Toyota 7LOP10CW, 7LOP10CF Order Picking Stacker Pallet Truck Repair Service Manual

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Price: US$ 38.00

Toyota 7LOP10CW, 7LOP10CF Order Picking Stacker Pallet Truck Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Toyota 7LOP10CW, 7LOP10CF Order Picking Stacker Pallet Truck, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Toyota 7LOP10CW, 7LOP10CF Order Picking Stacker Pallet Truck 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.

PRODUCT DETAILS:
Total Pages: 206 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

232370-040 - Toyota 7LOP10CW, 7LOP10CF Order Picking Stacker Pallet Truck Service Manual (Valid from serial number 931876-)

MAIN SECTIONS
2- Technical data.......9
  2.1 Tightening torques.......13
  2.2 General tightening torques.......14
3- Maintenance.......15
  3.1 Safety rules during maintenance work.......15
  3.2 Cleaning and washing.......17
    3.2.1 External cleaning.......17
    3.2.2 Cleaning the motor compartment.......17
    3.2.3 Electric components.......17
  3.3 Safe lifting.......18
  3.4 Lifting the truck.......19
  3.5 Maintenance schedule.......20
  3.6 Lubrication schedule.......25
  3.7 Oil and lubricant specifications.......26
4- Tools.......27
  4.1 Super Seal connectors.......27
  4.2 AMP connectors.......28
    4.2.1 AMP Connectors, 040 series.......29
    4.2.2 AMP connectors CPC.......30
  4.3 Molex connectors.......31
  4.4 Grease guns.......32
  4.5 Other tools.......33
5- Electric drive motor - 1760.......35
  5.1 General.......35
  5.2 Mechanical design.......35
  5.3 Disassembly of the motor from the truck.......36
  5.4 Assembly of the motor in the truck.......36
  5.5 Service and repairs.......37
    5.5.1 Disassembly of the motor.......37
    5.5.2 Disassembly, N side.......38
    5.5.3 Disassembly, D side.......38
    5.5.4 Wearing parts.......38
    5.5.5 Cleaning.......39
6- Driving unit/gear - 2550.......41
  6.1 Included components.......42
  6.2 Disassembly/Assembly Leakage from top cover.......43
    Assembly is done in reverse........43
  6.3 Replacing the drive axle jointing ring.......44
    6.3.1 Disassembly.......44
    6.3.2 Assembly.......45
  6.4 Replacing the wheel bolt.......46
7- Electromagnetic brake - 3370.......47
  7.1 Included components.......48
  7.2 Disassembly.......48
    7.2.1 Inspection.......48
  7.3 Assembly.......49
  7.4 Manual release of the brake.......49
  7.5 Adjustment.......49
    7.5.1 Adjusting the play.......49
8- Support wheels - 3500.......51
  8.1 Main components.......51
    8.1.1 Replacing the wheel.......52
      Disassembly.......52
      Assembly.......52
    8.1.2 Replacing the wheel bearings.......52
9- Electrical steering system - 4300.......53
  9.1 General.......53
    9.1.1 Electrical steering servo.......54
  9.2 Component overview.......55
  9.3 Adjustment.......57
    9.3.1 Reference sensor.......57
    9.3.2 Calibration.......57
      Parameter 36.......57
      Parameter 37.......57
  9.4 Disassembly/assembly of pushbuttons.......58
    9.4.1 Replacing the hornbutton/switch.......58
    9.4.2 Replacing the lifting/lowering pushbutton.......59
    9.4.3 Replacing the pushbutton.......59
  9.5 Replacing the potentiometer.......60
  9.6 Replacing the inductive brake sensor.......63
  9.7 Replacing the viscous damper.......66
10- Electrical systems - 5000.......69
  10.1 General.......69
    10.1.1 Software/hardware order numbers.......69
    10.1.2 Nomenclature.......70
  10.2 Electrical equipment overview.......71
    10.2.1 Electric component overview.......73
  10.3 Electrical wiring diagram.......76
    10.3.1 Symbol list.......76
    10.3.2 Overview.......77
    10.3.3 Detailed wiring diagram.......78
  10.4 Functional description.......87
    10.4.1 Description of steering system.......92
    10.4.2 Spider expansion unit (SEU).......93
    10.4.3 Speed limitation.......94
    10.4.4 Hour meter and battery condition.......95
    10.4.5 TLS - Truck log system (optional).......96
      General.......96
      Registration.......96
      Logging in/out SD16.......96
      Logging in/out S16.......96
      Collision sensor.......97
      Settings.......97
    10.4.6 ID unit (optional).......98
      General.......98
      Installation.......98
      Settings.......99
  10.5 Parameters & adjustments.......101
    10.5.1 General.......101
    10.5.2 Displaying parameters - without the CAN service key.......101
