7hbw23 RM Manual
7hbw23 RM Manual
7hbw23 RM Manual
tape.) Make
sure all parts are clean.
When you install a hose assembly, make
sure that it is not twisted when the fittings
are tightened. Always use two wrenches on
a swivel-type fittingone to hold the fitting
and the other to tighten the hose.
Hydraulic Cylinder
Fluid leakage indicates that the seal is worn.
Replace the seal, wiper, and retaining ring when
fluid leakage becomes excessive.
Cylinder Removal
1. Remove the tractor cover.
2. Remove retaining clip (see Figure 6-43).
3. Press the green ON (I) key on the keypad.
Leave the control handle in the neutral
(vertical) position.
4. Press the lift button, raise the forks to
maximum height and block them. See
Jacking Safety on page 2-9.
5. Lower the forks on the blocking to release
pressure on the hydraulic cylinder.
Manually press down on the cylinder after
the forks come to rest on the blocking to
disengage the cylinder from the tractor
frame.
6. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
Hot oil under pressure is present. Make
sure truck is safely blocked and
pressure is released.
7. Thoroughly clean the outside of the
cylinder before removing the hydraulic
hose. Remove the hose from the cylinder.
Cap and plug the fittings.
NOTE: Catch hydraulic fluid under the
hydraulic cylinder in a suitable
container.
1665 041.tif
Figure 6-43. Remove Retaining Clip
Retaining
Clip
1665 033.tif
Figure 6-44. Hydraulic Cylinder (shown extended with
retaining clip removed)
Hydraulic
Cylinder
Hydraulic
Hose
Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
Hydraulic Components
6-48 00700-CL340-05, Issued: 2 May 2005
8. Lift the cylinder up and out of the tractor
frame. Some spillage of hydraulic oil may
occur.
Cylinder Disassembly
1. Thoroughly clean the outside of the
cylinder.
2. Pull the rod out until the end of the rod
and the retaining ring are visible through
the inlet port. See Figure 6-45.
3. Insert a screwdriver into the inlet port and
slide the retaining ring into the deep
groove in the piston rod assembly.
4. Remove the rod assembly from the barrel.
5. Remove the retaining ring from the piston
rod.
6. Remove the wiper and seal from inside the
barrel assembly.
Cylinder Inspection
1. Thoroughly clean all parts and remove all
nicks and burrs with emery cloth.
2. Inspect the inside surface of the barrel
assembly for excessive wear or scoring.
3. Inspect the outside surface of the rod for
nicks, scratches, or scoring.
Cylinder Assembly
1. Make sure all parts are cleaned and dried
thoroughly. Lightly oil all metal parts
before reassembly.
2. Install new seal in the barrel. Install new
wiper in the barrel with lips facing inward.
3. Install new retaining ring in deep groove of
the piston rod end.
4. Oil outside of piston rod and carefully
insert rod into barrel.
5. Push rod into barrel until the retaining
ring is seen through the inlet port.
6. Insert a screwdriver into the inlet port and
slide the retaining ring into the lock
position.
7. Extend rod to full out position to make
sure the retaining ring is locked in place.
Cylinder Installation
1. Place the new cylinder into position in the
tractor frame. Install retaining clip (see
Figure 6-43).
NOTE: To prevent air from filling the cylinder,
install the cylinder with the rod
retracted.
2. Connect the hydraulic hose.
3. Reconnect the battery connector and press
the green ON (I) key on the keypad.
4. Press the lift button to extend the cylinder.
5. Check the hydraulic reservoir fluid level. If
necessary, add fluid. See Lubrication
Equivalency Chart on page A-2.
6. Remove the blocking. Lift and lower the
forks several times. Look for leakage
around the fittings and cylinder seal.
7. Recheck the hydraulic reservoir fluid level.
If necessary, add fluid.
8. Install the tractor cover.
Figure 6-45. Hydraulic Cylinder Disassembly
Barrel
Inlet Port
Seal
Wiper
Retaining Ring Rod
Toyota Model 7HBW23 Service Manual Section 6. Component Procedures
Hydraulic Components
00700-CL340-05, Issued: 2 May 2005 6-49
Hydraulic Solenoid
The hydraulic solenoid activates the hydraulic
solenoid release valve that releases pressure on
the lift cylinder, lowering the forks. See
Figure 6-46.
Removal
1. Make sure that the forks are fully lowered.
2. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
3. Remove the two wires from the terminals
on the solenoid.
4. Remove the nut holding the solenoid coil
to the solenoid valve.
5. Lift the solenoid coil off the solenoid valve
stem.
