic fluid.

Fill/Vent Plug

5. After the fluid has drained, flush the inside of the reservoir with a suitable cleaning solvent.

Hydraulic Reservoir

6. Dry the inside of the reservoir with clean, dry compressed air.

1665 040.tif

Figure 6-47.

Hydraulic Unit

Installation 1. Install the hydraulic unit on the tractor frame and attach with the previously removed screws.

2. Install the hydraulic line on the hydraulic unit.

3. Fill the reservoir with the specified hydraulic fluid. See “Lubrication Equivalency Chart” on page A-2. Use a funnel with a flexible neck. Fill the reservoir to within 1 in. (25.4 mm) below the filler plug elbow. Use up to 0.8 qt.

(0.75 liters). See Figure 6-47.

4. Install the vent plug. See Figure 6-47.

5. Connect all wires and cables to the pump motor switch and hydraulic solenoid.

6. Connect the battery connector and press the green ON (I) key on the keypad.

7. Raise and lower the forks. Check all hoses and fittings for leaks.

8. Lower the forks.

6-50

Installation 1. Inspect the reservoir O-ring and the inside leading edge for damage. Replace if necessary.

2. Lubricate the O-ring (with applicable hydraulic fluid) and install the O-ring.

3. Carefully install the reservoir on the adapter housing and attach with hose clamp. Torque clamp to 48 to 60 in. lb.

(5.5 to 7 Nm).

4. Install hydraulic unit in the truck. See “Installation” on page 6-50.

Filter Screen and Inlet Tube 1. Remove the reservoir. See “Hydraulic Reservoir”.

2. With the pump assembly inverted, unthread and remove the inlet tube fitting and sealing washer from the pump housing.

3. Clean the filter screen at the bottom of the inlet tube with a suitable solvent. See Figure 6-48.

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Hydraulic Components

4. From the pump side, blow dry with clean, dry compressed air.

Installation 1. Stand the motor assembly on end, with the adapter body facing up.

2. Lubricate the O-ring and install on the adapter body facing up.

Filter Screen

3. Insert the pump drive coupling on the end of the motor armature shaft, and fill the cavity with lubricant (Molybdenum anti-seize compound).

4. Align the splines on the motor drive and pump shaft. Gently push the pump pilot on the adapter.

Inlet Tube 27y7s158.tif

Figure 6-48.

Cleaning Filter Screen

Installation 1. Inspect the filter screen and inlet tube for damage. Replace if necessary.

2. Install the inlet tube sealing washer and fitting in the pump housing. Torque to 245 to 275 in. lbs. (27 to 31 Nm).

3. Install the hydraulic reservoir. See “Hydraulic Reservoir”.

5. Secure the pump with the two pump mounting bolts. Torque to 40 to 45 in. lb.

(4.5 to 5 Nm).

6. Check the inlet screen for clogging. Clean with a suitable solvent. Install the inlet tube fitting into the pump. Torque fitting to 245 to 275 in. lb. (27 to 31 Nm).

7. Install the reservoir. See “Hydraulic Reservoir” on page 6-50.

Lift Motor Removal

Hydraulic Pump NOTE: For replacement parts information refer to Parts Manual.

Removal 1. Remove the hydraulic unit from the truck and put on a clean bench for disassembly.

See “Hydraulic Unit” on page 6-49.

1. Remove the hydraulic unit from the truck.

See “Hydraulic Unit” on page 6-49.

2. Remove the two bolts from the end plate that attach the motor to the adapter body.

3. Separate the motor and the adapter body.

4. Remove the start solenoid from the side of the motor housing for later reuse.

2. Remove the reservoir to gain access to the pump. See “Hydraulic Reservoir”.

3. Remove the inlet tube with the filter screen from the pump housing.

4. Remove the two pump mounting bolts then remove the pump from the adapter body.

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Hydraulic Components

Installation 1. Stand the pump assembly on end, with the adapter body facing up.

2. Set aside the pump drive coupling for later reuse.

NOTE: The coupling is the mechanical connection between the pump shaft and the electric motor armature shaft. It may have been removed with the motor.

