Toyota Industrial Equipment Model 7HBW23 - 4,500 lb. Powered Pallet Walkie Service Manual

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This service manual PDF download for the Model 7HBW23 Toyota Industrial Equipment 4,500 lb. Powered Pallet Walkie has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

4,500 lb. Powered Pallet Walkie
Model 7HBW23
Serial No. 24,501 and up


TABLE OF CONTENTS :

Section 1. How To Use This Manual
Section 2. Safety
Section 3. Systems Overview
Section 4. Planned Maintenance
Section 5. Troubleshooting
Section 6. Component Procedures
Index


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
P/N: 00700-CL340-05
Total Pages : 159


This Toyota Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Section 1. How To Use This Manual
Map of the Manual
Manual Design
START Page
Section 2. Safety
Definitions
General Safety
Battery Safety
Jacking Safety
Fork Section
Tractor Section
Towing
Welding Safety
Static Safety
Figure 2?1. Anti-Static Kit With Wrist Strap and Mat
Section 3. Systems Overview
Truck Model Identification
Figure 3-1. Model 7HBW23 Pallet Truck
Vehicle Specifications
General Information
Figure 3-2. Model 7HBW23 General Information
Special Tools
Programmable Maintenance Tool
Figure 3-3. Programmable Maintenance Tool
Service Key
Figure 3-4. Service Key
Theory of Operation
Truck Starting
Lift/Lower
Direction/Speed Control
Power Amplifier
Electronic Tiller Arm Card (ETAC)
Section 4. Planned Maintenance
Maintenance Guidelines
Maintenance Manual
Planned Maintenance Schedule
Time Requirements
General Truck Operation
Daily
Every Two Months or 250 Operating Hours
Annually or Every 1500 Operating Hours
Grease Fittings
Figure 4-1: Load Wheel Axle (Cold Storage and Corrosion Protection Options only)
Section 5. Troubleshooting
How to Use This Chapter
Electrical Troubleshooting Guidelines
Checking for Shorts from Battery to Truck Frame
Checking for Shorts from Components to Truck Frame
Hydraulic Troubleshooting Guidelines
Definitions
Acceleration
Arm Angle Switches
Figure 5-1. Arm Angle Switches and Brake Actuation
Continuity
Creep Speed
Current Limiting
Deceleration
Emergency Reverse
ETAC (Electronic Tiller Arm Card)
Fault Codes
Open Circuit
Overvoltage Cutoff
PIN-Key Code
Short Circuit or “Short”
Speed Limiting
Thermal Cutback (Power Amplifier)
Tractor
Truck Off Delay (Keypad only)
Undervoltage Cutoff
List of Electrical Symbols
Control Handle Display and Programming
Figure 5?4. Control Handle Display
Special Truck Mode
Hour Meter (H)
Error Codes (E)
Parameters (P)
Display Part Numbers (Pn)
Service Display
Power Amplifier Fault Codes
Programmable Maintenance Tool (PMT)
Figure 5-8. Programmable Maintenance Tool
Figure 5-9. Connecting PMT to Power Amplifier
Monitor Mode
Faults Mode
Information Mode
Programmer Mode
List of Troubleshooting Charts/Tables
Troubleshooting Charts
Hydraulic Symptom Tables
Travel Symptom Tables
Troubleshooting Flowcharts
Symptom Tables: Lift/Lower System
Symptom Tables: Travel (Forward/Reverse) System
Section 6. Component Procedures
Component Locator Photo
Figure 6-1. Tractor Interior
Battery
Swingout Battery Pack
Figure 6-2. Multiple Battery Wiring Hookup
Maintenance-Free Batteries