6. Remove the solenoid valve stem from the
manifold.
Installation
1. Inspect the seat where the solenoid valve
stem seals against the manifold. The
sealing surface must be completely clean
and free from any nicks or damage.
2. Thread the solenoid valve body into the
manifold. Torque the valve body to 204 to
240 in. lbs (23 to 27 Nm).
3. Install the solenoid coil and tighten the
nut. Torque the nut to 48 to 60 in. lbs (5 to
7 Nm).
4. Connect the wires to the terminals.
5. Reconnect the battery connector and press
the green ON (I) key on the keypad. Test
the functions of the truck.
6. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
7. Install the tractor cover.
Hydraulic Unit
Draining and cleaning the hydraulic reservoir is
important to control the accumulation of
condensation and contamination that can
damage the hydraulic system.
Condensation is caused by the repeated heating
and cooling of hydraulic fluid during normal
operation. Contaminants include dirt, rust,
scaling and products of fluid deterioration.
Removal
Remove the hydraulic unit from the truck in
order to separate the pump from the motor.
1. Lower the forks completely.
2. Press the red OFF (O) key on the keypad.
Disconnect the battery connector. Remove
the tractor cover.
3. Remove and tag all wires and cables
connected to the pump motor. See
Figure 6-47.
4. Remove and cap the hydraulic line from
the hydraulic unit. Disconnect the
solenoid control wires.
5. Remove the bolts that attach the hydraulic
unit mounting bracket to the tractor
frame.
6. Remove the hydraulic unit from the truck.
1665 033.tif
Figure 6-46. Hydraulic Solenoid
Hydraulic Solenoid
Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
Hydraulic Components
6-50 00700-CL340-05, Issued: 2 May 2005
Installation
1. Install the hydraulic unit on the tractor
frame and attach with the previously
removed screws.
2. Install the hydraulic line on the hydraulic
unit.
3. Fill the reservoir with the specified
hydraulic fluid. See Lubrication
Equivalency Chart on page A-2. Use a
funnel with a flexible neck. Fill the
reservoir to within 1 in. (25.4 mm) below
the filler plug elbow. Use up to 0.8 qt.
(0.75 liters). See Figure 6-47.
4. Install the vent plug. See Figure 6-47.
5. Connect all wires and cables to the pump
motor switch and hydraulic solenoid.
6. Connect the battery connector and press
the green ON (I) key on the keypad.
7. Raise and lower the forks. Check all hoses
and fittings for leaks.
8. Lower the forks.
9. Check the hydraulic fluid level in the
reservoir.
Hydraulic Reservoir
Removal
1. Remove the hydraulic unit from the truck.
See Removal on page 6-49.
2. Remove the hose clamp that secures the
hydraulic reservoir to the adapter housing.
3. Tap the reservoir lightly to loosen. Wiggle
the reservoir sideways while pulling up on
the pump and motor at the same time to
remove.
4. Remove the reservoir and properly dispose
of the old hydraulic fluid.
5. After the fluid has drained, flush the
inside of the reservoir with a suitable
cleaning solvent.
6. Dry the inside of the reservoir with clean,
dry compressed air.
Installation
1. Inspect the reservoir O-ring and the inside
leading edge for damage. Replace if
necessary.
2. Lubricate the O-ring (with applicable
hydraulic fluid) and install the O-ring.
3. Carefully install the reservoir on the
adapter housing and attach with hose
clamp. Torque clamp to 48 to 60 in. lb.
(5.5 to 7 Nm).
4. Install hydraulic unit in the truck. See
Installation on page 6-50.
Filter Screen and Inlet Tube
1. Remove the reservoir. See Hydraulic
Reservoir.
2. With the pump assembly inverted,
unthread and remove the inlet tube fitting
and sealing washer from the pump
housing.
3. Clean the filter screen at the bottom of the
inlet tube with a suitable solvent. See
Figure 6-48.
1665 040.tif
Figure 6-47. Hydraulic Unit
Hydraulic
Reservoir
Adapter Body
(Pump)
Pump Motor
Lift Motor
Solenoid
Fill/Vent
Plug
Hydraulic
Solenoid
Toyota Model 7HBW23 Service Manual Section 6. Component Procedures
Hydraulic Components
00700-CL340-05, Issued: 2 May 2005 6-51
4. From the pump side, blow dry with clean,
dry compressed air.
Installation
1. Inspect the filter screen and inlet tube for
damage. Replace if necessary.
2. Install the inlet tube sealing washer and
fitting in the pump housing. Torque to 245
to 275 in. lbs. (27 to 31 Nm).