3. Insert the pump drive coupling on the end of the pump shaft and fill coupling cavity with lubricant (Molybdenum anti-seize compound).

4. Rotate the pump or the motor shaft to align the motor shaft correctly with the coupling.

5. Install the new motor on the adapter body.

Rotate the pump or the motor shaft if necessary to allow the motor to contact the adapter body.

6. Insert the screws into the motor end plate, through the motor, and into the adapter body.

7. Make sure the motor is mating flush with the adapter body. Torque screws to 36 to 45 in. lb. (4 to 5 Nm) maximum.

8. Install the start solenoid.

9. Install the hydraulic unit. See “Hydraulic Unit” on page 6-49.

Brush Replacement Brush Replacement Spring Tension

Replace brushes when they have worn to the minimum length of 0.35 in. (9 mm).

Adjust the spring tension of new brushes to 32 to 40 oz. (908.8 to 1136 gm).

Remove brush assembly then remove each brush and replace with a new one.

Hydraulic Fluid Proper Level To prevent air from entering the lines, fill the fluid level (with the forks fully lowered) to within 1 in. (25.4 mm) below the fill port elbow. See Figure 6-44. The usable reservoir capacity is 0.8 qt. (0.75 L). Add the specified fluid if necessary. See “Lubrication Equivalency Chart” on page A-2.

Changing Fluid Store and handle the hydraulic fluid with extreme care to prevent moisture and foreign matter from entering the hydraulic system.

Contaminated hydraulic fluid is the major cause of hydraulic system failures. Keep any service equipment, such as containers, funnels, and hand pumps, clean at all times. Cover them when not in use.

1. Lower the forks.

2. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

3. Remove the upper tractor cover.

4. Disconnect the lift cylinder hose at the hydraulic cylinder. See Figure 6-49.

Lift Cylinder Hose

1. Remove the lift motor from the hydraulic assembly before inspecting brushes.

2. Remove the two screws from the motor end cover. Remove end cover to access brushes.

3. Push each brush back into holder to disengage springs. Remove nuts and washers from side of drive end head.

6-52

1665 040.tif

Figure 6-49.

Hydraulic Connections

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Toyota Model 7HBW23 Service Manual

Section 6. Component Procedures Hydraulic Components

5. Insert the hose in a waste fluid container.

Fluid is under pressure and may spray or splash. Point hose away from your body and hold firmly in waste fluid container.

6. Connect the battery connector and press the green ON (I) key on the keypad.

7. Run the hydraulic pump by pressing the lift button until all the hydraulic fluid is pumped from the system.

Check Setting 1. Attach a jumper wire across the terminals of the lift-limit switch so the switch will not shut the pump down when the forks reach their upper limit.

2. Retract the lift cylinder completely. Press the red OFF (O) key on the keypad.

Remove the 90° elbow. Replace the elbow with a female run tee with a 1/8 in. NPT 0 to 3,500 psi (0 to 24131 kPa) pressure gauge. See Figure 6-50.

8. Press the red OFF (O) key on the keypad.

Disconnect the battery connector.

9. Reconnect the lift cylinder hose.

10. Remove the vent plug and fill the reservoir to within 1 in. (25.4 mm) below the filler port elbow with the recommended hydraulic fluid. See “Lubrication Equivalency Chart” on page A-2.

11. Replace the vent plug.

12. Connect the battery connector and press the green ON (I) key on the keypad.

13. Raise and lower the forks several times to purge air from the system.

Hydmtrpm.tif

14. Install the upper tractor cover.

15. Dispose of the waste fluid properly.

Adjusting Hydraulic Pump Pressure Relief Valve The hydraulic system is protected by a relief valve installed in the adapter body. The relief valve is set by the manufacturer to open at a specified pressure.

Checking Relief Valve Pressure

3. Press the green ON (I) key on the keypad.

Leave the control handle in the neutral (vertical) position.

4. Press the lift button and observe the indicator on the pressure gauge. When the forks reach the upper lift-limit, the pump will make a high pitched squeal indicating that the relief valve is opening.