Battery Maintenance
Figure 6-3. Battery Filler Plugs and Vent Holes
Tractor Covers
Figure 6-4. Top Cover Removal (decals omitted)
Power Cables
Figure 6-5. Power Cables
Wiring Harness
Figure 6-6. Wiring Harness
Fuses
Figure 6-7. Fuse/Circuit Breaker Location
Circuit Breaker
Test/Inspection
Figure 6-8. Circuit Breaker Location
Control Handle
Control Handle Disassembly
Figure 6-9. Horn Button Removal
Figure 6-10. Lift/Lower Button Removal
Figure 6-11. Push Button Removal
Control Handle Stem
Figure 6-12. Removing Cover
Figure 6-13. Cover Removed
Figure 6-14. Allen Head Cap Screws
Horn (H1)
Figure 6-15. Horn Location
Power Amplifier (A1)
Figure 6-16. Power Amplifier Location
Contactors
Main Contactor (K10)
Figure 6-17. Main Contactor K10
Lift Motor Contactor (K30)
Figure 6-18. Lift Motor Contactor K30
Master Control Relay (K4)
Inspection/Test
Figure 6-19. Master Control Relay (K4)
Switches (General)
Test/Inspection
Master Control ON/OFF Switch
Figure 6-20. Master Control ON/OFF Switch Location
Arm Angle Switches
Figure 6-21. Arm Angle Switches
Figure 6-22. Arm Angle Switch Screws
Figure 6-23. Control Handle Cover Installed
Lift-Limit Switch
Figure 6-24. Lift-Limit Switch
Key Switch (Optional)
Drive Unit
Transmission Assembly
Figure 6-25. Control Handle Assembly Removal
Figure 6-26: Terminal Block
Figure 6-27. Transmission Assembly, Exploded View
Drive Housing Lubrication
Figure 6-28. Transmission Assembly Fill/Drain Plugs
Drive Wheel
Figure 6-29. Drive Wheel Nuts
Figure 6-30. Tire Replacement
Electromagnetic Brake
Brake Disc Location
Figure 6-31. Brake Location
Air Gap Adjustment
Figure 6-32. Brake Gap Adjustment
Friction Disc Replacement
Figure 6-33: Friction Disc Replacement
Mechanically Releasing the Brake
Motors, General
Drive Motor Brush Inspection
Figure 6-34. Drive Motor Brush, Typical Location
Drive Motor Brush Spring Tension
Figure 6-35. Motor Brush Spring Tension Inspection
Motor Commutator
Figure 6-36. Mica Inspection
Terminal Nuts
Figure 6-37. Motor Terminal Nuts
Electric Motor Tests
Figure 6-38. Motor Circuits
Drive Motor
Figure 6-39: Drive Motor Brush Shield
Pallet Forks and Load Wheels
Load Wheels
Figure 6-40. Removing Set Screw
Load Wheel Pull Rod
Figure 6-41. Wheel Fork Set Screw Location (top view)
Carrier Frame Linkage
Figure 6-42: Lower Links
Hydraulic Components
General Guidelines
Hydraulic Cylinder
Figure 6-43. Remove Retaining Clip
Figure 6-44. Hydraulic Cylinder (shown extended with retaining clip removed)
Figure 6-45. Hydraulic Cylinder Disassembly
Hydraulic Solenoid
Figure 6-46. Hydraulic Solenoid
Hydraulic Unit
Figure 6-47. Hydraulic Unit
Hydraulic Reservoir
Filter Screen and Inlet Tube
Figure 6-48. Cleaning Filter Screen
Hydraulic Pump
Lift Motor
Hydraulic Fluid
Figure 6-49. Hydraulic Connections
Adjusting Hydraulic Pump Pressure Relief Valve
Figure 6-50. Checking Relief Valve Pressure
Cold Storage Conditioning
Lubrication Equivalency Chart
Torque Chart - Standard
Torque Chart - Metric
Decimal Equivalent Chart
Standard/Metric Conversions
Figure A-1. Electrical Schematic - Sheet 1 of 2
Figure A-2. Electrical Schematic - Sheet 2 of 2
Figure A-3. Hydraulic Schematic
Index

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