Toyota 7PLL24 Forklift Repair Manual (SN 723984) PDF Download

Description

TOYOTA Forklift 7PLL24 Service Manual SN 723984 – PDF DOWNLOAD

FILE DETAILS:

TOYOTA Forklift 7PLL24 Service Manual SN 723984 – PDF DOWNLOAD

Language : English
Pages : 156
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

TOYOTA Forklift 7PLL24 Service Manual SN 723984 – PDF DOWNLOAD

1- Contents 3
2- Technical data – M4 7
3- Installation and maintenance instructions – P1 13
31 Installation of the new truck 13
311 Lifting the truck 13
312 Fitting the battery 15
313 Start up 15
32 Introduction, maintenance 17
321 Safety regulations during maintenance work 17
322 Cleaning and washing 18
323 Cleaning the exterior 19
324 Cleaning the motor compartment 19
325 Electrical components 19
33 Safe lifting 20
4- Preventive maintenance – P2 21
41 Maintenance schedule 21
42 Lubrication chart 25
5- Oil and grease specification – P3 27
6- Tools 29
61 Super Seal connectors 29
62 AMP connectors 30
621 AMP Connectors, 040 series 31
63 Molex connectors 31
64 Grease guns 32
65 Other tools 33
7- Fork carriage – 0380 35
71 Component parts 35
72 Dismantling the fork carriage 37
73 Replacing the rollers 39
8- Engine suspension- 0450 41
81 Component parts 41
811 Component List 42
9- Electric drive motor – 1760 43
91 Component parts 43
92 Removing the motor from the truck 44
93 Refitting the motor in the truck 45
94 Service and repairs 45
941 Dismantling N-side 45
942 Dismantling D-side 45
943 Cleaning 46
10- Mechanical drive gear unit – 2550 47
101 Component parts 48
1011 Technical data 49
102 Dismantling/Assembly Leakage from the upper cover 49
103 Replacing the drive shaft gasket 50
1031 Dismantling 50
1032 Assembling 51
104 Replacing wheel bolt 52
11- Electromagnetic brake – 3370 53
111 Component parts 53
112 Dismantling 54
1121 Inspection 54
113 Assembling 55
114 Manual release of the brake 55
115 Adjustment 55
1151 Adjusting the play 55
12- Steering system – 4000 57
121 Component parts, mechanical steering 57
122 Component parts, servo steering (Option) 60
1221 Steering axle, servo steering (Option) 61
123 Adjustment, steering 65
1231 Adjusting the steering servo 65
1232 Adjusting the steering chain 65
124 Component parts, tiller arm 66
125 Adjustment, tiller arm 67
1251 Adjusting the brake microswitch 67
126 Tiller arm handle 68
127 Dismantling/Assembly, buttons 70
Change from ignition key to keyboard (2) 70
Change from keyboard to ignition key (2) 70
1271 Replacing the signal button/switch (9, 10) 71
1272 Replacing the lift/lower button (13) 71
1273 Replace the pushbutton (16) 72
13- Electrical systems – 5000 73
131 Electrical parts 73
132 Symbol list and electrical diagram 75
1321 Electrical wiring diagram 1(5) 77
1322 Electrical wiring diagram 2(5) 78
1323 Electrical wiring diagram 3(5) 79
1324 Electrical wiring diagram 4(5) 80
1325 Electrical wiring diagram 5(5) 81
1326 Electrical wiring diagram Servo (Option) 82
133 Functional description 83
1331 Starting the truck 83
1332 Driving without using platform and gates, speed £ 6 km/h 83
1333 Driving from platform without using gates,speed £ 6 km/h 83
1334 Driving from platform and using gates, speed ³ 8 km/h 83
1335 Neutral speed reduction 83
1336 Neutral speed reduction on slopes 84
1337 Braking 84
1338 Lifting the forks 84
1339 Lowering the forks 84
13310 Horn 84
134 Hour meter 85
135 Error codes 85
136 Parameters 97
1361 Driver parameters 97
1362 Parameter description 98
Parameter 1 98
Parameter 2 98
Parameter 3 98
Parameter 4 98
Parameter 5 98
1363 Service parameters 99
1364 Parameter description100
Parameter 10100
Parameter 14100
Parameter 15 – Non-configurable option100
Parameter 16 – Configurable option #1101
Parameter 17 – Configurable option #2101
Parameter 18 – Configurable option #3101
Parameter 19 – Configurable option #4101
Option parameters101
General101
Parameter #15 Non-configurable options101
Changing non-configurable options102
Parameter #16 to 19 configurable optional functions103
Changing configurable optional functions104
Parameter 20108
Parameter 21108
Recommendation on parameter setting for freely ventilated batteries109
Instructions for verifying parameter setting110
Recommendation on parameter setting for valve- controlled batteries (VRLA)111
Instructions for verifying parameter setting112
Parameter 22112
Parameter 25112
Parameter 28112
Parameter 39113
Login method and driver parameter access113
Expanded keypad – General113
Expanded keypad – Programming113
Service indication115
137 Part numbers118
138 Transistor panel118
1381 General118
139 Diagnostic and troubleshooting119
1391 Error codes and troubleshooting119
1392 Resetting errors120
1393 Safety120
1310 Technical specifications – Curtis 1243121
14- Hydraulic, pneumatic – 6000123
141 General123
1411 Hydraulic diagram123
1412 Symbol list124
142 Adjustments125
1421 Adjustment of the pressure limit valve125
143 Cleaning the filter126
15- PowerTrak cylinder – 6680127
151 Component parts127
152 Dismantling the PowerTrak cylinder128
1521 Replacing the gaskets in the PowerTrak cylinder129
153 Dismantling/assembling the ground pressure springs130
1531 Component parts130
1532 Dismantling131
1533 Assembling131
1534 Setting and sealing131
1535 Sealing132
16- TruckCom133
161 General133
162 Connection133
163 Layout134
1631 Main program screen134
1632 Nodes134
1633 Icons135
1634 Tool buttons and menu bar135
1635 Information window136
1636 Status bar136
164 Connection function136
165 Disconnection function136
166 Downloading program function137
1661 Normal downloading (truck with key)137
1662 Normal downloading (truck with keypad)137
1663 Emergency downloading (truck with keypad)138
1664 Emergency downloading (truck with keypad)138
1665 Downloading in old versions of logic card138
167 Truck report function139
168 Parameters function140
169 Diagnostics function140
1691 Representation of signal colours141
1692 “Tiller arm” tab141
1693 “Drive Controller” tab (transistor regulator driving)142
1694 “Pump controller” tab (transistor regulator pump)143
1695 “EPS” (steering servo tab)144
1696 SEU tab (Spider Extension Unit)145
1610 Other menu functions145
16101 Save to file145
16102 Download from file145
16103 Reset CAN adapter146
16104 Delete error code log146
16105 Reset hour meter146
16106 Read error code log146
16107 Adjust date and time146
16108 Adjusting the hour meter on older cards146
16109 Help146
About the TruckCom application146
161010 Exit146
1611 Specifications147
1612 Installation147
16121 Installation on a PC with Windows 95/ 98147
16122 Installation on a PC with Windows XP/ 2000148
Changes in Windows Control Panel150
16123 Installation on a PC with Windows NT153
16124 In case of communication problems with CAN153
16125 To uninstall153

S.V 26/02/2025