Adjust Setting

Relief Valve Settings Pressure Settings Truck Capacity 4,500 lb. (2,041 kg)

Figure 6-50.

PSI

kPa

3,000

20,684

Table 6-3: Truck Pressure Levels

00700-CL340-05, Issued: 2 May 2005

If the relief valve opens at a lower or higher pressure than the specified pressure, adjust the relief valve as follows: 1. Remove the hex cap covering the relief valve adjustment screw.

2. As you depress the lift button, turn the adjusting screw inward to increase the

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Hydraulic Components pressure setting or outward to decrease the pressure setting.

3. Check the indicator on the pressure gauge. After the relief valve is properly set, release the lift button.

4. Reinstall the hex cap. Torque to 144 to 180 in. lb. (16 to 20 Nm).

5. Recheck the relief valve setting.

6. Lower the forks completely. Press the red OFF (O) key on the keypad.

7. Remove the pressure gauge. Replace the elbow.

8. Press the green ON (I) key on the keypad.

Raise the forks. Inspect all hoses and fittings for leaks.

9. Adjust the lift-limit switch to shut down the pump when the forks reach their upper limit. See “Lift-Limit Switch” on page 6-25.

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Section 6. Component Procedures Cold Storage Conditioning

Cold Storage Conditioning New Toyota Pallet Trucks supplied with a standard conditioning package are designed to operate in an environment where temperatures range from 32° to 104°F (0° to 40°C) in a continuous duty cycle.

Trucks supplied with a cold storage conditioning package are designed to operate in temperatures to 5°F (–15°C) in a continuous duty cycle or to –13°F (–25°C) for in and out operation.

When a truck is installed in a cold storage environment, change the fluid in the hydraulic reservoir according to the recommended fluids listed in the Appendix. See “Lubrication Equivalency Chart” on page A-2.

00700-CL340-05, Issued: 2 May 2005

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Section 6. Component Procedures

Toyota Model 7HBW23 Service Manual

Cold Storage Conditioning

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Appendix

Toyota Model 7HBW23 Service Manual

Appendix

Appendix

00700-CL340-05, Issued: 2 May 2005

A-1

Appendix

Toyota Model 7HBW23 Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency Chart s

Table A-1.

Approved Lubricants Approved Toyota Lubricants

Where Used

Type

Drive Unit Gear Case –25° to +110°F (–31.5° to +43.3°C)

Synthetic Gear Lubricant

Mobil-1 or Texaco Synstar GL 75W - 90 Synthetic Gear Oil API Service Classification GL-5

00590-04835-71 (1 qt./0.9 liter) 00590-04837-71 (5 gal./18.9 liters)

Hydraulic Reservoir Standard Operation Down to +23° F (-5° C)

Hydraulic Fluid

Sunoco TH ISO VG 46

00590-04934-71 (1 qt./0.9 liter) 00590-04840-71 (5 gal./18.9 liters)

Hydraulic Reservoir Cold Storage Continuous Operation down to +5°F (-15° C) Intermittent Operation down to -13°F (-25° C)

Hydraulic Fluid

ATF ISO VG 32

00590-04842-71 (1 gal./3.8 liters) 00590-04843-71 (5 gal./18.9 liters)

Bearings and Bushings

Grease

Mystic JT-6 NLGI Grade 2

00590-04844-71 (10 cartridges per case) 00590-04845-71 (5 gal./18.9 liters)

A-2

Specification

Toyota Part Number

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Toyota Model 7HBW23 Service Manual

Appendix Torque Chart - Standard

Torque Chart - Standard Grade Identification Marking

Size 4-40 4-48 6-32 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 1 1/2-6 1 1/2-12

None SAE Grade 2 Bolts Tightening Torque Dry Oiled* in. lb. in. lb.

5 4 6 5 10 8 19 14 20 15 27 21 31 23 66 49 76 56 ft. lb. ft. lb.

11 8 12 9 20 15 23 17 30 24 35 25 50 35 55 40 70 55 80 60 100 75 110 85 175 130 195 145 165 125 185 140 250 190 270 200 350 270 400 300 500 380 550 420 660 490 740 560 870 650 980 730

SAE Grade 5 Bolts Tightening Torque Dry Oiled* in. lb. in. lb.