3. Install the hydraulic reservoir. See
Hydraulic Reservoir.
Hydraulic Pump
NOTE: For replacement parts information refer
to Parts Manual.
Removal
1. Remove the hydraulic unit from the truck
and put on a clean bench for disassembly.
See Hydraulic Unit on page 6-49.
2. Remove the reservoir to gain access to the
pump. See Hydraulic Reservoir.
3. Remove the inlet tube with the filter screen
from the pump housing.
4. Remove the two pump mounting bolts
then remove the pump from the adapter
body.
Installation
1. Stand the motor assembly on end, with
the adapter body facing up.
2. Lubricate the O-ring and install on the
adapter body facing up.
3. Insert the pump drive coupling on the end
of the motor armature shaft, and fill the
cavity with lubricant (Molybdenum
anti-seize compound).
4. Align the splines on the motor drive and
pump shaft. Gently push the pump pilot
on the adapter.
5. Secure the pump with the two pump
mounting bolts. Torque to 40 to 45 in. lb.
(4.5 to 5 Nm).
6. Check the inlet screen for clogging. Clean
with a suitable solvent. Install the inlet
tube fitting into the pump. Torque fitting
to 245 to 275 in. lb. (27 to 31 Nm).
7. Install the reservoir. See Hydraulic
Reservoir on page 6-50.
Lift Motor
Removal
1. Remove the hydraulic unit from the truck.
See Hydraulic Unit on page 6-49.
2. Remove the two bolts from the end plate
that attach the motor to the adapter body.
3. Separate the motor and the adapter body.
4. Remove the start solenoid from the side of
the motor housing for later reuse.
27y7s158.tif
Figure 6-48. Cleaning Filter Screen
Filter
Screen
Inlet
Tube
Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
Hydraulic Components
6-52 00700-CL340-05, Issued: 2 May 2005
Installation
1. Stand the pump assembly on end, with
the adapter body facing up.
2. Set aside the pump drive coupling for later
reuse.
NOTE: The coupling is the mechanical
connection between the pump shaft and
the electric motor armature shaft. It
may have been removed with the motor.
3. Insert the pump drive coupling on the end
of the pump shaft and fill coupling cavity
with lubricant (Molybdenum anti-seize
compound).
4. Rotate the pump or the motor shaft to
align the motor shaft correctly with the
coupling.
5. Install the new motor on the adapter body.
Rotate the pump or the motor shaft if
necessary to allow the motor to contact the
adapter body.
6. Insert the screws into the motor end plate,
through the motor, and into the adapter
body.
7. Make sure the motor is mating flush with
the adapter body. Torque screws to 36 to
45 in. lb. (4 to 5 Nm) maximum.
8. Install the start solenoid.
9. Install the hydraulic unit. See Hydraulic
Unit on page 6-49.
Brush Replacement
1. Remove the lift motor from the hydraulic
assembly before inspecting brushes.
2. Remove the two screws from the motor end
cover. Remove end cover to access
brushes.
3. Push each brush back into holder to
disengage springs. Remove nuts and
washers from side of drive end head.
Remove brush assembly then remove each
brush and replace with a new one.
Hydraulic Fluid
Proper Level
To prevent air from entering the lines, fill the
fluid level (with the forks fully lowered) to within
1 in. (25.4 mm) below the fill port elbow. See
Figure 6-44. The usable reservoir capacity is
0.8 qt. (0.75 L). Add the specified fluid if
necessary. See Lubrication Equivalency Chart
on page A-2.
Changing Fluid
Store and handle the hydraulic fluid with
extreme care to prevent moisture and foreign
matter from entering the hydraulic system.
Contaminated hydraulic fluid is the major
cause of hydraulic system failures. Keep any
service equipment, such as containers, funnels,
and hand pumps, clean at all times. Cover them
when not in use.
1. Lower the forks.
2. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
3. Remove the upper tractor cover.
4. Disconnect the lift cylinder hose at the
hydraulic cylinder. See Figure 6-49.
Brush
Replacement
Replace brushes when they have
worn to the minimum length of
0.35 in. (9 mm).
Spring
Tension
Adjust the spring tension of new
brushes to 32 to 40 oz. (908.8 to
1136 gm).
1665 040.tif
Figure 6-49. Hydraulic Connections
Lift Cylinder
Hose
Toyota Model 7HBW23 Service Manual Section 6. Component Procedures
Hydraulic Components
00700-CL340-05, Issued: 2 May 2005 6-53
5. Insert the hose in a waste fluid container.
Fluid is under pressure and may spray
or splash. Point hose away from your
body and hold firmly in waste fluid
container.