    10.5.3 Adjusting operator parameters - without the CAN service key.......102
    10.5.4 Displaying & changing parameters - CAN service key connected.......102
      Changing a parameter.......103
    10.5.5 List of operator parameters.......104
    10.5.6 Description of operator parameters.......105
      #1 - Speed, Fork direction.......105
      # 2 - Speed, Drive wheel direction.......105
      # 3 - Acceleration.......105
      # 4 - Neutral braking force.......105
      # 5 - Travel speed, cabin > 0.5 m.......105
      # 6 - Travel speed, walking at side.......105
      # 7 - Neutral braking, walking at side.......105
    10.5.7 List of Service parameters.......106
    10.5.8 Description of Service parameter.......107
      # 10 - PIN code.......107
      To enter a new PIN-code:.......108
      To remove an existing PIN-code:.......108
      # 11 - Reverse braking force.......109
      # 14 - Creep speed.......109
      #15 - Non-configurable options.......109
      Setting Non-configurable options.......109
      #16 - Configurable option #1.......110
      #17 - Configurable option #2.......110
      #19 - Configurable option #4.......110
      # 20 - Hour meter selection.......111
      # 21 - Battery size.......112
      # 22 - Machine type.......113
      # 23 - Function selection.......113
      # 24 - Special request.......113
      # 25 - Service interval.......113
      # 28 - Button selection.......113
      # 35 - Automatic log-off.......114
      # 36 - Steer servo calibration.......114
      # 37 - Steering offset.......115
      # 39 - Log-in method & operator parameter access.......115
      Extended keypad - General.......116
      Extended keypad - Programming.......116
    10.5.9 Configurable “Option” parameters.......118
      General.......118
      Parameter #16 to #19 configurable options.......119
      Setting Configurable options.......120
  10.6 Diagnostic and troubleshooting.......131
    10.6.1 General.......131
    10.6.2 Fault code history.......132
    10.6.3 List of fault codes.......132
    10.6.4 Transistor regulator troubleshooting and error codes.......138
      General.......138
      Transistor regulator errors.......139
      Resetting errors.......140
      Safety.......140
    10.6.5 Built-in Test Function.......141
      Digital inputs/outputs test mode.......142
    10.6.6 Transistor regulator inputs.......142
      Transistor regulator outputs.......143
      Digital input of logic card [A2].......143
      Digital input/output to expansion unit [A36].......144
      Digital input/output to expansion unit [A36] (Option).......144
      Extra functions.......145
    10.6.7 Display test mode.......145
  10.7 Technical specifications - Curtis 1243.......146
11- Hydraulic system - 6000.......147
  11.1 7LOP10CW.......147
    11.1.1 General.......147
    11.1.2 Hydraulic drawing and symbol list.......148
      Symbol list.......148
    11.1.3 Description.......149
      Lift.......149
      Lowering.......149
      Operating pressure.......149
      Relief valve.......149
      Pressure sensor.......149
  11.2 7LOP10CF.......150
    11.2.1 General.......150
    11.2.2 Hydraulic drawing and symbol list.......151
      Symbol list.......152
    11.2.3 Description.......152
      Cabin lifting.......152
      Cabin lowering.......152
      Initial forks.......153
      Initial forks lowering.......153
      Operating pressure.......153
      Relief valve.......153
      Check valve for the cabin / forks cylinders (3).......153
      Pressure sensors, B10/B11.......153
  11.3 Adjustments.......154
    Adjusting the pressure limiting valve.......154
12- Main lift chain system - 7120.......155
  12.1 General.......155
  12.2 Checking the chain setting.......155
  12.3 Chain inspection.......155
    12.3.1 Noise.......155
    12.3.2 Surface rust.......155
    12.3.3 Rusty links.......155
    12.3.4 Stiff links.......156
    12.3.5 Bolt rotation.......156
    12.3.6 Loose bolts.......156
    12.3.7 Outline wear.......157
    12.3.8 Stretching.......158
    12.3.9 Damage.......159
    12.3.10 Damaged discs.......159
    12.3.11 Damaged bolts.......159
    12.3.12 Dirty chain.......159
  12.4 Cleaning.......159
  12.5 Lubrication.......160
13- Fork carriage - 7420.......161
  13.1 Included components.......161
  13.2 Dismounting of the mast carriage........163
  13.3 Adjusting the play.......163