8 6 9 7 16 12 30 22 31 23 43 32 49 38 96 75 120 86 ft. lb. ft. lb.

17 13 19 14 30 23 35 25 50 35 55 40 75 55 90 65 110 80 120 90 150 110 170 130 260 200 300 220 430 320 470 350 640 480 700 530 800 600 880 660 1120 840 1240 920 1460 1100 1680 1260 1940 1460 2200 1640

SAE Grade 8 Bolts Tightening Torque Dry Oiled* in. lb. in. lb.

12 9 13 10 23 17 41 31 43 32 60 45 68 51 144 108 168 120 ft. lb. ft. lb.

25 18 25 20 45 35 50 35 70 55 80 60 110 80 120 90 150 110 170 130 220 170 240 180 380 280 420 320 600 460 660 500 900 680 1000 740 1280 960 1440 1080 1820 1360 2000 1500 2380 1780 2720 2040 3160 2360 3560 2660

Table A-2.

Torque Chart - Standard *NOTE: Use “oiled” values for bolts with thread-locking compound.

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A-3

Appendix

Toyota Model 7HBW23 Service Manual

Torque Chart - Metric

Torque Chart - Metric Ferrous Metric Bolts (The grade rating is stamped on the head of the bolt.)

Diameter (in millimeters)

Grade 8.8

Grade 10.9

Torque (with bolts oiled*)

Torque (with bolts oiled*)

Newton-meters

Foot-pounds

Newton-meters

Foot-pounds

6

8.6

6

12

9

8

21

15

29

21

10

42

30

58

43

12

72

55

101

75

16

174

130

245

181

20

340

255

475

350

24

580

435

820

605

Table A-3.

Torque Chart - Ferrous Metric *NOTE: Use “oiled” values for bolts with thread-locking compound.

Metric Bolts, Coarse Thread Diameter (in millimeters)

Torque (with bolts oiled*) Newton-meters

Foot-pounds

3

0.5

4.4

3.5

0.79

7.0

4

1.2

10.6

5

2.2

19.4

6

3.9

34.5

8

9

79.6

10

17

150

Table A-4.

Torque Chart - Non-Ferrous Metric *NOTE: Use “oiled” values for bolts with thread-locking compound.

A-4

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Appendix Decimal Equivalent Chart

Decimal Equivalent Chart 4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

1/64

.016

.02

.397

.031

.03

.794

3/64

.047

.05

1.191

.062

.06

1.587

5/64

.078

.08

1.984

.094

.09

2.381

.109

.11

2.778

.125

.12

3.175

.141

.14

3.572

.156

.16

3.969

11/64

.172

.17

4.366

.188

.19

4.762

13/64

.203

.20

5.159

.219

.22

5.556

.234

.23

5.593

.250

.25

6.350

.266

.27

6.747

.281

.28

7.144

19/64

.297

.30

7.540

.312

.31

7.937

21/64

.328

.33

8.334

.344

.34

8.731

.359

.36

9.128

.375

.38

9.525

.391

.39

9.922

.406

.41

10.319

.422

.42

10.716

.438

.44

11.112

.453

.45

11.509

.469

.47

11.906

.484

.48

12.303

.500

.50

12.700

1/32 1/16 3/32 7/64 1/8 9/64 5/32 3/16 7/32 15/64 1/4 17/64 9/32 5/16 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Table A-5.

Decimal Equivalent Chart

00700-CL340-05, Issued: 2 May 2005

A-5

Appendix

Toyota Model 7HBW23 Service Manual

Decimal Equivalent Chart 4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

33/64

.516

.52

13.097

.531

.53

13.494

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64

13.891

.56

14.288

.578

.58

14.684

.594

.59

15.081

.609

.61

15.478

.625

.62

15.875

.641

.64

16.272

.665

.66

16.669

.672

.67

17.065

.688

.69

17.462

.703

.70

17.859

.719

.72

18.256

.734

.73

18.653

.750

.75

19.050

.766

.77

19.447

.781

.78

19.844

.797

.80

20.241

.812

.81

20.637

.828

.83

21.034

.844

.84

21.431

.86

21.828

.875

.88

22.225

57/64

.891

.89

22.622

.906

.91

23.019

59/64

.922

.92

23.416

.938

.94

23.812

.953

.95

24.209

.969

.97

24.606

29/32 15/16 61/64 31/32 63/64

A-6

.55

.562

.859

7/8

Table A-5.