6. Connect the battery connector and press
the green ON (I) key on the keypad.
7. Run the hydraulic pump by pressing the
lift button until all the hydraulic fluid is
pumped from the system.
8. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
9. Reconnect the lift cylinder hose.
10. Remove the vent plug and fill the reservoir
to within 1 in. (25.4 mm) below the filler
port elbow with the recommended
hydraulic fluid. See Lubrication
Equivalency Chart on page A-2.
11. Replace the vent plug.
12. Connect the battery connector and press
the green ON (I) key on the keypad.
13. Raise and lower the forks several times to
purge air from the system.
14. Install the upper tractor cover.
15. Dispose of the waste fluid properly.
Adjusting Hydraulic Pump
Pressure Relief Valve
The hydraulic system is protected by a relief
valve installed in the adapter body. The relief
valve is set by the manufacturer to open at a
specified pressure.
Relief Valve Settings
Check Setting
1. Attach a jumper wire across the terminals
of the lift-limit switch so the switch will
not shut the pump down when the forks
reach their upper limit.
2. Retract the lift cylinder completely. Press
the red OFF (O) key on the keypad.
Remove the 90 elbow. Replace the elbow
with a female run tee with a 1/8 in. NPT
0 to 3,500 psi (0 to 24131 kPa) pressure
gauge. See Figure 6-50.
3. Press the green ON (I) key on the keypad.
Leave the control handle in the neutral
(vertical) position.
4. Press the lift button and observe the
indicator on the pressure gauge. When the
forks reach the upper lift-limit, the pump
will make a high pitched squeal indicating
that the relief valve is opening.
Adjust Setting
If the relief valve opens at a lower or higher
pressure than the specified pressure, adjust the
relief valve as follows:
1. Remove the hex cap covering the relief
valve adjustment screw.
2. As you depress the lift button, turn the
adjusting screw inward to increase the
Truck Capacity
Pressure Settings
PSI kPa
4,500 lb. (2,041 kg) 3,000 20,684
Table 6-3: Truck Pressure Levels
Hydmtrpm.tif
Figure 6-50. Checking Relief Valve Pressure
Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
Hydraulic Components
6-54 00700-CL340-05, Issued: 2 May 2005
pressure setting or outward to decrease
the pressure setting.
3. Check the indicator on the pressure
gauge. After the relief valve is properly set,
release the lift button.
4. Reinstall the hex cap. Torque to 144 to
180 in. lb. (16 to 20 Nm).
5. Recheck the relief valve setting.
6. Lower the forks completely. Press the red
OFF (O) key on the keypad.
7. Remove the pressure gauge. Replace the
elbow.
8. Press the green ON (I) key on the keypad.
Raise the forks. Inspect all hoses and
fittings for leaks.
9. Adjust the lift-limit switch to shut down
the pump when the forks reach their
upper limit. See Lift-Limit Switch on
page 6-25.
Toyota Model 7HBW23 Service Manual Section 6. Component Procedures
Cold Storage Conditioning
00700-CL340-05, Issued: 2 May 2005 6-55
Cold Storage
Conditioning
New Toyota Pallet Trucks supplied with a
standard conditioning package are designed to
operate in an environment where temperatures
range from 32 to 104F (0 to 40C) in a
continuous duty cycle.
Trucks supplied with a cold storage
conditioning package are designed to operate in
temperatures to 5F (15C) in a continuous
duty cycle or to 13F (25C) for in and out
operation.
When a truck is installed in a cold storage
environment, change the fluid in the hydraulic
reservoir according to the recommended fluids
listed in the Appendix. See Lubrication
Equivalency Chart on page A-2.
Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
Cold Storage Conditioning
6-56 00700-CL340-05, Issued: 2 May 2005
A
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p
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Toyota Model 7HBW23 Service Manual Appendix
00700-CL340-05, Issued: 2 May 2005 A-1
Appendix
Appendix Toyota Model 7HBW23 Service Manual
Lubrication Equivalency Chart
A-2 00700-CL340-05, Issued: 2 May 2005
Lubrication Equivalency
Chart
s
Table A-1. Approved Lubricants
Approved Toyota Lubricants
Where Used Type Specification Toyota Part Number
Drive Unit Gear Case
25 to +110F
(31.5 to +43.3C)
Synthetic Gear
Lubricant
Mobil-1 or Texaco Synstar GL
75W - 90 Synthetic Gear Oil
API Service Classification GL-5
00590-04835-71
(1 qt./0.9 liter)
00590-04837-71
(5 gal./18.9 liters)
Hydraulic Reservoir -
Standard Operation
Down to +23 F
(-5 C)
Hydraulic
Fluid
Sunoco TH
ISO VG 46
00590-04934-71
(1 qt./0.9 liter)
00590-04840-71
(5 gal./18.9 liters)
Hydraulic Reservoir -
Cold Storage
Continuous Operation
down to +5F (-15 C)
Intermittent Operation
down to -13F (-25 C)
Hydraulic
Fluid
ATF
ISO VG 32
00590-04842-71
(1 gal./3.8 liters)
00590-04843-71
(5 gal./18.9 liters)
Bearings and
Bushings
Grease Mystic JT-6
NLGI Grade 2
00590-04844-71
(10 cartridges per
case)
00590-04845-71
(5 gal./18.9 liters)
Toyota Model 7HBW23 Service Manual Appendix
Torque Chart - Standard
00700-CL340-05, Issued: 2 May 2005 A-3
Torque Chart - Standard
Grade
Identification
Marking
None
Size
SAE Grade 2 Bolts
Tightening Torque
SAE Grade 5 Bolts
Tightening Torque
SAE Grade 8 Bolts
Tightening Torque
Dry Oiled* Dry Oiled* Dry Oiled*
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 38 68 51
1/4-20 66 49 96 75 144 108
1/4-28 76 56 120 86 168 120
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 70 55 110 80 150 110
9/16-18 80 60 120 90 170 130
5/8-11 100 75 150 110 220 170
5/8-18 110 85 170 130 240 180
3/4-10 175 130 260 200 380 280
3/4-16 195 145 300 220 420 320
7/8-9 165 125 430 320 600 460
7/8-14 185 140 470 350 660 500
1-8 250 190 640 480 900 680
1-12 270 200 700 530 1000 740
1 1/8-7 350 270 800 600 1280 960
1 1/8-12 400 300 880 660 1440 1080
1 1/4-7 500 380 1120 840 1820 1360
1 1/4-12 550 420 1240 920 2000 1500
1 3/8-6 660 490 1460 1100 2380 1780
1 3/8-12 740 560 1680 1260 2720 2040
1 1/2-6 870 650 1940 1460 3160 2360
1 1/2-12 980 730 2200 1640 3560 2660
Table A-2. Torque Chart - Standard
*NOTE: Use oiled values for bolts with thread-locking compound.
Appendix Toyota Model 7HBW23 Service Manual
Torque Chart - Metric
A-4 00700-CL340-05, Issued: 2 May 2005
Torque Chart - Metric
Ferrous Metric Bolts
(The grade rating is stamped on the head of the bolt.)
Diameter
(in millimeters)
Grade 8.8 Grade 10.9
Torque (with bolts oiled*) Torque (with bolts oiled*)
Newton-meters Foot-pounds Newton-meters Foot-pounds
6 8.6 6 12 9
8 21 15 29 21
10 42 30 58 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Table A-3. Torque Chart - Ferrous Metric
*NOTE: Use oiled values for bolts with thread-locking compound.
Metric Bolts, Coarse Thread
Diameter
(in millimeters)
Torque (with bolts oiled*)
Newton-meters Foot-pounds
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10.6
5 2.2 19.4
6 3.9 34.5
8 9 79.6
10 17 150
Table A-4. Torque Chart - Non-Ferrous Metric
*NOTE: Use oiled values for bolts with thread-locking compound.
Toyota Model 7HBW23 Service Manual Appendix
Decimal Equivalent Chart
00700-CL340-05, Issued: 2 May 2005 A-5
Decimal Equivalent Chart
4ths 8ths 16ths 32nds 64ths
To 3
Places
To 2
Places
MM Equivalent
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
Table A-5. Decimal Equivalent Chart
Appendix Toyota Model 7HBW23 Service Manual
Decimal Equivalent Chart
A-6 00700-CL340-05, Issued: 2 May 2005
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400
4ths 8ths 16ths 32nds 64ths
To 3
Places
To 2
Places
MM Equivalent
Table A-5. Decimal Equivalent Chart
Toyota Model 7HBW23 Service Manual Appendix
Standard/Metric Conversions
00700-CL340-05, Issued: 2 May 2005 A-7
Standard/Metric
Conversions
To Convert... Multiply...