  13.4 Roller replacement.......163
  13.5 Dismounting of the initial fork carriage........164
14- TruckCom.......165
  14.1 General.......165
  14.2 Connection.......165
  14.3 Layout.......166
    14.3.1 Main program screen.......166
    14.3.2 Nodes.......166
    14.3.3 Icons.......167
    14.3.4 Tool buttons and menu bar.......167
    14.3.5 Information window.......168
    14.3.6 Status bar.......168
  14.4 Connection function.......168
  14.5 Disconnection function.......168
  14.6 Downloading program function.......169
    14.6.1 Normal downloading (truck with key).......169
    14.6.2 Normal downloading (truck with keypad).......169
    14.6.3 Emergency downloading (truck with keypad).......170
    14.6.4 Emergency downloading (truck with keypad).......170
    14.6.5 Downloading in old versions of logic card.......170
  14.7 Truck report function.......171
  14.8 Parameters function.......172
  14.9 Diagnostics function.......172
    14.9.1 Representation of signal colours.......173
    14.9.2 “Tiller arm” tab.......173
    14.9.3 “Drive Controller” tab (transistor regulator driving).......174
    14.9.4 “Pump controller” tab (transistor regulator pump).......175
    14.9.5 “EPS” (steering servo tab).......176
    14.9.6 SEU tab (Extra I/O module).......177
  14.10 Other menu functions.......177
    14.10.1 Save to file.......177
    14.10.2 Download from file.......177
    14.10.3 Reset CAN adapter.......178
    14.10.4 Delete error code log.......178
    14.10.5 Reset hour meter.......178
    14.10.6 Read error code log.......178
    14.10.7 Adjust date and time.......178
    14.10.8 Adjusting the hour meter on older cards.......178
    14.10.9 Help.......178
      About the TruckCom application.......178
    14.10.10 Exit.......178
  14.11 Specifications.......179
  14.12 Installation.......179
    14.12.1 Installation on a PC with Windows® 95/98.......179
    14.12.2 Installation on a PC with Windows XP/ 2000.......180
      Changes in Windows® control panel.......183
    14.12.3 Installation on a PC with Windows NT.......186
    14.12.4 In case of communication problems with CAN.......186
    14.12.5 To uninstall.......186
15- Destruction instructions.......187
  15.1 General.......187
  15.2 Procedure.......187
  15.3 Abbreviations.......188
  15.4 Sorting.......188
  15.5 Hoods, hatches (0340).......189
    15.5.1 Dismantling.......189
    15.5.2 Material handling.......189
  15.6 Hoods, hatches (0340).......190
    15.6.1 Dismantling.......190
    15.6.2 Material handling.......190
  15.7 Seat, cushions (0620).......191
    15.7.1 Dismantling.......191
    15.7.2 Material handling.......191
  15.8 Wall/floor covering (0670).......192
    15.8.1 Dismantling.......192
    15.8.2 Material handling.......192
  15.9 Electric motors (1700).......193
    15.9.1 Dismantling.......193
    15.9.2 Material handling.......193
  15.10 Drive assembly/gear (2550).......194
    15.10.1 Dismantling.......194
    15.10.2 Material handling.......194
  15.11 Wheels (3500).......195
    15.11.1 Dismantling.......195
    15.11.2 Material handling.......195
  15.12 Steering arm (4110).......196
    15.12.1 Dismantling.......196
    15.12.2 Material handling.......196
  15.13 General electronic equipment (5100).......197
    15.13.1 Dismantling.......197
    15.13.2 Material handling.......197
  15.14 Battery cut out connector/ contactor (5190).......198
    15.14.1 Dismantling.......198
    15.14.2 Material handling.......198
  15.15 Expansion unit “SEU”(5730).......199
    15.15.1 Dismantling.......199
    15.15.2 Material handling.......199
  15.16 Hydraulic unit (6100).......200
    15.16.1 Dismantling.......200
    15.16.2 Material handling.......200
  15.17 Hydraulic lines chassis (6230) and main lift cylinders (6610).......201
    15.17.1 Dismantling.......201
    15.17.2 Material handling.......201
  15.18 Frame/chassis (7420).......202
    15.18.1 Dismantling.......202
    15.18.2 Material handling.......202
  15.19 Charger adaptor (9380).......203
    15.19.1 Dismantling.......203
    15.19.2 Material handling.......203
  15.20 Other extra equipment, tuck log device (9420).......204
    15.20.1 Dismantling.......204
    15.20.2 Material handling.......204
  15.21 Other extra equipment, writing table (9500).......205
    15.21.1 Dismantling.......205
    15.21.2 Material handling.......205

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