.547

.984

.98

25.003

1.000

1.00

25.400

Decimal Equivalent Chart

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Appendix Standard/Metric Conversions

Standard/Metric Conversions To Convert...

Multiply...

Inches to Millimeters

Inches x 25.4

Millimeters to Inches

Millimeters x 0.039

Inches to Centimeters

Inches x 2.54

Centimeters to Inches

Centimeters x 0.394

Feet to Meters

Feet x 0.305

Meters to Feet

Meters x 3.281

Yards to Meters

Yards x 0.914

Meters to Yards

Meters x 1.094

Miles to Kilometers

Miles x 1.609

Kilometers to Miles

Kilometers x 0.621

Square Inches to Square Centimeters

Square Inches x 6.452

Square Centimeters to Square Inches

Square Centimeters x 0.155

Square Feet to Square Meters

Square Feet x 0.093

Square Meters to Square Feet

Square Meters x 10.753

Square Yards to Square Meters

Square Yards x 0.836

Square Meters to Square Yards

Square Meters x 1.196

Pints to Liters

Pints x 0.473

Liters to Pints

Liters x 2.113

Quarts to Liters

Quarts x 0.946

Liters to Quarts

Liters x 1.057

Gallons to Liters

Gallons x 3.785

Liters to Gallons

Liters x 0.26

Ounces to Grams

Ounces x 28.35

Grams to Ounces

Ounces x 0.035

Ounces to kilograms

Ounces x 0.028

Kilograms to ounces

Kilograms x 35.27

Pounds to Kilograms

Pounds x 0.454

Kilograms to pounds

Kilograms x 2.2

Pounds per Square Inch to Kilo pascals

Pounds per Square Inch x 6.894

Kilo pascals to Pounds per Square Inch

Kilo pascals x 0.145

Inch Pounds (in. lb.) to Newton Meters (Nm)

Inch Pounds x 0.113

Table A-6.

Conversion Table

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A-7

Appendix

Toyota Model 7HBW23 Service Manual

Standard/Metric Conversions To Convert...

Multiply...

Newton Meters (Nm) to Inch Pounds (in. lb.)

Newton Meters x 8.85

Foot Pounds (ft. lb.) to Newton Meters (Nm)

Foot Pounds x 1.3568

Newton Meters (Nm) to Foot Pounds (ft. lb.)

Newton Meters x 0.737

Miles per hour to kilometers per hour

Miles per hour x 0.6214

Kilometers per hour to miles per hour

Kilometers per hour x 1.609

Fahrenheit to Celsius

(°F – 32) x 0.555

Celsius to Fahrenheit

(°C x 1.8) + 32

Table A-6.

A-8

Conversion Table

00700-CL340-05, Issued: 2 May 2005

Schematics

Toyota Model 7HBW23 Service Manual

Schematics

Schematics

00700-CL340-05, Issued: 2 May 2005

A-9

Schematics

Toyota Model 7HBW23 Service Manual

MASTER CONTROL ON/OFF S21

1881 002.eps

Figure A-1. Electrical Schematic - Sheet 1 of 2

A-10

00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual

Schematics

MASTER CONTROL ON/OFF

1881 002.eps

Figure A-2. Electrical Schematic - Sheet 2 of 2

00700-CL340-05, Issued: 2 May 2005

A-11

Schematics

Toyota Model 7HBW23 Service Manual

1881 002.eps

Lift Cylinder

Solenoid Valve

Check Valve

Flow Control

Pressure Relief Valve

Motor Pump

Filter Reservoir

Figure A-3. Hydraulic Schematic

A-12

00700-CL340-05, Issued: 2 May 2005

Index

Toyota Model 7HBW23 Service Manual

Index

Index A Acceleration . . . . . . . . . . . . . . . . . . . . 5-6 Anti-Static Kit . . . . . . . . . . . . . . . . . . 2-12 Arm Angle Switches . . . . . . . . . . . . . . 6-24

