7hbw23 RM 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

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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
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.
Manual Design
1-4 00700-CL340-05, Issued: 2 May 2005

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
START Page
1-6 00700-CL340-05, Issued: 2 May 2005
startpg2.wmf
To test,
inspect, adjust,
remove/install a
component?
Yes
No
START-
2
To find
general reference
information?
To locate an
object or
procedure by
name?
Go to Section 6
"Component Procedures"
Go to the
"Appendix"
Go to the Index
Yes
Yes
No
Alphabetical List of
Component Procedures
Component Locator

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Toyota Model 7HBW23 Service Manual Section 2. Safety
00700-CL340-05, Issued: 2 May 2005 2-1
Section 2. Safety
Section 2. Safety Toyota Model 7HBW23 Service Manual
Definitions
2-2 00700-CL340-05, Issued: 2 May 2005
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous
situation exists that, if not avoided,
could result in death or serious injury.
Caution means a potentially hazardous
situation exists that, if not avoided,
could result in minor or moderate injury
or in damage to the truck or nearby
objects.
General Safety
00700-CL340-05, Issued: 2 May 2005 2-3
General Safety
Do not operate or work on this truck unless you
are trained, qualified, and authorized to do so
and have read the Owner/Operator Manual.
Know the trucks controls and what they do.
Do not operate this truck if it needs repair or if
it is in any way unsafe.
Operate this truck only from the operators
position.
Before working on this truck, always press the
red OFF key (O) on the keypad and disconnect
the trucks battery connector (unless this
manual tells you otherwise).
Do not wear watches, rings, or jewelry when
working on this truck.
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General Safety
2-4 00700-CL340-05, Issued: 2 May 2005
Follow the scheduled lubrication, maintenance,
and inspection steps.
Follow exactly the safety and repair instructions
in this manual. Do not take shortcuts.
Do not use an open flame near the truck.
Do not use gasoline or other flammable liquids
for cleaning parts.
Clean up any hydraulic fluid, oil, or grease that
has leaked or spilled on the floor.
Always park this truck indoors.
Do not park this truck in a cold storage area
overnight.
Do not wash this truck with a hose.
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General Safety
00700-CL340-05, Issued: 2 May 2005 2-5
Do not add to or modify this truck until you
contact your local Toyota Industrial Equipment
Dealer to receive written manufacturer
approval.
Battery Safety
2-6 00700-CL340-05, Issued: 2 May 2005
Battery Safety
As a battery is being charged, an
explosive gas mixture forms within and
around each cell. If the area is not
properly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure
there are no open flames or sparks in
the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. If any electrolyte comes in
contact with your clothing or skin, flush
the area immediately with cold water. If
the solution gets on your face or in your
eyes, flush the area with cold water and
get medical help immediately.
Wear personal protective equipment to protect
eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields), and a rubber apron.
Make sure a shower and eyewash station are
nearby in case there is an accident.
A battery gives off explosive gases. Never
smoke, use an open flame, or use anything that
gives off sparks near a battery.
Keep the charging area well-ventilated to avoid
hydrogen gas concentration.
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Battery Safety
00700-CL340-05, Issued: 2 May 2005 2-7
Press the red OFF key (O) on the keypad before
disconnecting the battery from the truck at the
battery connector. Do not break live circuits at
the battery terminals. A spark often occurs at
the point where a live circuit is broken.
Do not lay tools or metal objects on top of the
battery. A short circuit or explosion could
result.
Keep batteries clean. Corrosion causes shorts
to the frame and possibly sparks.
Keep plugs, terminals, cables, and receptacles
in good condition to avoid shorts and sparks.
Keep filler plugs firmly in position at all times
except when the electrolyte level is checked,
when water is added to the cells, or when the
specific gravity is checked.
Make sure the vent holes in the filler plugs are
open to permit the gas to escape from the cells.
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Vent Hole
Battery Safety
2-8 00700-CL340-05, Issued: 2 May 2005
Do not permit cleaning solution, dirt, or any
foreign matter to enter the cells.
Make sure you install the correct size battery. A
smaller or lighter weight battery could seriously
affect truck stability. See the trucks
specification plate for more information.
Never plug a battery charger into the trucks
battery connector. Plug the battery charger only
into the battery connector from the battery.
Follow the charging procedures in the Battery
Instruction Manual and in the Battery Charger
Instruction Manual.
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Jacking Safety
00700-CL340-05, Issued: 2 May 2005 2-9
Jacking Safety
When it is necessary to jack the truck off the
floor to perform maintenance procedures,
observe the following safety precautions:
1. Lower the forks completely. Remove any
load.
2. Position all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Press the red OFF key (O) on the keypad
and disconnect the battery connector.
5. Position the jack under the designated
jacking points.
Use extreme care when the truck is
jacked up. Keep hands and feet clear
from vehicle while jacking the truck.
After the truck is jacked, position solid
blocks beneath it to support it. DO NOT
rely on the jack alone to support the
truck.
Fork Section
1. Using the lift button, raise the forks to
maximum height.
2. Block the fork section. The tractor section
will remain on the floor.
3. Lower the forks on the blocks.
Tractor Section
1. Position the jack in the designated jacking
position.
2. Jack one side of the truck so that the drive
tire is off the floor no more than 1 in.
(25.4 mm).
3. Block that side of the truck in place.
4. Jack the other side of the truck level with
the first side.
5. Block that side of the truck in place.
NOTE: After working on a vehicle, test all
controls and functions to assure correct
operation.
Towing
2-10 00700-CL340-05, Issued: 2 May 2005
Towing
To safely tow this truck:
1. Lower the forks and remove any load.
3. Using a suitable towing vehicle, lift the
tractor end of the truck until the drive tire
is no more than 1 in. (25.4 mm) off the
floor.
4. Tow the truck slowly in the tractor-first
direction.
NOTE: If a suitable towing vehicle is not
available, the electromagnetic brake
must be disabled to move this truck. See
Mechanically Releasing the Brake on
page 6-34.
Welding Safety
00700-CL340-05, Issued: 2 May 2005 2-11
Welding Safety
Flame cutting or welding on painted
surfaces may produce potentially
harmful fumes, smoke and vapors. Prior
to performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where
the operation(s) will be performed.
Coating removal may be by mechanical
methods, chemical methods or a
combination of methods. Flame cutting
and/or welding operations must be
carried out only in well ventilated areas
using local exhaust if necessary.
Before working on this truck, make sure that:
Fire protection equipment is nearby.
You know where the nearest eyewash
station is located.
Disconnect the battery before you attempt
to inspect, service, or repair the lift truck.
Discharge residual charge in the power
amplifier by connecting a load across the
power amplifiers B+ and B (such as a
contactor coil or by pressing the horn
button).
Do a test for shorts to frame. See
Checking for Shorts from Components to
Truck Frame on page 5-3. If any shorts
are detected, remove them before you
proceed with the welding operation.
Clean the area to be welded.
Protect all truck components from heat,
weld spatter, and debris.
Attach the ground cable as close to the
weld area as possible.
Do not perform any welding operations
near the electrical components.
If welding must be done near the battery
compartment, remove the battery from the
truck.
When you are finished welding, perform all
ground tests and electrical inspections
before the vehicle is operated.
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Static Safety
2-12 00700-CL340-05, Issued: 2 May 2005
Static Safety
Electronic circuit boards and devices used on
this truck can be damaged by the discharge of
static electricity, called electrostatic discharge.