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to kilograms Ounces x 0.028
Kilograms to ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to pounds Kilograms x 2.2
Pounds per Square Inch to Kilo pascals Pounds per Square Inch x 6.894
Kilo pascals to Pounds per Square Inch Kilo pascals x 0.145
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Table A-6. Conversion Table
Appendix Toyota Model 7HBW23 Service Manual
Standard/Metric Conversions
A-8 00700-CL340-05, Issued: 2 May 2005
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Miles per hour to kilometers per hour Miles per hour x 0.6214
Kilometers per hour to miles per hour Kilometers per hour x 1.609
Fahrenheit to Celsius (F 32) x 0.555
Celsius to Fahrenheit (C x 1.8) + 32
To Convert... Multiply...
Table A-6. Conversion Table
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Toyota Model 7HBW23 Service Manual Schematics
00700-CL340-05, Issued: 2 May 2005 A-9
Schematics
Schematics Toyota Model 7HBW23 Service Manual
A-10 00700-CL340-05, Issued: 2 May 2005
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Figure A-1. Electrical Schematic - Sheet 1 of 2
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Toyota Model 7HBW23 Service Manual Schematics
00700-CL340-05, Issued: 2 May 2005 A-11
1881 002.eps
Figure A-2. Electrical Schematic - Sheet 2 of 2
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Schematics Toyota Model 7HBW23 Service Manual
A-12 00700-CL340-05, Issued: 2 May 2005
1881 002.eps
Figure A-3. Hydraulic Schematic
Motor
Pump
Filter
Reservoir
Flow Control Check
Valve
Solenoid
Valve
Pressure
Relief
Valve
Lift
Cylinder
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Toyota Model 7HBW23 Service Manual Index
00700-CL340-05, Issued: 2 May 2005 I-1
Index
A
Acceleration . . . . . . . . . . . . . . . . . . . . 5-6
Anti-Static Kit . . . . . . . . . . . . . . . . . . 2-12
Arm Angle Switches . . . . . . . . . . . . . . 6-24
B
Battery
Adding Water . . . . . . . . . . . . . . . . . 6-7
Charging . . . . . . . . . . . . . . . . . . . . 6-6
Maintenance . . . . . . . . . . . . . . . . . 6-5
Maintenance-Free . . . . . . . . . . . . . 6-5
Safety . . . . . . . . . . . . . . . . . . . . . . 2-6
Specific Gravity . . . . . . . . . . . . . . . 6-7
Storage . . . . . . . . . . . . . . . . . . . . . 6-8
Voltage Check . . . . . . . . . . . . . . . . 6-7
Brake . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Disc Location . . . . . . . . . . . . . . . . 6-33
Friction Disc Replacement . . . . . . 6-34
Gap Adjustment . . . . . . . . . . . . . 6-33
C
Cables, Power . . . . . . . . . . . . . . . . . . 6-10
Carrier Frame Linkage . . . . . . . . . . . 6-46
Caution and Error Codes . . . . . . . . . . 5-10
Circuit Breaker . . . . . . . . . . . . . . . . . 6-13
Codes, Caution and Error . . . . . . . . . 5-10
Cold Storage Conditioning . . . . . . . . . 6-55
Contactors . . . . . . . . . . . . . . . . . . . . 6-20
Control Handle
Changing Horn Button/Switch . . 6-15
Changing Lift/Lower Button . . . . 6-16
Changing Push Button . . . . . . . . 6-16
Disassembly . . . . . . . . . . . . . . . . 6-15
Display and Programming . . . . . . . 5-9
Stem . . . . . . . . . . . . . . . . . . . . . . 6-16
Control Handle Assembly . . . . . . . . . 6-18
Conversions, Standard/Metric . . . . . . . A-7
Cover, Tractor . . . . . . . . . . . . . . . . . . . 6-9
Creep Speed . . . . . . . . . . . . . . . . . . . . 5-6
Current Limiting . . . . . . . . . . . . . . . . . 5-6
D
Decimal Equivalent Chart . . . . . . . . . . A-5
Definitions . . . . . . . . . . . . . . . . . . . . . . 5-6
Display and Programming
Error Codes . . . . . . . . . . . . . . . . . . 5-9
Hourmeter . . . . . . . . . . . . . . . . . . . 5-9