B Battery Adding Water . . . . . . . . . . . . . . . . . 6-7 Charging . . . . . . . . . . . . . . . . . . . . 6-6 Maintenance . . . . . . . . . . . . . . . . . 6-5 Maintenance-Free . . . . . . . . . . . . . 6-5 Safety . . . . . . . . . . . . . . . . . . . . . . 2-6 Specific Gravity . . . . . . . . . . . . . . . 6-7 Storage . . . . . . . . . . . . . . . . . . . . . 6-8 Voltage Check . . . . . . . . . . . . . . . . 6-7 Brake . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Disc Location . . . . . . . . . . . . . . . . 6-33 Friction Disc Replacement . . . . . . 6-34 Gap Adjustment . . . . . . . . . . . . . 6-33

C Cables, Power . . . . . . . . . . . . . . . . . . 6-10 Carrier Frame Linkage . . . . . . . . . . . 6-46 Caution and Error Codes . . . . . . . . . . 5-10 Circuit Breaker . . . . . . . . . . . . . . . . . 6-13 Codes, Caution and Error . . . . . . . . . 5-10 Cold Storage Conditioning . . . . . . . . . 6-55 Contactors . . . . . . . . . . . . . . . . . . . . 6-20 Control Handle Changing Horn Button/Switch . . 6-15 Changing Lift/Lower Button . . . . 6-16 Changing Push Button . . . . . . . . 6-16 Disassembly . . . . . . . . . . . . . . . . 6-15 Display and Programming . . . . . . . 5-9 Stem . . . . . . . . . . . . . . . . . . . . . . 6-16 Control Handle Assembly . . . . . . . . . 6-18 Conversions, Standard/Metric . . . . . . . A-7 Cover, Tractor . . . . . . . . . . . . . . . . . . . 6-9 Creep Speed . . . . . . . . . . . . . . . . . . . . 5-6 Current Limiting . . . . . . . . . . . . . . . . . 5-6

D

Definitions . . . . . . . . . . . . . . . . . . . . . . 5-6 Display and Programming Error Codes . . . . . . . . . . . . . . . . . . 5-9 Hourmeter . . . . . . . . . . . . . . . . . . . 5-9 Part Numbers . . . . . . . . . . . . . . . . 5-20 Drive Housing Lubrication . . . . . . . . . 6-30 Drive Motor Brush Inspection/Replacement . . . 6-35 Brush Spring Tension . . . . . . . . . . 6-36 Commutator . . . . . . . . . . . . . . . . . 6-36 Drive Unit Brake, Electromagnetic . . . . . . . . . 6-33 Drive Motor Brush Replacement . . . . . . . . . 6-42 Drive Wheel . . . . . . . . . . . . . . . . . 6-31 Lubrication . . . . . . . . . . . . . . . . . . 6-30 Transmission Assembly . . . . . . . . 6-27 Drive Wheel . . . . . . . . . . . . . . . . . . . . 6-31

E Electrical Schematic . . . . . . . . . . . . . . A-10 Electrical Symbols, List of . . . . . . . . . . . 5-8 Electrical Troubleshooting . . . . . . . . . . 5-3 Electromagnetic Brake . . . . . . . . . . . . 6-33 Electrostatic Discharge . . . . . . . . . . . . 2-12 Emergency Reverse . . . . . . . . . . . . . . . . 5-6 Equivalent Chart, Decimal . . . . . . . . . . A-5 Error and Caution Codes . . . . . . . . . . 5-10 Error Codes . . . . . . . . . . . . . . . . . . . . . 5-9 History . . . . . . . . . . . . . . . . . . . . . . 5-9 ESD, See Electrostatic Discharge

