Toyota Electric Powered Pallet Truck Model 7HBW23 Repair Service Manual

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Price: US$ 49.00

Complete service repair manual with Electrical Wiring Diagrams for Toyota Electric Powered Pallet Truck Model 7HBW23, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Toyota 4,500 lb. Powered Pallet Walkie Model 7HBW23 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

00700-CL340-05 (May 2005) - Toyota 4,500 lb. Powered Pallet Walkie Model 7HBW23 (SN 24,501 & up) Service Manual.pdf
00715-00120-05 - Toyota Electric Walkie Low-Lift Pallet Truck 7HBW23 Master Quality Parts Manual.pdf
Toyota Electric Walkie Low-Lift Pallet Truck 7HBW23 Programming QuickGuide.pdf
wiring_diagram.pdf

PRODUCT DETAILS:
Total Pages: 284 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS

MAIN SECTIONS
00700-CL340-05 (May 2005) - Toyota 4,500 lb. Powered Pallet Walkie Model 7HBW23 (SN 24,501 & up) Service Manual.....1
  R/M: 7HBW23 SN: 24,501 and up.....1
    Table of Contents.....3
    Section 1. How To Use This Manual.....6
      Map of the Manual.....7
      Manual Design.....8
      START Page.....10
    Section 2. Safety.....13
      Definitions.....14
      General Safety.....15
      Battery Safety.....18
      Jacking Safety.....21
        Fork Section.....21
        Tractor Section.....21
      Towing.....22
      Welding Safety.....23
      Static Safety.....24
        Figure 21. Anti-Static Kit With Wrist Strap and Mat.....24
    Section 3. Systems Overview.....26
      Truck Model Identification.....27
        Figure 3-1. Model 7HBW23 Pallet Truck.....27
      Vehicle Specifications.....27
      General Information.....28
        Figure 3-2. Model 7HBW23 General Information.....28
      Special Tools.....29
        Programmable Maintenance Tool.....29
          Figure 3-3. Programmable Maintenance Tool.....29
        Service Key.....29
          Figure 3-4. Service Key.....29
      Theory of Operation.....30
        Truck Starting.....30
        Lift/Lower.....30
        Direction/Speed Control.....30
        Power Amplifier.....32
        Electronic Tiller Arm Card (ETAC).....32
    Section 4. Planned Maintenance.....35
      Maintenance Guidelines.....36
        Maintenance Manual.....36
        Planned Maintenance Schedule.....36
        Time Requirements.....36
        General Truck Operation.....36
        Daily.....37
        Every Two Months or 250 Operating Hours.....38
        Annually or Every 1500 Operating Hours.....39
        Grease Fittings.....39
          Figure 4-1: Load Wheel Axle (Cold Storage and Corrosion Protection Options only).....39
    Section 5. Troubleshooting.....42
      How to Use This Chapter.....43
      Electrical Troubleshooting Guidelines.....44
        Checking for Shorts from Battery to Truck Frame.....44
        Checking for Shorts from Components to Truck Frame.....44
      Hydraulic Troubleshooting Guidelines.....46
      Definitions.....47
        Acceleration.....47
        Arm Angle Switches.....47
          Figure 5-1. Arm Angle Switches and Brake Actuation.....47
        Continuity.....47
        Creep Speed.....47
        Current Limiting.....47
        Deceleration.....47
        Emergency Reverse.....47
        ETAC (Electronic Tiller Arm Card).....47
        Fault Codes.....48
        Open Circuit.....48
        Overvoltage Cutoff.....48
        PIN-Key Code.....48
        Short Circuit or “Short”.....48
        Speed Limiting.....48
        Thermal Cutback (Power Amplifier).....48
        Tractor.....48
        Truck Off Delay (Keypad only).....48
        Undervoltage Cutoff.....48
      List of Electrical Symbols.....49
      Control Handle Display and Programming.....50
        Figure 54. Control Handle Display.....50
        Special Truck Mode.....50
        Hour Meter (H).....50
        Error Codes (E).....50
        Parameters (P).....58
        Display Part Numbers (Pn).....61
      Service Display.....62
      Power Amplifier Fault Codes.....65
      Programmable Maintenance Tool (PMT).....67
        Figure 5-8. Programmable Maintenance Tool.....67
        Figure 5-9. Connecting PMT to Power Amplifier.....67
        Monitor Mode.....67
