Toyota Forklift 7SM08F Master Service Manual 904519 – PDF DOWNLOAD
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Toyota Forklift 7SM08F Master Service Manual 904519 – PDF DOWNLOAD
Language : English
Pages : 174
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota Forklift 7SM08F Master Service Manual 904519 – PDF DOWNLOAD
Maintenance:
All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter. The operator may adapt them to local conditions, but it is important that the intervals comply with TOYOTA’s minimum requirements.
The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations. The following running times have been used when calculating the intervals:
Day time:08.00-17.00 (20 hr./week)
2-shifts:06.00-14.00, 14.00-22.00 (40 hr./week)
3-shifts:06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)
Ensure the truck is given a regular maintenance service after every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work are carried out.
3.1 Safety regulations with maintenance work:
Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.
•Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so
•Keep the area where you carry out the service clean. Oil or water makes the floor slippery
•Never wear loose objects or jewellery when working on the truck
TABLE OF CONTENTS:
Toyota Forklift 7SM08F Master Service Manual 904519 – PDF DOWNLOAD
1- Contents.................................................................... 3 2- Technical data.............................................................. 7 2.1 General tightening torques............................................. 10 3- Maintenance................................................................. 11 3.1 Safety regulations with maintenance work............................... 11 3.2 Cleaning and washing................................................... 12 3.2.1 External cleaning................................................ 13 3.2.2 Cleaning the motor compartment................................... 13 3.2.3 Electrical components............................................ 13 3.3 Safe lifting........................................................... 14 3.4 Maintenance Schedule................................................... 15 Approximate time required.............................................. 18 3.5 Lubrication chart...................................................... 20 4- Oil and grease specification................................................ 21 5- Tools....................................................................... 23 5.1 Super Seal connectors.................................................. 23 5.2 AMP connectors......................................................... 24 5.2.1 AMP Connectors, 040 series....................................... 25 5.3 Molex connectors....................................................... 25 5.4 Grease guns............................................................ 26 5.5 Other tools............................................................ 27 6- Chassis - 0000.............................................................. 29 6.1 Support arms........................................................... 29 6.1.1 Main Components.................................................. 29 6.1.2 Maintenance...................................................... 30 7- Electric drive motor - 1000................................................. 33 7.1 Component parts........................................................ 33 7.2 Service/Repairs........................................................ 35 7.2.1 Dismantling of motor from truck.................................. 35 7.2.2 Assembling....................................................... 35 7.2.3 Dismantling of motor............................................. 36 7.2.4 Assembling of motor.............................................. 37 7.2.5 Cleaning......................................................... 37 8- Drive unit/gear - 2000...................................................... 39 8.1 Component parts........................................................ 39 8.2 Leakage from top cover................................................. 41 8.2.1 Dismantling...................................................... 41 8.2.2 Assembling is carried out in the reverse order................... 41 8.3 Changing of the drive shaft’s sealing ring............................. 42 8.3.1 Dismantling...................................................... 42 8.3.2 Assembling....................................................... 42 9- Brake system - 3000......................................................... 43 9.1 Main components........................................................ 43 9.2 Maintenance............................................................ 44 9.2.1 Exchange of brake disc........................................... 44 10- Steering - 4000............................................................ 45 10.1 Component parts, tiller arm........................................... 45 10.2 Tiller arm handle..................................................... 47 10.2.1 Dismantling/Assembling.......................................... 49 Changing of signal button/switch (9, 10)........................... 49 Changing of lift/lowering button (13).............................. 50 Changing of pushbutton (16)........................................ 50 11- Electrical systems - 5000.................................................. 51 11.1 General............................................................... 51 11.2 Software/hardware part numbers........................................ 52 11.3 Nomenclature.......................................................... 52 11.4 Electrical equipment overview......................................... 53 11.5 Electrical component list............................................. 55 11.6 Electrical circuit overview........................................... 58 11.7 Symbol list........................................................... 59 11.8 Electrical wiring diagram............................................. 60 11.9 Functional description................................................ 65 11.9.1 Theory of operation............................................. 65 11.9.2 Transistor regulator............................................ 71 11.9.3 Spider expansion unit (SEU) (option)............................ 71 11.9.4 Speed limitation................................................ 74 11.9.5 Hour meter and battery condition................................ 75 11.10 Diagnostic and troubleshooting....................................... 77 11.10.1 General........................................................ 77 11.10.2 Error code history............................................. 77 11.10.3 List of error codes............................................ 78 11.10.4 Transistor regulator errors.................................... 