Static charges can accumulate from normal
operation of the truck as well as movement or
contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
on shoes, styrofoam coffee cups, etc.).
Accumulated static can be discharged through
human skin to a circuit board or component by
touching the parts. Static discharge is also
possible through the air when a charged object
is placed close to another surface at a different
electrical potential. Static discharge can occur
without you seeing or feeling it.
Whenever working on or near static-sensitive
electronics, always use static discharge
precautions.
1. Place a static discharge wrist strap around
your wrist. Connect the ground lead to the
wrist strap connector.
2. Connect the ground strap to an
unpainted, grounded surface on the truck
frame.
3. If you are removing or installing
static-sensitive components, place them
on a correctly grounded static mat.
4. To transport static-sensitive components,
including failed components being
returned, place the components in an
anti-static bag or box (available from your
Toyota Dealer).
The wrist strap and associated accessories
should be tested monthly to verify they are
working correctly. A defective static discharge
wrist band will not alert you that it is bad.
Figure 2-1 shows the components of the Toyota
anti-static field service kit, part number
00590-04849-71. The kit includes a wrist strap,
ground cord and static-dissipative work surface
(mat). Follow the instructions packaged with
this kit.
Wrist straps are available in quantities of 25, as
part number 00590-04848-71.
A wrist strap tester is available as part number
00590-04850-71.
Contact your authorized Toyota Dealer for
information.
Figure 2-1. Anti-Static Kit With Wrist Strap and Mat
Static-Dissipative
Work Surface
Wrist Strap
Ground Cord

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Toyota Model 7HBW23 Service Manual Section 3. Systems Overview
00700-CL340-05, Issued: 2 May 2005 3-1
Section 3. Systems Overview
Section 3. Systems Overview Toyota Model 7HBW23 Service Manual
Truck Model Identification
3-2 00700-CL340-05, Issued: 2 May 2005
Truck Model
Identification
Vehicle Specifications
The total weight of the load must include
the pallet and the container or the
device holding the load.
1581 001.tif
Figure 3-1. Model 7HBW23 Pallet Truck
Category
Maximum Load Capacity 4,500 lb. (2,041 kg)
Upright Height 50.8 in. (129.1 cm)
Overall Length (Handle Raised) up to 81.8 in. (207.8 cm)
Overall Width 28.0 in. (711 mm)
Maximum Lift Height 8.65 in. (219.7 mm)
Regular Speed, Maximum 3.9 mph (6.3 kph)
Stopping Distance 6 ft. (1.83 m)
Battery Compartment Width 7.8 or 9.0 in. (198 or 228 mm)
Battery Voltage 24V
Minimum Battery Weight 200 lb. (91 kg)
Maximum Battery Weight 660 lb. (299 kg)
Truck Weight Without Battery 800 lb. (362 kg)
Wheel: Drive 10 x 5 in. Rubber
Wheel: Load 3.25 x 5 in. Polyurethane (2)
General Information
00700-CL340-05, Issued: 2 May 2005 3-3
General Information
Figure 3-2. Model 7HBW23 General Information
Drive Unit
Page 6-27
Battery
Page 6-4
Control Handle
Page 6-14
Pallet Forks and
Load Wheels
Page 6-45
Special Tools
3-4 00700-CL340-05, Issued: 2 May 2005
Special Tools
Programmable Maintenance
Tool
The optional Programmable Maintenance Tool
(PMT) (P/N 00590-49981-71) permits you to
test and diagnose the power amplifier in the
truck. See Figure 3-3.
The PMT is powered by the host power amplifier
through the four-pin connector installed at the
bottom of the power amplifier.
Service Key
Use the optional Service Key
(P/N 00590-42683-71) directly on the truck to
troubleshoot and program the truck service
parameter settings. See Parameters (P) on
page 5-17.
27y7s021.tif
Figure 3-3. Programmable Maintenance Tool Figure 3-4. Service Key
Theory of Operation
00700-CL340-05, Issued: 2 May 2005 3-5
Theory of Operation
Truck Starting
To start the truck, the battery is plugged in, the
Master Control ON/OFF switch is in the ON
position, the PIN-key code is entered in the
keypad, and the green ON (|) key pressed (or
optional key switch is ON). See Service
Display on page 5-21.
Lift/Lower
The lift/lower system consists of an electrically
operated hydraulic pump assembly and related
components.
The hydraulic pump assembly consists of a
positive displacement rotary gear pump with
reservoir mounted to an adapter. A DC electric
motor is mounted to the opposite side of the
pump adapter. An adjustable relief valve, check
valve, and a solenoid operated lowering valve
are installed within the adapter.
With the forks elevated, the normally closed
solenoid valve and the check valve prevent
hydraulic fluid from returning to the reservoir.
Lift
When the battery is connected, the truck is ON,
and the lift button pressed:
a lift signal is detected via hall effect
sensors, converted into the lift instruction,
and transmitted via the Controller Area
network (CAN) to the power amplifier.
the lift pump contactor (K30) closes,
applying B+ to the lift pump motor (M3)
causing the lift pump to operate.
hydraulic fluid is drawn into the lift pump.
as the pump rotates, oil is forced out the
pressure port through the lift hose to the
lift cylinder. Oil cannot return to the
reservoir because of the closed pressure
relief valve and closed lowering solenoid
valve.
hydraulic pressure in the lift cylinder
raises the forks.
lift limit switch (S36) transmits a lift limit
signal to the power amplifier which
removes power to the lift motor when the
forks reach a preset lift limit.
When the lift button is released:
the pump contactor coil (K30) is
de-energized. This stops the lift motor and
pump. The forks are held in position by
hydraulic fluid trapped in the cylinder by
the check valve, the static position of the
relief valve, and the closed lowering
solenoid valve (Y10).
the relief valve opens if the hydraulic
pressure exceeds the preset limit.
Lower
When the battery is connected, the truck is ON,
and the lower button is pressed:
lower signal is detected via hall effect
sensors, converted into the lower
instruction, and transmitted via the CAN
to the power amplifier.
lowering solenoid valve (Y10) opens.
hydraulic fluid in the lift cylinder returns
to the hydraulic reservoir through the
lowering valve and the flow control valve.
The lowering speed is regulated by the flow
control valve.
the forks lower.
Direction/Speed Control
The following descriptions assume the battery is
charged and connected, the truck is ON, and
main contactor (K10) is energized.
Control Handle Positioning
When the control handle is in the full upright
position, the parking brake is engaged. When
the control handle is positioned from 6 to 46 of
the full upright position, the brake disengages e
Theory of Operation
3-6 00700-CL340-05, Issued: 2 May 2005
(when travel is requested), Arm Angle B switch
(S25) closes and enables slow speed travel.
When the control handle is placed beyond 46
from the full upright position, Arm Angle A
switch (S24) also closes, enabling fast speed
travel. When the control handle is placed in the
bottom 8 of its operating range, Arm Angle B
switch opens, activating the parking brake.
Travel Request, Forks Trailing
When the thumb controls are rotated in the
forward direction (tractor-first) from neutral:
a forward travel signal is detected via hall
effect sensors, converted into a travel
instruction in the ETAC (See Electronic
Tiller Arm Card (ETAC) on page 3-7.) and
transmitted via the Controller Area
network (CAN) to the power amplifier.
the ETAC verifies that the emergency
reverse button is not activated before
supplying the travel command to the
power amplifier.
the ETAC verifies that switch S25 (Arm
Angle B) is engaged for slow speed mode.
the ETAC verifies that both switch S24
(Arm Angle A) and switch S25 (Arm Angle
B) are engaged for fast speed mode.
the voltage at M of the drive motor will
vary from 24V to 1V. The voltage is
proportional to the position of the thumb
controls.
the drive wheel starts to rotate in forward
direction at a speed proportional to the
voltage at M.
