Section 4. Planned MaintenanceToyota Model 7HBW23 Service Manual Maintenance Guidelines

Every Two Months or 250 Operating Hours

Perform daily checks plus the following:

Item Every Two Months or Every 250 Operating Hours

Grease FittingsLubricate all grease fittings.

ForksCheck the lift-limit switch for lift motor cut-out. Adjust if necessary

Lubrication PointsLubricate all levers, shafts ,and linkage points.

Lift CylinderCheck the lift cylinder for leaks. Repair or replace cylinder if necessary. See “Hydraulic Cylinder” on page6-47.

Hydraulic SystemCheck for correct fluid level with the forks fully lowered to within 1in. (25.4 mm) of filler plug. Add fluid if necessary. See “Lubrication Equivalency Chart” on pageA-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 page6-49.

GeneralCheck for loose hardware. Tighten if necessary. Check the tightness of the drive unit mounting bolts. Tighten if necessary.

Electrical SystemVisually inspect all cables for damage. Replace if necessary. See “Power Cables” on page6-10. Check for electrical shorts to frame. See “Checking for Shorts from Battery to Truck Frame” on page5-3.

Master Control RelayCheck contacts for welded condition. See “Inspection/Test” on page6-21.

Drive WheelCheck the tightness of the mounting bolts on the drive wheel. Torque to 55 ft. lb. (75 Nm).

Drive UnitCheck for oil leaks. If leaks are found, check the oil level. If the oil level is low, determine the cause. See “Drive Unit” on page6-27. Check the transmission pivot bearing.

Motor BrushesCheck 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 SwitchesCheck adjustment.

Load WheelCheck the load wheel bearings and linkage.

BrakeCheck the brake disc for wear. Adjust or replace if necessary. See “Electromagnetic Brake” on page6-33.

Battery SystemClean the battery and the truck. See “Battery Maintenance” on page6-5.

Annually or Every 1500 Operating Hours

Perform Every Two Month checks plus the following:

Drive HousingChange the oil in the drive housing. See “Drive Housing Lubrication” on page6-30.

00700-CL340-05, Issued: 2 May 20054-5