81 Resetting errors................................................... 82 Safety............................................................. 82 11.10.5 Built-in Test Function......................................... 83 Digital inputs/outputs test mode................................... 84 Inputs check....................................................... 84 Outputs check...................................................... 85 Option buttons check............................................... 86 Display test mode.................................................. 86 11.11 Parameters........................................................... 87 11.11.1 General........................................................ 87 11.11.2 Viewing parameters - without the CAN service key............... 87 11.11.3 Adjusting operator parameters - without the CAN service key.... 88 11.11.4 Viewing & changing parameters - CAN service key connected...... 89 Changing a parameter............................................... 90 11.11.5 Summary of driver parameters................................... 91 11.11.6 Description of driver parameters............................... 92 #1 - Maximum speed in Turtle mode.................................. 92 #2 - Maximum speed................................................. 92 #3 - Maximum acceleration.......................................... 92 #4 - Neutral braking force......................................... 92 #5 - Automatic log-off............................................. 92 11.11.7 Summary of service parameters.................................. 93 11.11.8 Description of service parameters.............................. 94 # 10 - PIN code.................................................... 94 To enter a new PIN-code:........................................... 94 To remove an existing PIN-code:.................................... 94 # 14 - Creep speed................................................. 95 #15 - Non-configurable options..................................... 95 Setting Non-configurable options................................... 95 #16 - Configurable option #1....................................... 96 #17 - Configurable option #2....................................... 96 #18 - Configurable option #3....................................... 96 #19 - Configurable option #4....................................... 96 # 20 - Hour meter selection........................................ 97 # 21 - Battery size................................................ 97 Instructions for verifying parameter setting....................... 97 #22 - [S10] Type................................................... 98 #25 - Service interval............................................. 98 #28 - Forks lift button selection.................................. 98 #39 - Log-in method & operator parameter access.................... 98 Extended keypad - General.......................................... 99 Extended keypad - Programming...................................... 99 11.11.9 Configurable “Option” Parameters...............................102 General............................................................102 Summary of base options............................................102 Convention for configurable options................................103 Detailed option parameter tables...................................105 11.12 Technical specifications - Curtis 1243...............................116 12- Hydraulic system - 6000....................................................117 12.1 General...............................................................117 12.2 Hydraulics diagram and components.....................................118 12.3 Description...........................................................120 Lift...................................................................120 Lowering...............................................................120 Operating pressure.....................................................120 Pressure limit valve...................................................120 12.4 Adjustments...........................................................121 Adjustment of the pressure limit valve.................................121 13- Lift mast - 7000...........................................................123 13.1 Main mast.............................................................123 13.1.1 Components......................................................123 13.1.2 Maintenance.....................................................124 Mounting...........................................................124 Lubrication........................................................124 13.1.3 Cylinder........................................................125 Disassembly........................................................125 Assembly...........................................................125 13.2 Fork carriage.........................................................126 13.2.1 Maintenance.....................................................126 13.3 Main lift chain system................................................127 13.3.1 Checking the chain setting......................................127 13.3.2 Chain inspection................................................127 Noise..............................................................127 Surface rust.......................................................127 Rusty links........................................................127 Stiff links........................................................127 Bolt rotation......................................................128 Loose bolts........................................................128 Outline wear.......................................................128 Stretching.........................................................129 Damage.............................................................130 Damaged discs......................................................130 Damaged bolts......................................................130 Dirty chain........................................................130 13.3.3 Cleaning........................................................130 13.3.4 Lubrication.....................................................131 14- Peripherals - 8000.........................................................133 14.1 Battery charger (Inbuilt).............................................133 14.1.1 General.........................................................133 14.1.2 Charging........................................................133 14.1.3 Troubleshooting and service.....................................134 14.1.4 Technical data..................................................134 14.1.5 Charging settings...............................................135 Freely ventilated batteries........................................135 Valve regulated batteries..........................................135 