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.
00700-CL340-05, Issued: 2 May 2005