Travel Request, Forks-First
When the thumb controls are rotated in the
reverse direction (forks-first) from neutral:
reverse travel signal is detected via hall
effect sensors, converted into a travel.
instruction in the ETAC, and transmitted
via the CAN-bus to the power amplifier.
the ETAC verifies that the emergency
reverse button is not activated before
supplying the travel command to the
power amplifier.
the ETAC verifies that switch S25 (Arm
Angle B) is engaged for slow speed mode
the ETAC verifies that both switch S24
(Arm Angle A) and switch S25 (Arm Angle
B) are engaged for fast speed mode.
the voltage at M of the drive motor will
vary from 24V to 1V. The voltage is
proportional to the position of the thumb
controls.
the drive wheel starts to rotate in reverse
direction at a speed proportional to the
voltage at M.
Emergency Reverse
If the emergency reverse button (belly button) is
closed with the control handle lowered in travel
mode, the control system provides an
immediate, rapid acceleration in the reverse
(forks-first) direction. The following occurs:
the emergency reverse signal is converted
into a reverse travel instruction and
transmitted via the CAN-bus to the power
amplifier.
travel and speed inputs are ignored.
the power amplifier provides maximum
torque immediately after the emergency
reverse button is activated.
maximum reverse travel continues until
the emergency reverse button is released.
Theory of Operation
00700-CL340-05, Issued: 2 May 2005 3-7
Power Amplifier
The basic functions of the power amplifier
includes:
the direction control section that controls
the drive motor direction by manipulating
the drive motor field polarity according to
the directional signal inputs from the
ETAC.
the speed control section that controls the
drive motor speed and torque by
monitoring the position change of the Arm
Angle A and Arm Angle B switches.
Variable motor speed is accomplished by
separate control of field and armature
currents.
the emergency reverse circuitry in the
ETAC which provides the directional travel
control commands to the power amplifier.
the control circuit section which controls
all truck inputs and outputs (excluding
handle head inputs).
Electronic Tiller Arm Card (ETAC)
The programmable motor control functions are
performed by the electronic circuitry housed
within the control handle [Electronic Tiller Arm
Card (ETAC)]. The basic functions of the ETAC
include:
monitoring relative positioning of the
thumb controls to eighteen hall effect
sensors for speed and direction control
monitoring the position of the emergency
reverse button for emergency reversing of
the truck direction
monitoring truck performance and
providing input data and commands to the
service display
providing lift/lower input commands to
the power amplifier
monitor horn switches S18-1 and S18-2
for horn operation
monitoring and defining truck
performance parameters
Theory of Operation
3-8 00700-CL340-05, Issued: 2 May 2005

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Toyota Model 7HBW23 Service Manual Section 4. Planned Maintenance
00700-CL340-05, Issued: 2 May 2005 4-1
Section 4. Planned Maintenance
Section 4. Planned Maintenance Toyota Model 7HBW23 Service Manual
Maintenance Guidelines
4-2 00700-CL340-05, Issued: 2 May 2005
Following a planned maintenance program:
Promotes maximum truck performance
Prolongs truck life
Reduces costly down time
Avoids unnecessary repairs
Planned maintenance includes:
Lubrication
Cleaning
Inspection
Service
Perform all of the scheduled checks and
maintenance during the suggested intervals.
The intervals given in this guide are based on
normal operating conditions. When operating
under abnormal or severe conditions, perform
these services more often as necessary to keep
the unit in good operating condition.
See Lubrication Equivalency Chart on
page A-2. Refer to the manufacturers
supplements for components not listed on the
following pages.
Maintenance Manual
Use this manual as required to perform all
repair procedures listed in the Planned
Maintenance Schedule.
Planned Maintenance Schedule
Perform all inspections and lubrication in
accordance with the Planned Maintenance
Schedule. See Lubrication Equivalency Chart
on page A-2.
NOTE: Daily (8 hour) inspections should be
performed by an authorized
Owner-Employee.
All listed repairs should be scheduled
for a convenient time between an
authorized Customer Representative
and the Qualified Service Technician. All
repairs should be carried out AFTER the
planned maintenance tasks are
completed. Labor and parts for repairs
should be calculated as part of the
standard truck maintenance costs,
separate from the planned maintenance
charges.
Time Requirements
Performing Planned Maintenance will require
approximately 0.75 hour.
General Truck Operation
Operate all functions of the truck and
check for any abnormal operation
Talk to the operator to see if any problems
were noticed
Check to see if all the safety and
operational decals are in place and legible
List repairs required
00700-CL340-05, Issued: 2 May 2005 4-3
Daily
Perform the daily checks and report any faults
or abnormal conditions to your supervisor.
Item Daily or Eight-Hour Checklist
Battery Check cleanliness and exterior condition. See Battery Maintenance on
page 6-5.
Check the charge.
Check the weight.
Check the free play of the battery. Make sure the battery does not
move more than 0.5 in. (13 mm) in any direction.
Battery Connector Check the connector. Make sure all powered functions shut down when
disconnected.
Make sure the battery is properly installed.
General Operation Check that the horn operates when you press the horn button. (Battery
must be connected and the Master Control ON/OFF switch must be
ON.)
Check the speed and thumb controls.
Check the steering operation.
Check the lifting and lowering functions.
Check the operation of the emergency reverse button.
Check the operation of the Master ON/OFF Switch.
Note any unusual noise during operation, and report it to your
supervisor or maintenance personnel.
Brake/Control
Handle
Verify the drive motor does not run while the brake is applied.
Check that the control handle returns to the vertical position when
released.
Decals Warning/Safety/Operational decals must be in position and legible.
Contact your local authorized Toyota Industrial Equipment Dealer if
any decal is damaged or missing.
Hydraulic System Check for oil leaks.
Wheels/Tires Check the condition of the drive wheel and load wheels. Remove any
steel chips and foreign material to prevent damage to the wheels.
Check for gouging and chunking of the surface. If damaged, report to
your supervisor or maintenance personnel.
4-4 00700-CL340-05, Issued: 2 May 2005
Every Two Months or 250 Operating Hours
Perform daily checks plus the following:
Item Every Two Months or Every 250 Operating Hours
Grease Fittings Lubricate all grease fittings.
Forks Check the lift-limit switch for lift motor cut-out. Adjust if necessary
Lubrication Points Lubricate all levers, shafts ,and linkage points.
Lift Cylinder Check the lift cylinder for leaks. Repair or replace cylinder if
necessary. See Hydraulic Cylinder on page 6-47.
Hydraulic System Check for correct fluid level with the forks fully lowered to within
1 in. (25.4 mm) of filler plug. Add fluid if necessary. See
Lubrication Equivalency Chart on page A-2.
Check hydraulic connections and mountings.
Check the tightness of the pump and motor hardware.
Check hoses, tubes, and fittings for leaks. Replace hoses or seals.
Clean the fill/vent plug. See Hydraulic Unit on page 6-49.
General Check for loose hardware. Tighten if necessary.
Check the tightness of the drive unit mounting bolts. Tighten if
necessary.