        Faults Mode.....68
        Information Mode.....68
        Programmer Mode.....68
      List of Troubleshooting Charts/Tables.....70
        Troubleshooting Charts.....70
        Hydraulic Symptom Tables.....70
        Travel Symptom Tables.....70
      Troubleshooting Flowcharts.....72
      Symptom Tables: Lift/Lower System.....76
      Symptom Tables: Travel (Forward/Reverse) System.....80
    Section 6. Component Procedures.....85
      Component Locator Photo.....87
        Figure 6-1. Tractor Interior.....87
      Battery.....88
        Swingout Battery Pack.....88
          Figure 6-2. Multiple Battery Wiring Hookup.....88
        Maintenance-Free Batteries.....89
        Battery Maintenance.....89
          Figure 6-3. Battery Filler Plugs and Vent Holes.....89
      Tractor Covers.....93
        Figure 6-4. Top Cover Removal (decals omitted).....93
      Power Cables.....94
        Figure 6-5. Power Cables.....94
      Wiring Harness.....95
        Figure 6-6. Wiring Harness.....95
      Fuses.....96
        Figure 6-7. Fuse/Circuit Breaker Location.....96
      Circuit Breaker.....97
        Test/Inspection.....97
          Figure 6-8. Circuit Breaker Location.....97
      Control Handle.....98
        Control Handle Disassembly.....99
          Figure 6-9. Horn Button Removal.....99
          Figure 6-10. Lift/Lower Button Removal.....100
          Figure 6-11. Push Button Removal.....100
        Control Handle Stem.....100
          Figure 6-12. Removing Cover.....100
          Figure 6-13. Cover Removed.....100
          Figure 6-14. Allen Head Cap Screws.....101
      Horn (H1).....102
        Figure 6-15. Horn Location.....102
      Power Amplifier (A1).....103
        Figure 6-16. Power Amplifier Location.....103
      Contactors.....104
        Main Contactor (K10).....104
          Figure 6-17. Main Contactor K10.....104
        Lift Motor Contactor (K30).....104
          Figure 6-18. Lift Motor Contactor K30.....104
      Master Control Relay (K4).....105
        Inspection/Test.....105
          Figure 6-19. Master Control Relay (K4).....105
      Switches (General).....107
        Test/Inspection.....107
        Master Control ON/OFF Switch.....107
          Figure 6-20. Master Control ON/OFF Switch Location.....107
        Arm Angle Switches.....108
          Figure 6-21. Arm Angle Switches.....108
          Figure 6-22. Arm Angle Switch Screws.....108
          Figure 6-23. Control Handle Cover Installed.....108
        Lift-Limit Switch.....109
          Figure 6-24. Lift-Limit Switch.....109
        Key Switch (Optional).....110
      Drive Unit.....111
        Transmission Assembly.....111
          Figure 6-25. Control Handle Assembly Removal.....111
          Figure 6-26: Terminal Block.....111
          Figure 6-27. Transmission Assembly, Exploded View.....113
        Drive Housing Lubrication.....114
          Figure 6-28. Transmission Assembly Fill/Drain Plugs.....114
        Drive Wheel.....115
          Figure 6-29. Drive Wheel Nuts.....115
          Figure 6-30. Tire Replacement.....115
      Electromagnetic Brake.....117
        Brake Disc Location.....117
          Figure 6-31. Brake Location.....117
        Air Gap Adjustment.....117
          Figure 6-32. Brake Gap Adjustment.....117
        Friction Disc Replacement.....118
          Figure 6-33: Friction Disc Replacement.....118
        Mechanically Releasing the Brake.....118
      Motors, General.....119
        Drive Motor Brush Inspection.....119
          Figure 6-34. Drive Motor Brush, Typical Location.....119
        Drive Motor Brush Spring Tension.....120
          Figure 6-35. Motor Brush Spring Tension Inspection.....120
        Motor Commutator.....120
          Figure 6-36. Mica Inspection.....120
        Terminal Nuts.....123
          Figure 6-37. Motor Terminal Nuts.....123
        Electric Motor Tests.....123
          Figure 6-38. Motor Circuits.....123
      Drive Motor.....126
        Figure 6-39: Drive Motor Brush Shield.....126
      Pallet Forks and Load Wheels.....129
        Load Wheels.....129
          Figure 6-40. Removing Set Screw.....129
        Load Wheel Pull Rod.....129
