Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD
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Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD
Language : English
Pages : 150
Downloadable : Yes
File Type : PDF
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Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD
Introduction Maintenance – P1:
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
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TABLE OF CONTENTS:
Toyota Forklift Truck 7PM18 7PM20 7PML20 Service Manual SN 723984 – PDF DOWNLOAD
1- Table of contents...................................................................... 3 2- Technical data - M4.................................................................... 11 3- Introduction Maintenance - P1.......................................................... 15 3.1 Safety regulations with maintenance work.......................................... 15 3.2 Cleaning and washing.............................................................. 16 3.2.1 External cleaning........................................................... 17 3.2.2 Cleaning the motor compartment.............................................. 17 3.2.3 Electrical components....................................................... 17 3.3 Safe lifting...................................................................... 18 4- Preventive maintenance - P2............................................................ 19 4.1 Maintenance schedule.............................................................. 19 4.2 Lubrication schedule.............................................................. 24 5- Oil and grease specifica tion - P3..................................................... 25 6- Tools - P4............................................................................. 27 6.1 Super Seal connectors............................................................. 27 6.2 AMP connectors.................................................................... 28 6.2.1 AMP Connectors, 040 series.................................................. 29 6.3 Molex connectors.................................................................. 29 6.4 Other tools....................................................................... 30 7- Engine suspension- 0450................................................................ 31 7.1 Component parts................................................................... 31 7.1.1 Component List.............................................................. 32 8- Electric drive motor - 1760............................................................ 33 8.1 Component parts................................................................... 33 8.1.1 Dismantling/assembling of motor from truck.................................. 34 8.1.2 Assembling.................................................................. 35 8.2 Service/Repairs................................................................... 35 8.2.1 Dismantling of motor........................................................ 35 8.2.2 Assembling of motor......................................................... 36 8.2.3 Cleaning.................................................................... 37 8.3 Technical data.................................................................... 38 9- Mechanical drive gear unit - 2550...................................................... 39 9.1 Component parts................................................................... 40 9.1.1 Technical data.............................................................. 41 9.2 Leakage from top cover............................................................ 42 Dismantling....................................................................... 42 Assembling........................................................................ 42 9.3 Changing of the drive shaft’s sealing ring........................................ 42 Dismantling....................................................................... 42 Assembling........................................................................ 43 10- Electro magnetic brake - 3370......................................................... 45 10.1 Main components.................................................................. 45 10.2 Maintenance...................................................................... 46 10.2.1 Exchange of brake disc..................................................... 46 11- Electro magnetic brake - 3370......................................................... 47 11.1 Main components.................................................................. 47 11.2 Maintenance...................................................................... 48 11.2.1 Basic Adjustment of gap.................................................... 48 Adjustment:................................................................... 48 11.2.2 Exchange of brake disc..................................................... 49 12- Steering system - 4000................................................................ 51 12.1 Component parts, tiller arm...................................................... 51 12.2 Adjustments...................................................................... 52 12.2.1 Adjusting of brake microswitch............................................. 52 12.3 Tiller arm handle................................................................ 53 12.3.1 Dismantling/Assembling..................................................... 54 Change from ignition key to keyboard (2)...................................... 55 Change from keyboard to ignition key (2)...................................... 55 Changing of signal button/switch (9, 10)...................................... 56 Changing of lift/lowering button (13)......................................... 56 Changing of pushbutton (16)................................................... 57 13- Electrical System - 5000.............................................................. 59 13.1 Electrical components............................................................ 59 13.2 Symbol List and Wiring Diagram................................................... 61 13.2.1 Wiring diagram 1(5)........................................................ 63 13.2.2 Wiring diagram 2(5)........................................................ 64 13.2.3 Wiring diagram 3(5)........................................................ 65 13.2.4 Wiring diagram 4(5)........................................................ 66 13.2.5 Wiring diagram 5(5)........................................................ 67 13.2.6 Wiring diagram 1(5)........................................................ 68 13.2.7 Wiring diagram 2(5)........................................................ 69 13.2.8 Wiring diagram 3(5)........................................................ 70 13.2.9 Wiring diagram 4(5)........................................................ 71 13.2.10 Wiring diagram 5(5)....................................................... 72 13.3 Operating description............................................................ 73 13.3.1 Starting truck............................................................. 73 13.3.2 Driving speed £ 6 km/h..................................................... 73 13.3.3 Braking in neutral mode.................................................... 73 13.3.4 Braking in neutral mode on a slope......................................... 73 13.3.5 Braking.................................................................... 74 13.3.6 Lifting the forks.......................................................... 74 13.3.7 Lowering the forks......................................................... 74 13.3.8 Horn....................................................................... 74 13.4 Hour meter....................................................................... 74 13.5 Error codes...................................................................... 75 13.6 Parameters....................................................................... 89 13.6.1 Operator parameters........................................................ 89 13.6.2 Parameter description...................................................... 90 Parameter 1................................................................... 90 Parameter 2................................................................... 90 Parameter 3................................................................... 90 Parameter 4................................................................... 90 Parameter 5................................................................... 90 13.6.3 Service parameters......................................................... 91 13.6.4 Parameter description...................................................... 