Toyota 7HBW23 Powered Pallet Walkie OEM Service & Repair Manual

00700-CL340-05, Issued: 2 May 2005 4,500 lb. Powered Pallet Walkie Model 7HBW23 Serial No. 24,501 and up SERVICE MANUAL

1042390A ©2005 by Toyota Industrial Equipment. All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electroinc retrieval or transfer, or recording without the written permission of the publisher. Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual.

Toyota Model 7HBW23 Service Manual Table of Contents 00700-CL340-05, Issued: 2 May 2005 iii Table of Contents How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Static Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Control Handle Display and Programming . . . . . . . . . . . . . . . . . . . . . 5-9 Service Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Programmable Maintenance Tool (PMT) . . . . . . . . . . . . . . . . . . . . . . 5-26 List of Troubleshooting Charts/Tables . . . . . . . . . . . . . . . . . . . . . . . 5-29 Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . 5-39 Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Component Locator Photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Tractor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Horn (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Power Amplifier (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Master Control Relay (K4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Switches (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Table of Contents Toyota Model 7HBW23 Service Manual iv 00700-CL340-05, Issued: 2 May 2005 Electromagnetic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Pallet Forks and Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

How To Use

Toyota Model 7HBW23 Service Manual Section 1. How To Use This Manual 00700-CL340-05, Issued: 2 May 2005 1-1 Section 1. How To Use This Manual

Section 1. How To Use This Manual Toyota Model 7HBW23 Service Manual Map of the Manual 1-2 00700-CL340-05, Issued: 2 May 2005 Map of the Manual map.wmf How to Use This Manual Safety Systems Overview Scheduled Maintenance Trouble Shooting Component Procedures Appendix Index Map of the Manual Manual Design Start Page Vehicle Specifications Theory of Operations General System Data Component Location Photos Alphabetical List of Component Procedures Programmable Maintenance Tool Fault Codes Definitions Electrical & Hydraulic T.S. Guidelines Troubleshooting Charts and Symptom Tables

Toyota Model 7HBW23 Service Manual Section 1. How To Use This Manual Manual Design 00700-CL340-05, Issued: 2 May 2005 1-3 Manual Design The Toyota Model 7HBW23 Service Manual is designed with the following objectives in mind: • Provide technical coverage for expected levels of user expertise • Anticipate your needs and reduce your decisions regarding maintenance • Reduce page flipping through a “one-stop shopping” approach The two-line running page header at the top of each page tells you the following: • Name of the manual (Toyota Model 7HBW23 Service Manual) • Current chapter title (example: this page How to Use This Manual) • Current topic (example: this page Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual. The START page asks a few simple questions to guide you to the correct chapter. • How to Use This Manual explains the manual format and design and contains the START page. • Safety explains warning and caution notes, general safety rules and safety rules for batteries, static, jacking, and welding. • Systems Overview includes truck specifications and theory of operation information. • Planned Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently. • Troubleshooting is a set of “decision-tree” charts and symptom tables designed to take you from a symptom to a specific sequence of tests in order to isolate a bad component. • “TS1: START TROUBLESHOOTING” on page 5-31 will guide you to the individual troubleshooting symptom chart you need. • When you are familiar with the symptoms listed, you may instead find the symptom chart from the “List of Troubleshooting Charts/Tables” on page 5-29. • When you complete a troubleshooting procedure, make sure to follow the steps in the “END1: End of Troubleshooting Procedure” on page 5-33. • Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual truck components. Components are listed in an order that considers: • Frequency of attention • Physical attachment (example: brake must be removed before drive motor) • Functional relation (for example: drive motor and drive unit components are grouped together) To find a component procedure, you may use one of three methods: • Look up the component name. See “Component Procedures” on page 6-1. • Find the component. See “Component Locator Photo” on page 6-3. • Look up the component name in the Index. See “Index” on page I-1. • Appendix contains reference information such as torque values, lubricants, and schematics. • Index lists subjects alphabetically.

Section 1. How To Use This Manual Toyota Model 7HBW23 Service Manual Manual Design 1-4 00700-CL340-05, Issued: 2 May 2005

Toyota Model 7HBW23 Service Manual Section 1. How To Use This Manual START Page 00700-CL340-05, Issued: 2 May 2005 1-5 Section 1. How To Use This Manual START Page startpg1.wmf START: Why are you here? To review safety precautions? Go to Chart START-2 Yes To do scheduled maintenance? To examine specifications or theory of operations? To troubleshoot a problem? No No No No Go to Section 2 "Safety" Go to Section 3 "Systems Overview" Go to Section 4 "Scheduled Maintenance" Go to Section 5 "Troubleshooting" Yes Yes Yes List of Troubleshooting Charts START Troubleshooting

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Toyota 7HBW23 Powered Pallet Walkie OEM Service & Repair Manual

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