15- TruckCom...................................................................137 15.1 General...............................................................137 15.2 Connection............................................................137 15.3 Layout................................................................138 15.3.1 Main program screen.............................................138 15.3.2 Nodes...........................................................138 15.3.3 Icons...........................................................139 15.3.4 Tool buttons and menu bar.......................................139 15.3.5 Information window..............................................140 15.3.6 Status bar......................................................140 15.4 Connection function...................................................140 15.5 Disconnection function................................................140 15.6 Downloading program function..........................................141 15.6.1 Normal downloading (truck with key).............................141 15.6.2 Normal downloading (truck with keypad)..........................141 15.6.3 Emergency downloading (truck with keypad).......................142 15.6.4 Emergency downloading (truck with keypad).......................142 15.6.5 Downloading in old versions of logic card.......................142 15.7 Truck report function.................................................143 15.8 Parameters function...................................................144 15.9 Diagnostics function..................................................144 15.9.1 Representation of signal colours................................145 15.9.2 “Tiller arm” tab................................................145 15.9.3 “Drive Controller” tab (transistor regulator driving)...........146 15.9.4 “Pump controller” tab (transistor regulator pump)...............147 15.9.5 “EPS” (steering servo tab)......................................148 15.9.6 SEU tab (Extra I/O module)......................................149 15.10 Other menu functions.................................................149 15.10.1 Save to file...................................................149 15.10.2 Download from file.............................................149 15.10.3 Reset CAN adapter..............................................150 15.10.4 Delete error code log..........................................150 15.10.5 Reset hour meter...............................................150 15.10.6 Read error code log............................................150 15.10.7 Adjust date and time...........................................150 15.10.8 Adjusting the hour meter on older cards........................150 15.10.9 Help...........................................................150 About the TruckCom application.....................................150 15.10.10 Exit..........................................................150 15.11 Specifications.......................................................151 15.12 Installation.........................................................151 15.12.1 Installation on a PC with Windows 95/ 98.......................151 15.12.2 Installation on a PC with Windows XP/ 2000.....................152 Changes in Windows Control Panel...................................154 15.12.3 Installation on a PC with Windows NT...........................157 15.12.4 In case of communication problems with CAN.....................157 15.12.5 To uninstall...................................................157 16- Destruction instructions...................................................159 16.1 General...............................................................159 16.2 Procedure.............................................................159 16.3 Abbreviations.........................................................160 16.4 Sorting...............................................................160 16.5 Chassis (0300)........................................................161 Disassembly............................................................161 Material handling......................................................161 16.6 Hoods, hatches (0340).................................................162 Disassembly............................................................162 Material handling......................................................162 16.7 Electric Pump Motor (1710)............................................163 Disassembly............................................................163 Material handling......................................................163 16.8 Electric Drive Motor (1760)...........................................163 Disassembly............................................................163 Material handling......................................................163 16.9 Drive assembly/gear (2550)............................................164 Disassembly............................................................164 Material handling......................................................164 16.10 Wheels (3500)........................................................165 Disassembly............................................................165 Material handling......................................................165 16.11 Steering handle (4110)...............................................166 Disassembly............................................................166 Material handling......................................................166 16.12 Tiller arm (4110)....................................................167 Disassembly............................................................167 Material handling......................................................167 16.13 General electrical equipment (5100)..................................168 Disassembly............................................................168 Material handling......................................................168 16.14 Sensor (5800)........................................................169 Disassembly............................................................169 Material handling......................................................169 16.15 Hydraulic unit (6100)................................................170 Disassembly............................................................170 Material handling......................................................170 16.16 Hydraulic cables/lift cylinder (6230/6610)...........................171 Disassembly............................................................171 Material handling......................................................171 16.17 Main mast and fork carriage (7100)...................................171 Disassembly............................................................171 Material handling......................................................171
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