F Fault Codes . . . . . . . . . . . . . . . . 5-7, 5-24 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

G Grease Fittings . . . . . . . . . . . . . . . . . . . 4-5

H Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Decimal Equivalent Chart . . . . . . . . . . A-5

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I-1

Index

Toyota Model 7HBW23 Service Manual

Hydraulic Components Cylinder Assembly . . . . . . . . . . . . . . . . . 6-48 Disassembly . . . . . . . . . . . . . . 6-48 Inspection . . . . . . . . . . . . . . . . 6-48 Installation . . . . . . . . . . . . . . . 6-48 Removal . . . . . . . . . . . . . . . . . 6-47 Fluid Changing . . . . . . . . . . . . . . . . . 6-52 Level . . . . . . . . . . . . . . . . . . . . 6-52 Hydraulic Pump Removal/Installation . . . . . . . . 6-51 Hydraulic Reservoir Installation . . . . . . . . . . . . . . . 6-50 Removal . . . . . . . . . . . . . . . . . 6-50 Hydraulic Unit Installation . . . . . . . . . . . . . . . 6-50 Relief Valve Adjustment . . . . . . 6-53 Removal . . . . . . . . . . . . . . . . . 6-49 Solenoid Installation . . . . . . . . . . . . . . . 6-49 Removal . . . . . . . . . . . . . . . . . 6-49 Hydraulic Schematic . . . . . . . . . . . . . .A-12 Hydraulic Troubleshooting . . . . . . . . . .5-5

I Identification, Model . . . . . . . . . . . . . . .3-2

J Jacking Safety . . . . . . . . . . . . . . . . . . .2-9

K key code . . . . . . . . . . . 5-7, 5-9, 5-19, 5-20 Key Switch (Optional) . . . . . . . . . . . . . 6-26

L Lift Motor . . . . . . . . . . . . . . . . . . . . . . 6-51 Lift-Limit Switch . . . . . . . . . . . . . . . . . 6-25 Adjustment . . . . . . . . . . . . . . . . . . 6-25 List of Electrical Symbols . . . . . . . . . . .5-8 Load Wheels . . . . . . . . . . . . . . . . . . . . 6-45 Carrier Frame Linkage . . . . . . . . . 6-46 Pull Rod Removal/Replacement . . . 6-45 Removal/Replacement . . . . . . . . . . 6-45 Lubrication Equivalency Chart . . . . . . .A-2 Lubrication, Drive Housing . . . . . . . . . 6-30

I-2

M Maintenance Annually/Every 1500 Hours . . . . . . 4-5 Daily . . . . . . . . . . . . . . . . . . . . . . . 4-3 Every Two Months/250 Hours . . . . 4-4 Map, Navigating the Manual . . . . . . . . . 1-2 Master Control ON/OFF Switch . . . . . 6-23 Master Control Relay . . . . . . . . . . . . . 6-21 Metric Conversions . . . . . . . . . . . . . . . A-7 Model Identification . . . . . . . . . . . . . . . 3-2 Motor Controller . . . . . . . . . . . . . . . . . . 3-7 Undertemperature . . . . . . . . . . . . . 5-7 Motors Drive . . . . . . . . . . . . . . . . . .6-35, 6-42 General . . . . . . . . . . . . . . . . . . . . 6-35 Lift . . . . . . . . . . . . . . . . . . . . . . . . 6-51

N Neutral Braking . . . . . . . . . . . . . . . . . . 5-6

O Operation Directional/Speed Control . . . . . . . 3-5 Lift/Lower . . . . . . . . . . . . . . . . . . . 3-5 Motor Controller . . . . . . . . . . . . . . . 3-7 Truck Starting . . . . . . . . . . . . . . . . 3-5 Overvoltage Cutoff . . . . . . . . . . . . . . . . 5-7

P Pallet Forks . . . . . . . . . . . . . . . . . . . . 6-45 PIN-key code . . . . . . . 5-7, 5-9, 5-19, 5-20 Plugging . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Power Amplifier Thermal Cutback . . . . . . . . . . . . . . 5-7 Programmable Maintenance Tool .3-4, 5-26 Pump, Hydraulic . . . . . . . . . . . . . . . . 6-51