Electrical System Visually inspect all cables for damage. Replace if necessary. See
Power Cables on page 6-10.
Check for electrical shorts to frame. See Checking for Shorts from
Battery to Truck Frame on page 5-3.
Master Control Relay Check contacts for welded condition. See Inspection/Test on
page 6-21.
Drive Wheel Check the tightness of the mounting bolts on the drive wheel.
Torque to 55 ft. lb. (75 Nm).
Drive Unit Check for oil leaks. If leaks are found, check the oil level. If the oil
level is low, determine the cause. See Drive Unit on page 6-27.
Check the transmission pivot bearing.
Motor Brushes Check the condition of brushes, springs, and holders.
Check that the brush length exceeds the minimum length.
Drive motor - 0.59 in. (15 mm)
Hydraulic pump motor - 0.35 in. (9 mm)
Arm Angle Switches Check adjustment.
Load Wheel Check the load wheel bearings and linkage.
Brake Check the brake disc for wear. Adjust or replace if necessary. See
Electromagnetic Brake on page 6-33.
Battery System Clean the battery and the truck. See Battery Maintenance on
page 6-5.
00700-CL340-05, Issued: 2 May 2005 4-5
Annually or Every 1500 Operating Hours
Perform Every Two Month checks plus the
following:
Grease Fittings
Item Annually or Every 1500 Hours
Drive Housing Change the oil in the drive housing.
See Drive Housing Lubrication on page 6-30.
Figure 4-1: Load Wheel Axle (Cold Storage and
Corrosion Protection Options only)
4-6 00700-CL340-05, Issued: 2 May 2005

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting
00700-CL340-05, Issued: 2 May 2005 5-1
Section 5. Troubleshooting
Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual
How to Use This Chapter
5-2 00700-CL340-05, Issued: 2 May 2005
How to Use This Chapter
This section uses decision-tree charts and
symptom tables designed to take you from a
symptom to a specific sequence of tests in order
to isolate a failing component.
Use the TS1: START
TROUBLESHOOTING on page 5-31 to
guide you to the individual symptom chart
you need.
When youre familiar with the symptoms
listed, you may instead simply look up the
symptom chart from the List of
Troubleshooting Charts/Tables on
page 5-29.
As you work with a troubleshooting symptom
table, you may be instructed to test various
electrical connector pins.
Every time you complete a troubleshooting
procedure, make sure you follow the steps in
the END1: End of Troubleshooting
Procedure on page 5-33.
If the troubleshooting symptom tables do not
isolate the problem, or if the symptoms are not
consistent or repeatable, go to GEN1: General
Troubleshooting on page 5-31. This chart
will help you approach the problem in a
systematic and logical manner.
Electrical Troubleshooting Guidelines
00700-CL340-05, Issued: 2 May 2005 5-3
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. Check
the electrolyte level and state-of-charge. See
Battery on page 6-4. Block the truck
whenever a troubleshooting procedure requires
turning the key switch ON. This avoids
accidents caused by unexpected truck travel.
Unless otherwise directed, disconnect
the battery connector when you check
electrical circuits or components with an
ohmmeter. Electrical current can cause
damage to the ohmmeter.
Save time and trouble by looking for simple
causes first.
Visually inspect all wiring and electrical
components for:
loose connections or connectors
loose or broken terminals
damaged terminals, blocks, or strips
broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
Use an ohmmeter to check for wiring continuity
and shorts.
For information on pin, connector, and harness
connections, see Wiring Harness on page 6-11
and List of Electrical Symbols on page 5-8.
Checking for Shorts from
Battery to Truck Frame
1. Press the red OFF (O) key on the keypad
2. Using a voltmeter set on a 50 VDC scale.
attach the leads as follows:
negative () lead to an unpainted,
grounded surface on the truck frame
positive (+) lead to the positive battery
terminal
The voltmeter must show no more than
3V.
3. Now attach the leads as follows:
negative () lead to the negative battery
terminal
positive (+) lead to an unpainted,
grounded surface on the truck frame
The voltmeter must show no more than
3V.
4. If you get more than a 3V reading in Steps
2 or 3:
a. Remove the battery from the truck. See
Battery on page 6-4.
b. Thoroughly clean the battery. See
Battery Maintenance on page 6-5.
c. Reinstall the battery.
d. Repeat steps 2 and 3 to see if this has
eliminated the problem.
e. If excessive voltage is still found, have
the battery checked for internal
leakage.
Checking for Shorts from
Components to Truck Frame
2. Use an ohmmeter and measure the
resistance to an unpainted, grounded
surface on the frame at B+, B, and all
fuses.
A resistance reading of less than
1000 ohms indicates a serious short to
frame. If this condition exists, find the
source of low resistance or short to frame
using step 6. Do not continue until this
condition is corrected.
3. Remove the battery from the truck. See
Battery on page 6-4.
4. Connect the battery lead to the truck.
5-4 00700-CL340-05, Issued: 2 May 2005
5. Use an ammeter to measure the leakage
current to an unpainted, grounded surface
on the frame at B+, B, all fuses, and all
motors. If the current is less than 0.001
ampere (1mA), the truck system passes. If
the current exceeds 1mA, go to step 6.
6. To find the cause of the low resistance,
disconnect the power cables from each
motor or major subassembly one at a time,
to determine if that item is causing the low
resistance.
Hydraulic Troubleshooting Guidelines
00700-CL340-05, Issued: 2 May 2005 5-5
Hydraulic Troubleshooting Guidelines
When you check voltage at solenoids, make
sure hydraulic lines and components are fully
installed.
Use an ohmmeter to check for wiring continuity
to solenoids.
Unless otherwise directed, disconnect
the battery connector when you check
electrical circuits or components with an
ohmmeter. Electrical current can cause
damage to the ohmmeter.
Visually inspect all hydraulic lines and
components for:
Leaking connections or connectors
Loose or broken fittings
Damaged tubing, hoses, vents, or seals
Definitions
5-6 00700-CL340-05, Issued: 2 May 2005
Definitions
Acceleration
The process where the trucks acceleration
characteristic is determined when the truck
starts from a stop. This is a operator parameter
(Acceleration). The range is from 30% to 90% in
increments of 5%. Default is 80%. A lower
number gives less aggressive acceleration. See
Parameters (P) on page 5-17.
Arm Angle Switches
The Arm Angle Switches (S24 and S25)
determine brake activation and truck travel
speed. Each switch is activated by the control
handle. The control handle must be positioned
between 6 of vertical and 8 of horizontal for
the switches to be closed. See Figure 5-1.
When the control handle is in the full upright
position, the parking brake engages. When the
control handle is positioned from 6 to 46 of
the full upright position, the brake disengages
(when travel is requested), Arm Angle B switch
(S25) closes and enables slow speed travel. See
Table 5-2. When the control handle is placed
beyond 46 from the full upright position, Arm
Angle A switch (S24) also closes, enabling fast
speed travel. When the control handle is placed
within 8 of horizontal, Arm Angle switch B
opens, activating the parking brake.
Continuity
A continuous and uninterrupted path between
two or more locations in an electrical circuit,
typically having a resistance of less than 1 ohm.
Creep Speed
Creep speed is a service parameter that defines
speed at low throttle positions. Creep speed
range is adjustable from 10 to 10. The factory
default value is 5. A negative number
enhances low speed maneuverability. A positive
number makes the truck more responsive. See
Parameters (P) on page 5-17.