Part Numbers . . . . . . . . . . . . . . . . 5-20
Drive Housing Lubrication . . . . . . . . . 6-30
Drive Motor
Brush Inspection/Replacement . . . 6-35
Brush Spring Tension . . . . . . . . . . 6-36
Commutator . . . . . . . . . . . . . . . . . 6-36
Drive Unit
Brake, Electromagnetic . . . . . . . . . 6-33
Drive Motor
Brush Replacement . . . . . . . . . 6-42
Drive Wheel . . . . . . . . . . . . . . . . . 6-31
Lubrication . . . . . . . . . . . . . . . . . . 6-30
Transmission Assembly . . . . . . . . 6-27
Drive Wheel . . . . . . . . . . . . . . . . . . . . 6-31
E
Electrical Schematic . . . . . . . . . . . . . . A-10
Electrical Symbols, List of . . . . . . . . . . . 5-8
Electrical Troubleshooting . . . . . . . . . . 5-3
Electromagnetic Brake . . . . . . . . . . . . 6-33
Electrostatic Discharge . . . . . . . . . . . . 2-12
Emergency Reverse . . . . . . . . . . . . . . . . 5-6
Equivalent Chart, Decimal . . . . . . . . . . A-5
Error and Caution Codes . . . . . . . . . . 5-10
Error Codes . . . . . . . . . . . . . . . . . . . . . 5-9
History . . . . . . . . . . . . . . . . . . . . . . 5-9
ESD, See Electrostatic Discharge
F
Fault Codes . . . . . . . . . . . . . . . . 5-7, 5-24
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
G
Grease Fittings . . . . . . . . . . . . . . . . . . . 4-5
H
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Index Toyota Model 7HBW23 Service Manual
I-2 00700-CL340-05, Issued: 2 May 2005
Hydraulic Components
Cylinder
Assembly . . . . . . . . . . . . . . . . . 6-48
Disassembly . . . . . . . . . . . . . . 6-48
Inspection . . . . . . . . . . . . . . . . 6-48
Installation . . . . . . . . . . . . . . . 6-48
Removal . . . . . . . . . . . . . . . . . 6-47
Fluid
Changing . . . . . . . . . . . . . . . . . 6-52
Level . . . . . . . . . . . . . . . . . . . . 6-52
Hydraulic Pump
Removal/Installation . . . . . . . . 6-51
Hydraulic Reservoir
Installation . . . . . . . . . . . . . . . 6-50
Removal . . . . . . . . . . . . . . . . . 6-50
Hydraulic Unit
Installation . . . . . . . . . . . . . . . 6-50
Relief Valve Adjustment . . . . . . 6-53
Removal . . . . . . . . . . . . . . . . . 6-49
Solenoid
Installation . . . . . . . . . . . . . . . 6-49
Removal . . . . . . . . . . . . . . . . . 6-49
Hydraulic Schematic . . . . . . . . . . . . . .A-12
Hydraulic Troubleshooting . . . . . . . . . .5-5
I
Identification, Model . . . . . . . . . . . . . . .3-2
J
Jacking Safety . . . . . . . . . . . . . . . . . . .2-9
K
key code . . . . . . . . . . . 5-7, 5-9, 5-19, 5-20
Key Switch (Optional) . . . . . . . . . . . . . 6-26
L
Lift Motor . . . . . . . . . . . . . . . . . . . . . . 6-51
Lift-Limit Switch . . . . . . . . . . . . . . . . . 6-25
Adjustment . . . . . . . . . . . . . . . . . . 6-25
List of Electrical Symbols . . . . . . . . . . .5-8
Load Wheels . . . . . . . . . . . . . . . . . . . . 6-45
Carrier Frame Linkage . . . . . . . . . 6-46
Pull Rod Removal/Replacement . . . 6-45
Removal/Replacement . . . . . . . . . . 6-45
Lubrication Equivalency Chart . . . . . . .A-2
Lubrication, Drive Housing . . . . . . . . . 6-30
M
Maintenance
Annually/Every 1500 Hours . . . . . . 4-5
Daily . . . . . . . . . . . . . . . . . . . . . . . 4-3
Every Two Months/250 Hours . . . . 4-4
Map, Navigating the Manual . . . . . . . . . 1-2
Master Control ON/OFF Switch . . . . . 6-23
Master Control Relay . . . . . . . . . . . . . 6-21
Metric Conversions . . . . . . . . . . . . . . . A-7
Model Identification . . . . . . . . . . . . . . . 3-2
Motor Controller . . . . . . . . . . . . . . . . . . 3-7
Undertemperature . . . . . . . . . . . . . 5-7
Motors
Drive . . . . . . . . . . . . . . . . . .6-35, 6-42