          Figure 6-41. Wheel Fork Set Screw Location (top view).....129
        Carrier Frame Linkage.....130
          Figure 6-42: Lower Links.....130
      Hydraulic Components.....131
        General Guidelines.....131
        Hydraulic Cylinder.....131
          Figure 6-43. Remove Retaining Clip.....131
          Figure 6-44. Hydraulic Cylinder (shown extended with retaining clip removed).....131
          Figure 6-45. Hydraulic Cylinder Disassembly.....132
        Hydraulic Solenoid.....133
          Figure 6-46. Hydraulic Solenoid.....133
        Hydraulic Unit.....133
          Figure 6-47. Hydraulic Unit.....134
        Hydraulic Reservoir.....134
        Filter Screen and Inlet Tube.....134
          Figure 6-48. Cleaning Filter Screen.....135
        Hydraulic Pump.....135
        Lift Motor.....135
        Hydraulic Fluid.....136
          Figure 6-49. Hydraulic Connections.....136
        Adjusting Hydraulic Pump Pressure Relief Valve.....137
          Figure 6-50. Checking Relief Valve Pressure.....137
      Cold Storage Conditioning.....139
      Lubrication Equivalency Chart.....143
      Torque Chart - Standard.....144
      Torque Chart - Metric.....145
      Decimal Equivalent Chart.....146
      Standard/Metric Conversions.....148
        Figure A-1. Electrical Schematic - Sheet 1 of 2.....152
        Figure A-2. Electrical Schematic - Sheet 2 of 2.....153
        Figure A-3. Hydraulic Schematic.....154
    Index.....156
00715-00120-05 - Toyota Electric Walkie Low-Lift Pallet Truck 7HBW23 Master Quality Parts Manual.....160
  Front Cover.....160
  Parts Ordering Instructions.....161
  General Information.....162
  Index.....165
  0000 Chassis.....167
    0340-000 Inspection covers (Shields & guards).....169
    0342-000 Inspection covers (“EE” electrical box).....171
    0380-002 Fork frame.....173
    0850-000 Signs, warnings.....177
  1000 Motors.....179
    1750-100 Pump motor.....181
    1760-000 Drive motor assembly.....183
  2000 Transmission / Drive Gear.....185
    2550-000 Transmission assembly.....187
  3000 Brake / Wheel System.....189
    3370-000 Electromagnetic parking brake.....191
    3530-000 Drive wheel.....193
    3540-000 Support (skid shoe).....195
    3540-100 Support (caster wheel).....197
    3550-000 Load wheel.....199
    3560-100 Caster wheel.....201
  4000 Steering System.....203
    4110-001 Steering arm / wheel (Tiller arm).....205
    4111-001 Steering control head.....207
    4180-000 Steering bearing.....211
  5000 Electrical System.....213
    5110-001 Battery pack, swing out.....215
    5110-101 Battery pack, swing out, power wires.....217
    5113-001 Battery pack (GNB Pallet Pro™ Start / Stop charger).....219
    5180-000 Current collector (Static strap “EE”).....221
    5190-001 Battery contactor / plug (Battery connector).....223
    5311-000 Start / stop switch.....225
    5390-000 Control cables / harness Serial number 24501 - 25304.....227
    5390-001 Control cables / harness Serial number 25305 - UP.....229
    Serial Number 25305 - UP.....228
    5433-000 Motor cables Serial number 24501 - 25304.....231
    Serial Number 24501 - 25304.....230
    5433-001 Motor cables Serial number 25305 - UP.....233
    5436-001 Contactor panel.....235
    5460-000 Drive controller.....237
  6000 Hydraulic System.....239
    6100-100 Hydraulic pump.....241
    6125-100 Hoses, pipes, connections, mounting points.....243
    6420-000 Lift cylinder.....245
  7000 Operating Function - Lifting Device.....247
  8000 Peripheral / Installation Equipment.....249
  9000 Options / Attachments.....251
    9720-100 Removable load backrest.....253
  10000 Tools.....255
    10020-001 Special tools and lubrications.....257
    10020-002 Special tools (seal installing).....259
  11000 Alphabetical / Numerical Index.....261
    Alphabetical Index.....263
    Numerical Index.....267
Toyota Electric Walkie Low-Lift Pallet Truck 7HBW23 Programming QuickGuide.....272
wiring_diagram.....280
  1042401a_7hbw23_schematic.....280
  7hbw23 sn 24501- repair manual cl340-05 wiring diagram.....282

Toyota Electric Powered Pallet Truck Model 7HBW23 Repair Service Manual

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