Current Limiting
A protective function of the power amplifier that
prevents excessive current levels from
damaging drive components.
Deceleration
The process where the trucks braking
(regenerative) characteristic is determined by
any reduction in throttle, including neutral.
This is a operator parameter (Deceleration). See
Parameters (P) on page 5-17. The range is
from 40% to 90% in increments of 5%. Default
is 65%. A lower number gives less aggressive
deceleration.
Emergency Reverse
Emergency Reverse is activated when the
emergency reverse button is pressed while the
control arm is in a drive position. After the
button is released, normal operation is
resumed.
ETAC (Electronic Tiller Arm Card)
Programmable motor control functions are
performed by the electronic circuitry (ETAC)
housed within the control handle. See
Electronic Tiller Arm Card (ETAC) on
page 3-7.
1820 001.EPS
Figure 5-1. Arm Angle Switches and Brake Actuation
Table 5-2. Control Handle/Switch Positions
Position A Switch B Switch Function
Top 6 Open Open Brake Applied
6 to 46 Open Closed Slow Speed
46 plus Closed Closed Fast Speed
Bottom 8 Closed Open Brake Applied
6
8
Definitions
00700-CL340-05, Issued: 2 May 2005 5-7
Fault Codes
The ETAC provides fault information by
displaying fault codes via the LED display built
into the handle head. See Power Amplifier
Fault Codes on page 5-24.
Open Circuit
A lack of a continuous path between two or
more electrical connections; usually greater
than one megohm resistance.
Overvoltage Cutoff
Occurs when there is very high voltage (greater
than 34V) at the power amplifier B+ connection.
Code C42 or E142 may be displayed and the
truck must be restarted.
PIN-Key Code
Trucks produced with a standard handle
mounted keypad are protected from
unauthorized operation by Personal
Identification Number (PIN) keypad entry codes.
Up to 10 operators can be assigned their own
individual PIN-key code (of one to four digits) for
access to the truck. Each operator can also set
individual driver parameters. The default
operator PIN-key code is number 1.
Short Circuit or Short
A short circuit is an unspecified path in a
circuit that provides unwanted full or partial
continuity between two or more locations in an
electrical circuit.
Example 1: Two insulated wires are physically
next to each other and the insulation has worn
off each of the wires. The conductors are now
touching each other, causing a short circuit.
Example 2: The insulation has worn away on a
power cable from the battery to a junction post
in the truck. The wire conductors are touching
the tractor frame, causing a short circuit of the
battery cable.
Speed Limiting
The ETAC limits maximum speed:
Max speed, Slow Mode parameter
determines the maximum speed value sent
by the ETAC to the power amplifier (max.
PWM) for both directions of travel while in
Slow. This is a programmable parameter.
Max speed, Fast Mode parameter
determines the maximum speed value sent
by the ETAC to the power amplifier (max.
PWM) for both directions of travel while in
Fast. This is a programmable parameter.
Thermal Cutback (Power
Amplifier)
Thermal cutback of the power amplifier is below
13F (25C) or above 185F (85C). At 185F
to 203F (85C to 95C), the PWM drive current
limit is linearly decreased from full set current
down to zero. At 13F to 40F (25C to
40C), the current limit is reduced to approx.
half the set current, resulting in reduced travel
speed. Below 40F (40C) or above 203F
(95C), the allowed PWM is 0%.
Tractor
The body section of the truck that contains the
motors, drive unit, controls, and handle.
Truck Off Delay (Keypad only)
Sets the truck OFF delay time (energy saving
feature). If this time delay passes while the
truck is in a brake position and the truck is idle
(no inputs requested), the ETAC powers the
truck OFF. Driver parameter settings are 0 to
20 minutes. When the parameter is set to 0, or
the truck has the key switch option, the truck
never powers OFF.
Undervoltage Cutoff
Occurs when there is very low voltage (less than
13V) at power amplifier B+ connection. Code
C41 is displayed and the truck must be
restarted.
List of Electrical Symbols
5-8 00700-CL340-05, Issued: 2 May 2005
List of Electrical Symbols
Refer also to electrical schematics found in the Appendix and wiring harness component
procedures.
Table 5-3. List of Symbols
Symbol Description Function Remark
A1 Power Amplifier Drive motor controller
A2 Electronic tiller arm card Vehicle controller
A6 Operator display Displays various functions
A17 Keypad PIN inputs and access
maintenance modes
Trucks with keypad
B+ Battery Positive 24V
B Battery Negative 24V
CB1 Circuit Breaker Drive/Pump motor circuit 110 amp
F50 Fuse Keypad and tiller arm card 10 amp
F51 Fuse Main control 10 amp
H1 Horn
J11 Wire Connection Handle stem base
J41 Wire Connection Service key (CAN)
K4 Relay Main
K10 Contactor Main
K30 Contactor Pump motor
M1 Motor Drive
M3 Motor Pump
R1 Resistor Pre-charge PTC
S17 Switch Key Trucks with key switch
S18 Switch Horn
S21 Switch Master Control ON/OFF
S24 Switch Arm Angle A
S25 Switch Arm Angle B
S36 Switch Lift limit
Y1 Coil Brake
Y10 Coil Lower valve
Control Handle Display and Programming
00700-CL340-05, Issued: 2 May 2005 5-9
The display located on the top of the control
handle displays the operator and
machine-specific register.
Special Truck Mode
To enter a special truck mode:
1. Press and hold the horn button (S18). At
the same time turn the key switch ON, or
enter the operator-specific PIN-key code
on the keypad, then press the green ON (I)
key on the keypad.
2. Continue to hold the horn button while
the display (see Figure 5-4) cycles through
the following functions:
H = Hour Meter
E = Error Codes
P = Parameters
Pn = Hardware and Software Part
Numbers
3. Release the horn button at the selected
display.
Hour Meter (H)
To change Hour Meter settings:
1. Enter the special truck mode.
2. Continue to hold the horn button until H
is displayed. The hour meter indicator
(hourglass icon) is illuminated. See
Figure 5-4.
3. Choose the desired time to be displayed by
pressing the thumb controls:
A. = key time
b. = activity time (drive, lift, lower)
c. = drive motor time
d. = pump motor time
s. = time to service
Press the thumb control to step between
the different functions. The display shows
the number of hours for each function. See
Parameter 20 on page 5-20.
4. Press the red OFF (O) key on the keypad to
end the hour meter display.
Error Codes (E)
When an error occurs, a code is displayed. See
Caution and Error Codes on page 5-10.
Error Code History
To access Error Code History:
1. Enter the special truck mode. See Special
Truck Mode on page 5-9.
2. Press and hold the horn button until E is
displayed. The error indicator (wrench
icon) is illuminated. See Figure 5-4.
Use the thumb control to scroll through
the last 50 error codes. The latest fault
is shown first. The display first shows
the error code and then the hour the
fault occurred.
The error codes are divided into two
groups C = caution and E = error.
The C error codes are not stored. It is
only a caution and is highlighted on the
display as long as the fault exists.
For example, if you only have one fault
registered in the memory, the second
empty place is shown like this: Fault: E
- - - and time: - - - -.
3. End displaying the error code history by
pressing the red OFF (O) key on the
keypad.