General . . . . . . . . . . . . . . . . . . . . 6-35
Lift . . . . . . . . . . . . . . . . . . . . . . . . 6-51
N
Neutral Braking . . . . . . . . . . . . . . . . . . 5-6
O
Operation
Directional/Speed Control . . . . . . . 3-5
Lift/Lower . . . . . . . . . . . . . . . . . . . 3-5
Motor Controller . . . . . . . . . . . . . . . 3-7
Truck Starting . . . . . . . . . . . . . . . . 3-5
Overvoltage Cutoff . . . . . . . . . . . . . . . . 5-7
P
Pallet Forks . . . . . . . . . . . . . . . . . . . . 6-45
PIN-key code . . . . . . . 5-7, 5-9, 5-19, 5-20
Plugging . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Power Amplifier
Thermal Cutback . . . . . . . . . . . . . . 5-7
Programmable Maintenance Tool .3-4, 5-26
Pump, Hydraulic . . . . . . . . . . . . . . . . 6-51
R
Ramp Shape . . . . . . . . . . . . . . . . . . . . 5-7
Relay, Master Control . . . . . . . . . . . . . 6-21
Toyota Model 7HBW23 Service Manual Index
00700-CL340-05, Issued: 2 May 2005 I-3
S
Safety
Battery . . . . . . . . . . . . . . . . . . . . . 2-6
Definitions . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . 2-3
Jacking . . . . . . . . . . . . . . . . . . . . . 2-9
Static . . . . . . . . . . . . . . . . . . . . . . 2-12
Towing . . . . . . . . . . . . . . . . . . . . . 2-10
Welding . . . . . . . . . . . . . . . . . . . . 2-11
Schematics
Electrical . . . . . . . . . . . . . . . . . . . A-10
Hydraulic . . . . . . . . . . . . . . . . . . A-12
Sequencing Delay . . . . . . . . . . . . . . . . 5-7
Service Key . . . 3-4, 5-17, 5-18, 5-20, 5-21
Solenoid, Hydraulic . . . . . . . . . . . . . . 6-49
Special Tools . . . . . . . . . . . . . . . . . . . . 3-4
Programmable Maintenance Tool . . 3-4
Service Key . . . . . . . . . . . . . . . . . . 3-4
Specifications, Vehicle . . . . . . . . . . . . . 3-2
Speed Limiting . . . . . . . . . . . . . . . . . . 5-7
Static Discharge . . . . . . . . . . . . . . . . 2-12
Static Wrist Strap . . . . . . . . . . . . . . . 2-12
Static-Sensitive Components . . . . . . . 2-12
Strap, Static . . . . . . . . . . . . . . . . . . . 2-12
Switches
Arm Angle . . . . . . . . . . . . . . . . . . 6-24
General . . . . . . . . . . . . . . . . . . . . 6-23
Key Switch (Optional) . . . . . . . . . 6-26
Lift-Limit . . . . . . . . . . . . . . . . . . . 6-25
Master Control ON/OFF . . . . . . . 6-23
Test/Inspection . . . . . . . . . . . . . . 6-23
Symptom Tables
Lift/Lower System . . . . . . . . . . . . 5-35
Travel (Forward/Reverse) System . 5-39
T
Tests
Electric Motor . . . . . . . . . . . . . . . 6-39
Theory of Operation . . . . . . . . . . . . . . . 3-5
Torque Chart
Metric . . . . . . . . . . . . . . . . . . . . . . A-4
Standard . . . . . . . . . . . . . . . . . . . . A-3
Towing Safety . . . . . . . . . . . . . . . . . . 2-10
Tractor Cover . . . . . . . . . . . . . . . . . . . 6-9
Installation . . . . . . . . . . . . . . . . . . 6-9
Removal . . . . . . . . . . . . . . . . . . . . 6-9
Troubleshooting
Electrical . . . . . . . . . . . . . . . . . . . . 5-3
Hydraulic . . . . . . . . . . . . . . . . . . . . 5-5
List of Charts/Tables . . . . . . . . . . 5-29
Symptom Tables . . . . . . . . . 5-35, 5-39
Truck Model Identification . . . . . . . . . . 3-2
Truck Specifications . . . . . . . . . . . . . . . 3-2
U
Undervoltage Cutback . . . . . . . . . . . . . 5-7
V
Vehicle Specifications . . . . . . . . . . . . . . 3-2
W
Welding Safety . . . . . . . . . . . . . . . . . . 2-11
Wheels
Load . . . . . . . . . . . . . . . . . . . . . . . 6-45
Wiring Harness . . . . . . . . . . . . . . . . . . 6-11
Inspection . . . . . . . . . . . . . . . . . . . 6-11
Wrist Strap . . . . . . . . . . . . . . . . . . . . . 2-12
Index Toyota Model 7HBW23 Service Manual
I-4 00700-CL340-05, Issued: 2 May 2005