R Ramp Shape . . . . . . . . . . . . . . . . . . . . 5-7 Relay, Master Control . . . . . . . . . . . . . 6-21

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Toyota Model 7HBW23 Service Manual

S Safety Battery . . . . . . . . . . . . . . . . . . . . . 2-6 Definitions . . . . . . . . . . . . . . . . . . . 2-2 General . . . . . . . . . . . . . . . . . . . . . 2-3 Jacking . . . . . . . . . . . . . . . . . . . . . 2-9 Static . . . . . . . . . . . . . . . . . . . . . . 2-12 Towing . . . . . . . . . . . . . . . . . . . . . 2-10 Welding . . . . . . . . . . . . . . . . . . . . 2-11 Schematics Electrical . . . . . . . . . . . . . . . . . . . A-10 Hydraulic . . . . . . . . . . . . . . . . . . A-12 Sequencing Delay . . . . . . . . . . . . . . . . 5-7 Service Key . . . 3-4, 5-17, 5-18, 5-20, 5-21 Solenoid, Hydraulic . . . . . . . . . . . . . . 6-49 Special Tools . . . . . . . . . . . . . . . . . . . . 3-4 Programmable Maintenance Tool . . 3-4 Service Key . . . . . . . . . . . . . . . . . . 3-4 Specifications, Vehicle . . . . . . . . . . . . . 3-2 Speed Limiting . . . . . . . . . . . . . . . . . . 5-7 Static Discharge . . . . . . . . . . . . . . . . 2-12 Static Wrist Strap . . . . . . . . . . . . . . . 2-12 Static-Sensitive Components . . . . . . . 2-12 Strap, Static . . . . . . . . . . . . . . . . . . . 2-12 Switches Arm Angle . . . . . . . . . . . . . . . . . . 6-24 General . . . . . . . . . . . . . . . . . . . . 6-23 Key Switch (Optional) . . . . . . . . . 6-26 Lift-Limit . . . . . . . . . . . . . . . . . . . 6-25 Master Control ON/OFF . . . . . . . 6-23 Test/Inspection . . . . . . . . . . . . . . 6-23 Symptom Tables Lift/Lower System . . . . . . . . . . . . 5-35 Travel (Forward/Reverse) System . 5-39

Index

Troubleshooting Electrical . . . . . . . . . . . . . . . . . . . . 5-3 Hydraulic . . . . . . . . . . . . . . . . . . . . 5-5 List of Charts/Tables . . . . . . . . . . 5-29 Symptom Tables . . . . . . . . . 5-35, 5-39 Truck Model Identification . . . . . . . . . . 3-2 Truck Specifications . . . . . . . . . . . . . . . 3-2

U Undervoltage Cutback . . . . . . . . . . . . . 5-7

V Vehicle Specifications . . . . . . . . . . . . . . 3-2

W Welding Safety . . . . . . . . . . . . . . . . . . 2-11 Wheels Load . . . . . . . . . . . . . . . . . . . . . . . 6-45 Wiring Harness . . . . . . . . . . . . . . . . . . 6-11 Inspection . . . . . . . . . . . . . . . . . . . 6-11 Wrist Strap . . . . . . . . . . . . . . . . . . . . . 2-12

T Tests Electric Motor . . . . . . . . . . . . . . . 6-39 Theory of Operation . . . . . . . . . . . . . . . 3-5 Torque Chart Metric . . . . . . . . . . . . . . . . . . . . . . A-4 Standard . . . . . . . . . . . . . . . . . . . . A-3 Towing Safety . . . . . . . . . . . . . . . . . . 2-10 Tractor Cover . . . . . . . . . . . . . . . . . . . 6-9 Installation . . . . . . . . . . . . . . . . . . 6-9 Removal . . . . . . . . . . . . . . . . . . . . 6-9

00700-CL340-05, Issued: 2 May 2005

I-3

Index

Toyota Model 7HBW23 Service Manual

I-4

00700-CL340-05, Issued: 2 May 2005