5
Figure 5-4. Control Handle Display
A
B C D E
A
C E D B
Explanation of
Symbols:
A = Numerical Field
B = Hour Meter
Indicator
C = Parameter
Control
D = Battery
Indicator
E = Error Indicator
5-10 00700-CL340-05, Issued: 2 May 2005
Caution and Error Codes
Code C14 - Arm Angle Reference Warning
Reason Control handle was not in up position at power ON or after the truck has not
been used for a time.
Performance Limits Travel is not allowed until code is cleared.
How to Clear Code Code is cleared when tiller arm is moved to upright (Top Brake) position.
Possible Causes
and Corrective
Actions
Control handle stuck in down position
a. Check up-stop
Arm angle input stuck ON
a. Check arm angle switch A and B for correct operation. Repair or
replace as necessary.
b. Check input to power amplifier.
Code C19 - Default parameter warning
Reason Parameter(s) out-of-range, or incompatible with software version.
Performance Limits Truck functions are not allowed until after this code is cleared.
How to Clear Code Parameter area is automatically corrected and then code is cleared.
Possible Causes
and Corrective
Actions
ETAC parameter area is bad.
If the code does not clear after 10 seconds, try restarting the truck.
Cycle the truck OFF then ON. If the code does not automatically clear,
replace the ETAC.
Code C20 - Thumb Control Warning
Reason Thumb control was not in neutral position at power ON, or a throttle
position sensor failure was detected. See Code E160 - Error In Reversing
Circuit on page 5-15.
Performance Limits Truck functions are not allowed until code is cleared.
How to Clear Code Code is cleared after problem is corrected.
Possible Causes
and Corrective
Actions
Thumb control is stuck in drive position.
ETAC is bad.
Check the mechanical portions of the throttle controller. Give special
attention to the magnet arm alignment with the ETAC sensors and to the
non-metallic parts of the emergency reverser.
Code C28 - Master Control ON/OFF Switch Warning
Reason Power amplifier could not be reset via the CAN-bus at power ON, or power
amplifier reports Master Control ON/OFF switch is open.
Performance Limits Truck functions are not allowed after this code has been set.
How to Clear Code This code can only be cleared after the problem is resolved and truck is
cycled OFF/ON.
00700-CL340-05, Issued: 2 May 2005 5-11
Possible Causes
and Corrective
Actions
Master Control ON/OFF switch activated
Low voltage to power amplifier (especially while lifting or driving) due to
over-current or short-circuit.
Try a known-good battery
PTC R1 missing, faulty, or tripped (very high resistance, due to excessive
current while main contactor is open; should automatically recover).
Carefully check to see if R1 is hot (tripped). If so, unplug battery and
allow it to cool. Locate low impedance path that tripped R1 and correct.
Wire #24 at 0V due to J5 not connected, blown fuse, or bad wiring.
Check for 24 V at J5-16
Short or open circuit in CAN wiring, or electrical noise in CAN wiring due
to bad connection or outside interference, both at power ON.
Check CAN wiring
Try operating truck in different environment
Bad power amplifier
Code C28 - Master Control ON/OFF Switch Warning
Code C29 - Time To Service Warning
Reason See Service Parameter 25 on page 5-19.
Performance Limits None
How to Clear Code See Service Parameter 25 on page 5-19.
Possible Causes
and Corrective
Actions
Time to perform service or service counter not reset after last service.
Code C41 - Battery Undervoltage Warning
Reason Voltage at power amplifier B+ connection less than 17V. Note: Low voltage
can also cause problems such as electrical components not powering
up/staying activated and CAN errors.
Performance Limits Truck functions are allowed unless the voltage was below 13V. If voltage was
below 13V, the truck must be restarted. (Code C28 may be displayed)
How to Clear Code Code is cleared when voltage recovers.
Possible Causes
and Corrective
Actions
Battery voltage less than 17V
Time to charge battery
Check for correct voltage
Battery parameter not adjusted correctly.
Circuit breaker open due to overloading, or short circuit (a misadjusted
brake may have caused overloading leading to an open circuit breaker).
Open circuit to power amplifier B+ connection.
Check cabling
Bad power amplifier
Code C42 - Battery Overvoltage Warning
Reason High voltage (greater than 30V) at power amplifier B+ connection.
Performance Limits When 34V is exceeded, overvoltage cutoff occurs and no truck functions are
allowed. Truck may need to be restarted (Code E142 may be displayed)
How to Clear Code Code is cleared when voltage recovers.
5-12 00700-CL340-05, Issued: 2 May 2005
NOTE: For 100 series error codes, throttle is
not allowed, outputs are off (brake is
engaged), and main contactor is
dropped. Code is cleared when problem
is resolved and truck is cycled OFF/ON
(unless otherwise noted).
Possible Causes
and Corrective
Actions
High battery voltage.
Check for correct voltage
Battery may be overcharged
Extreme regenerative braking.
Battery charger attached to truck.
Code C42 - Battery Overvoltage Warning
Code C43 - Power Amplifier Thermal Cutback
Reason High or low temperature (above 185F [85C] or below 13F [25C]) at
power amplifier heat sink.
Performance Limits Truck functions may be allowed.
How to Clear Code Code is cleared when power amplifier heat sink temperature recovers.
Possible Causes
and Corrective
Actions
Operating in extreme environment.
Excessive load on vehicle.
Check brake adjustment
Reduce the value of parameters 2, 3, and/or 4 to help decrease motor
temperature.
Incorrect power amplifier mounting.
Bad power amplifier.
Code C44 (hot is displayed) - Traction Motor Thermal Cutback
Reason High traction motor temperature detected.
Performance Limits Truck functions are allowed, but maximum speed value sent to power
amplifier is reduced.
How to Clear Code Code is cleared when temperature recovers.
Possible Causes
and Corrective
Actions
Operating in extreme environment,
temperature.
Airflow to motor restricted.
Bad motor wiring, or bad motor.
Code C46 - Severe Traction Motor Thermal Cutback
Reason Very high traction motor temperature or extreme operation detected.
Performance Limits Truck functions are allowed, but maximum speed value sent to power
amplifier is reduced.
How to Clear Code Code is cleared when temperature recovers.
Possible Causes
and Corrective
Actions
Operating in extreme environment,
temperature.
Airflow to motor restricted.
Bad motor wiring, or bad motor.
00700-CL340-05, Issued: 2 May 2005 5-13
Code E101 - Power Amplifier Does Not Correspond with the Type of Truck
Reason Power amplifier is not compatible with ETAC software.
Possible Cause/
Corrective Action
Replace power amplifier with correct power amplifier.
Code E104 - Brake Output Error
Reason Power amplifier could not detect presence of brake coil.
Possible Cause/
Corrective Action
Open circuit due to brake or wiring; check brake and wiring.
Brake may not be releasing or stuck on motor end bell.
Master control relay missing or stuck open.
Main contactor open circuit (especially after it has closed).
Communication error due to Programmable Maintenance Tool (PMT).
Unplug PMT and allow to completely reboot before turning truck ON.
Code E106 - Digital Output or Field Overcurrent
Reason Power amplifier attempted to deliver more current than allowed to main
contactor coil, traction motor field winding, or digital output.
Possible Cause/
Corrective Action
Check main contactor coil, traction motor field winding, digital outputs, and
associated wiring.
Replace power amplifier.
Code E107 - Contactor Off
Reason Contactor probably present but controller could not close it successfully.
Possible Cause/
Corrective Action
Problem with main contactor tips.
If contactor clicks prior to displaying this code, polish contactor tips. If
this is unsuccessful, replace contactor.
Low voltage.