92 Parameter 10.................................................................. 92 Parameter 14.................................................................. 93 Parameter 15 - Non-configurable option........................................ 93 Parameter 16 - Configurable option #1......................................... 93 Parameter 17 - Configurable option #2......................................... 93 Parameter 18 - Configurable option #3......................................... 93 Parameter 19 - Configurable option #4......................................... 93 Option parameters............................................................. 93 General....................................................................... 93 Parameter #15 Non-configurable options........................................ 93 Changing non-configurable options............................................. 94 Parameter #16 to 19 configurable optional functions........................... 95 Changing configurable optional functions...................................... 95 Parameter 20..................................................................100 Parameter 21..................................................................100 Recommendation on parameter setting for freely ventilated batteries...........101 Instructions for verifying parameter setting..................................102 Recommendation on parameter setting for valve- controlled batteries (VRLA)....103 Instructions for verifying parameter setting..................................104 Parameter 22..................................................................104 Parameter 25..................................................................104 Parameter 28..................................................................104 Parameter 39..................................................................105 Login method and driver parameter access......................................105 Expanded keypad - General.....................................................105 Expanded keypad - Programming.................................................105 Service indication............................................................107 13.7 Part number......................................................................110 13.8 Transistor panel.................................................................110 13.8.1 General....................................................................110 13.9 Troubleshooting..................................................................111 13.9.1 Error codes and troubleshooting............................................111 13.9.2 Reset error................................................................112 13.9.3 Safety.....................................................................112 13.10 Technical specifications - Curtis 1243..........................................113 14- Hydraulic/Pneumatik - 6000............................................................115 14.1 General..........................................................................115 14.2 Hydraulic chart and list of symbols..............................................115 14.2.1 List of Symbols............................................................115 14.3 Adjustments 7PM18................................................................116 14.3.1 Adjusting the pressure limit valve.........................................116 14.3.2 Tools......................................................................117 14.4 Adjustments 7PM20................................................................118 14.4.1 Adjusting the pressure limit valve.........................................118 14.5 Hydraulic chart and list of symbols..............................................119 14.5.1 List of Symbols............................................................119 14.6 Adjusting the pressure limit valve...............................................120 15- PowerTrak cylinder - 6680.............................................................121 15.1 Component parts..................................................................121 15.2 Dismantling of PowerTrak cylinder................................................122 16- Battery charger (Inbuilt) - 8340......................................................123 16.1 General..........................................................................123 16.2 Charging.........................................................................123 16.3 Troubleshooting and service......................................................124 16.4 Technical data...................................................................124 16.5 Charging settings................................................................125 16.5.1 Freely ventilated batteries................................................125 16.5.2 Valve regulated batteries..................................................125 17- Control/computer equipment - 8700.....................................................127 17.1 General..........................................................................127 17.2 Connection.......................................................................127 17.3 Layout...........................................................................128 17.3.1 Main program screen........................................................128 17.3.2 Nodes......................................................................128 17.3.3 Icons......................................................................129 17.3.4 Tool buttons and menu bar..................................................129 17.3.5 Information window.........................................................130 17.3.6 Status bar.................................................................130 17.4 Connection function..............................................................130 17.5 Disconnection function...........................................................130 17.6 Downloading program function.....................................................131 17.6.1 Normal downloading (truck with key)........................................131 17.6.2 Normal downloading (truck with keypad).....................................131 17.6.3 Emergency downloading (truck with keypad)..................................132 17.6.4 Downloading in old versions of logic card..................................132 17.6.5 Emergency downloading (truck with keypad)..................................132 17.7 Truck report function............................................................133 17.8 Parameters function..............................................................134 17.9 Diagnostics function.............................................................134 17.9.1 Representation of signal colours...........................................135 17.9.2 “Tiller arm” tab...........................................................135 17.9.3 “Drive Controller” tab (transistor regulator - travel).....................136 17.9.4 “Pump controller” tab (transistor regulator - pump)........................137 17.9.5 “EPS” steering servo tab...................................................138 17.10 Other menu functions............................................................139 17.10.1 Save to file..............................................................139 17.10.2 Download from file........................................................139 17.10.3 Reset CAN adapter.........................................................139 17.10.4 Delete error code log.....................................................139 17.10.5 Reset hour meter..........................................................139 17.10.6 Read error code log.......................................................139 17.10.7 Adjust date and time......................................................140 17.10.8 Adjusting the hour meter on older cards...................................140 17.10.9 Help......................................................................140 About the TruckCom application................................................140 17.10.10 Exit.....................................................................140 17.11 Specifications..................................................................140 17.12 Installation....................................................................141 17.12.1 Installation on a PC with Windows® 95/98..................................141 17.12.2 Installation on a PC with Windows XP/ 2000................................142 17.12.3 Installation on a PC with Windows NT......................................147 17.12.4 In case of communication problems with CAN................................147 17.12.5 To uninstall..............................................................147
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