Try closing contactor with a known-good battery.
Short in contactor coil wiring.
Replace contactor.
Code E108 - Contactor Welded or Missing
Reason Main contactor tips probably welded or missing.
Possible Cause/
Corrective Action
Main contactor tips welded.
Open or short circuit in contactor circuit.
Check contactor, wiring (coil), and cabling.
Code E110 - Braking System Fault
Reason Power amplifier detected problem with braking functions.
Possible Cause/
Corrective Action
Short-circuit in brake circuit.
Check brake and wiring.
5-14 00700-CL340-05, Issued: 2 May 2005
Code E112 - Arm Angle Sequence Fault
Reason Incorrect sequence of arm angle inputs.
Possible Cause/
Corrective Action
Arm angle input stuck on or off.
Problem with arm angle input wiring.
Problem with tiller arm. Check for correct sequence of arm angle switches.
Communication error due to power amplifier PMT; allow PMT to reboot
before turning truck ON.
Code E114 - Traction Motor Speed Fault
Reason Controller detected stalled traction motor.
Possible Cause/
Corrective Action
Traction motor stalled.
Excessive traction motor load at low speed. Brake may not be releasing or
stuck on motor endbell. Check brake adjustment.
Power amplifier may be bad.
Code E140 - Checksum Error
Reason ETAC software detected that checksum was invalid.
Possible Cause/
Corrective Action
Internal ETAC fault (Control handle head).
Bad software. Try downloading new software.
Code E141 - Software Problem
Reason ETAC found problem with software.
Possible Cause/
Corrective Action
Internal ETAC fault (Control handle head).
Bad software. Try downloading new software.
Code E142 - Power Amplifier Disable Error
Reason Power amplifier detected a major fault.
Possible Cause/
Corrective Action
Severe overvoltage (especially at main contactor close); check for correct
voltage.
High current through a digital output. Check power amplifier outputs and
wiring.
Open circuit in traction motor field circuit wiring or windings.
Replace power amplifier.
Code E150 - Drive Communication Error
Reason ETAC did not receive CAN data from the power amplifier.
Possible Cause/
Corrective Action
Short or open circuit in CAN wiring.
Electrical noise in CAN wiring caused by bad connection, outside
interference, or low voltage. Check CAN wiring. Try driving with a
known-good battery or in a different environment.
Bad power amplifier; ETAC internal error.
00700-CL340-05, Issued: 2 May 2005 5-15
Code E151 - Drive Communication Tx Error
Reason ETAC could not send CAN data to the power amplifier.
Possible Cause/
Corrective Action
interference, or low voltage (especially while lifting or driving) possibly
caused by over-current or short-circuit. Check CAN wiring. Try driving with
a known-good battery or in a different environment.
Code E157 - CAN-bus Off Error
Reason ETAC detected problem with the CAN-bus.
Possible Cause/
Corrective Action
Code E159 - Over Run Error
Reason ETAC detected problem with the CAN-bus.
Possible Cause/
Corrective Action
Code E160 - Error In Reversing Circuit
Reason ETAC detected problem with throttle position sensors, including the sensor
used to initiate emergency reversing. See Code C20 - Thumb Control
Warning.
Possible Cause/
Corrective Action
Check the mechanical portions of the throttle controller. Give special
attention to the magnet arm alignment with the ETAC sensors and to the
non-metallic parts of the emergency reverser.
Bad ETAC.
Code E161 - Lower Valve Error
Reason Power amplifier could not detect presence of lower valve coil.
Possible Cause/
Corrective Action
Lower valve missing.
Open or short circuit in lower valve or wiring; master control relay missing
or stuck open; main contactor open circuit (especially after it has closed);
communication error due to PMT. Allow PMT to reboot before turning truck
ON. Bad power amplifier.
Code E200 - Field Open
Reason Power amplifier detected open field.
Possible Cause/
Corrective Action
Open circuit in traction motor field circuit. Check traction motor field wiring
and field windings in motor.
Harness broken. Bad power amplifier.
5-16 00700-CL340-05, Issued: 2 May 2005
Code E201 - M Error
Reason Power amplifier detected a drive circuit fault.
Possible Cause/
Corrective Action
Traction motor cabling bad; bad power amplifier.
Code E202 - Power Amplifier Sensor Error
Reason Power amplifier reported an armature current sensor fault.
Possible Cause/
Corrective Action
Abnormal vehicle operation.
Low battery voltage or undersized battery.
Code E214 - Power Amplifier CAN Time-out
Reason Power amplifier did not receive CAN data from the ETAC, or power amplifier
selftest failed.
Possible Cause/
Corrective Action
Bad power amplifier; Bad ETAC.
00700-CL340-05, Issued: 2 May 2005 5-17
Parameters (P)
Modifying specific truck parameters will
change the driving characteristics of the
truck.
Programming Truck Parameters
To program the trucks operating parameters
follow directions below (also see Setting
Individual PIN-key codes on page 5-18):
1. Enter special truck mode. See Special
2. Release the horn button when the P is
displayed. The parameter control indicator
(wheel icon) is illuminated. See Figure 5-4.
3. Use the thumb control to scroll to the
desired truck parameter you want to
change or view. See Table 5-5. Release the
thumb control to neutral when the desired
parameter number is shown.
4. Press the horn button once to access the
parameter. The parameter symbol on the
display starts flashing.
5. Change the parameter value by pressing
the thumb control up or down. Release the
thumb control to neutral when the desired
parameter number is shown.
6. Press the horn button again to confirm the
change. The parameter symbol on the
display stops flashing and remains
illuminated.
7. End programming by pressing the red OFF
(O) key on the keypad.
The truck parameter change is complete. The
next time the truck is started, the new
parameter is in effect.
Programming Service Parameters
1. Connect the service key at J41. See
Special Tools on page 3-4.
2. Enter Special Truck Mode. See Special
3. Press and hold the horn button until P is
4. Use thumb control to scroll to the desired
service parameter to be changed. See
Table 5-6.
Table 5-5. Truck Parameters
Parameter Name Unit Range Step Default Description
01 Max speed,
slow mode
% 10 to 40 2 20 Max Speed, slow mode
10: low speed
40: full speed
02 Max speed,
fast mode
% 70 to 98 2 94 Max speed, fast mode
70: low speed
98: full speed
03 Acceleration % 30 to 90 5 80 30: low acceleration
90: full acceleration
04 Deceleration % 40 to 90 5 65 Defines motor speed
reduction force when thumb
control goes to neutral
position.
40: low reduction force
90: full reduction force
05 Truck off delay
(keypad only)
min 0 to 20 1 0 The time until the truck is
powered OFF (truck with
key-pad only). Time is
counted while the truck is idle
and brake is applied.
5-18 00700-CL340-05, Issued: 2 May 2005
NOTE: All parameters can be viewed; however,
not all parameters can be changed.
Individual operator parameters (1
through 5) may or may not be accessed,
depending on the value of parameter 39.
Service Parameter Display
When parameters 1 thru 5, and 10 are viewed
with the service key, both the parameter
number (left side of display) and the 1st
operator number (right side of display) are
shown.
As the service parameter number display
progresses through parameters 1, 2 ..., 10 the
display will roll over to the next operator (the
operator number increases). If a parameter is
changed, it is valid only for the operator shown.
After all operators and operator parameters are
scrolled through, service parameters 11 thru 40
are displayed.
To quickly display/access a service parameter
rotate the thumb control away from the forks
(sequence backwards through the
parameters/operators).
Setting Individual PIN-key codes
1. Connect the service key at J41. See
Special Tools on page 3-4. Make sure
that the Master Control ON/OFF switch is
ON.
2. Enter Special Truck Mode. See Special
3. Press and hold the horn button until P is
If the horn button is released at the wrong
time, turn the truck OFF and start over.
4. Use the thumb control to scroll through
the service parameters. While the thumb
control is held and briefly after it is
released, both the parameter number (on
the left side of the display) and the
operator number (on the right-this only
occurs if the service key is connected) are
displayed. Stop (release the thumb control)
at parameter 10 (PIN-key code) (See
Parameter 10 on page 5-20.) for the 1st
operator; the default value of 1 will be
displayed.
5. Press the horn button once to access this
parameter. The parameter symbol on the
display flashes. Now you can make
changes to the value of the 1st operators
PIN-key code.
Changing the 1st operators PIN-key
code will alter default operation. You
will not be able to press 1 and green
ON (I) to power the truck unless a
operators PIN-key code is set to a value
of 1.
6. Rotate the thumb control in fork direction
to increase the PIN-key code value, or in
operator direction to decrease the value.
Holding the thumb control in a direction
for a time will help quickly advance to
larger numbers (for example, codes greater
than 100). The PIN-key code can be from
one to four digits long. Release the thumb
control when the desired value is reached.
7. Press the horn button again to confirm the
new PIN-key code value. The parameter
symbol on the display stops flashing.
8. To enable additional operators; rotate the
thumb control in the fork direction to roll
over to the 2nd operator, and stop at
parameter 10. The default value of 0 will
be displayed. Follow the previous steps for
the desired number of different PIN-key
codes you want to set up. There are a total
of ten operators.
NOTE: Disabling all operators (all PIN-key code
values = 0) prohibits truck operation
without the service key.
NOTE: Use unique PIN-key codes to avoid
confusion. If two operators have the
same PIN-key code, the higher number
operators parameters will be used. For
example if both the 1st and 2nd
operator PIN-key code is 1111, and the
1st operators max speed is 80% and the
2nd operators max speed is 90%, when
someone logs in with 1111 the max
speed used will be 90%.
00700-CL340-05, Issued: 2 May 2005 5-19
Parameter Description
Parameter 1
Maximum speed value sent to the power
amplifier while in Slow mode except during
Turtle Torque (gives torque boost if high load is
encountered).
Parameter 2
Top Speed - Reduces speed value sent from the
ETAC to the power amplifier while in Fast mode
(all throttle positions).
Parameter 3
Acceleration - Defines the trucks acceleration
characteristic when the truck starts from a
stop. A high number gives maximum
acceleration, a lower number gives less
aggressive acceleration.
Parameter 4
Auto-Plug Braking in Neutral - Defines the
trucks automatic plug-braking characteristic
when throttle is reduced (including to neutral).
A lower number gives less aggressive
deceleration.
Parameter 5
Automatic Time Off Interval (touch pad only)-
The time until the truck is switched OFF
(energy saving feature) when the truck is idle
and the brake is applied. Time is counted from
when the latest power output is requested. If
truck has key switch option, the truck never
powers OFF. Range is from 1 minute to 20
minutes (a setting of 0 disables automatic time
off).
Table 5-6. Service Parameters
Parameter Name Unit Range Step Default Description
10 PIN-key
code
0 to 9999 1 1 Capability to assign up to 10 PIN-key codes
(for 10 different operators)
14 Creep
speed
10 to 10 1 5 Defines how much output the power
amplifier gives when you reach the first
speed sensor.
10 = low speed when reaching first speed
sensor
10 = high speed when reaching first speed
sensor
20 Hour
meter
selection
1 to 5 1 2 1 (A.) = key time
2 (b.) = activity time
3 (c.) = drive
4 (d.) = lift
5 (s.) = time to service
21 Battery
size
1 to 20 1 8 Battery size selection
25 Service
interval
hours 0 to 2000 50 0 Sets/resets service timer. C29 displays
when time is up. To reset timer, access this
parameter without changing the value.
39 Access
code
1 to 4 1 3 Defines what access level service personnel
have to parameters.
1 = key switch/operator parameters open,
2 = key switch/operator parameters closed,
3 = keypad/operator parameters open,
4 = keypad/operator parameters closed
(when closed, Service Key is required to
access truck parameters).
5-20 00700-CL340-05, Issued: 2 May 2005
Parameter 10
All trucks with a touch pad have a temporary
key code set at the factory. By default the 1st
operators PIN-key code is the single digit
number 1 and all other operators PIN-key
codes are 0 which disables that operator. The
key code logic has ten (10) registers for
individual operator key codes. To add additional
operators, change these PIN-key codes to
numbers other than 0. See Setting Individual
PIN-key codes on page 5-18. A Service Key is
required to assign up to 10 operators their own
PIN-key code (one to four digits) for access to
the truck.
Parameter 14
Defines the speed at low throttle positions. A
negative number enhances low speed
maneuverability. A positive number makes the
truck more responsive.
Parameter 20
You choose the hour meter you want to display.
1 = A. (key time)
2 = b. (activity time)
3 = c. (drive motor time)
4 = d. (pump motor time)
5 = S. (time to service)
Parameter 21
Data must be provided about the battery
installed in the truck.
The battery state-of-charge reset voltage is
25.2V and the lift cutout occurs when the
display shows 0% state-of-charge.
To adjust the disconnection point of the battery
discharge indicator, measure:
the acid concentration of a fully-charged
battery (must be between 1.27 and
1.29 SG)
at lift cutout, acid concentration should be
about 1.14 SG.
NOTE: Acid concentration varies with different
battery brands.
Make sure that you have the correct
parameter setting. Otherwise the
battery can be destroyed.
Parameter 25
With this parameter you can set a time limit to
next service from 0 to 2000 hours in steps of 50
hours. When it is time for service, you will get
caution 29 (C29) on the display. To disable the
service timer, set this parameter to 0. To reset
the service timer, simply access this parameter
without changing the value.
Parameter 39
This parameter determines whether the truck
has a key switch or keypad and what access
level service personnel will have to the operator
parameters. This parameter is adjustable:
1 = key switch connected, driver
parameters open.
2 = key switch connected, driver
parameters must be opened with service
key.
3 = keypad connected, driver parameters
open.
4 = keypad connected, driver parameters
must be opened with service key.
Display Part Numbers (Pn)
1. Enter the special truck mode.
2. Press and hold the horn button until Pn
is displayed.
3. Use the thumb control to scroll and
display the following information:
HPn = Hardware part number
HSn = Hardware serial number
SPn = Software part number
4. End displaying the part number by
pressing the red OFF (O) key on the
keypad.
Service Display
00700-CL340-05, Issued: 2 May 2005 5-21
Service Display
Connect the service key (see Special
Tools on page 3-4) in connection point
J41 and press the green ON key (I) to start
the lift truck.
The battery status is displayed and the
symbol D is lit continually.
Press horn button (S18) to toggle between
display modes. See table below:
* They are displayed by highlighting the
segments of three of the figures (A).
Digital Inputs/Outputs from Power
Amplifier
The first most significant figure active (marked
with arrow).
Power amplifier inputs
Flashing Symbol Displayed Data
B Speed reference value sent to
power amplifier.
C Digital inputs/outputs from
power amplifier and ETAC.
See Digital Inputs/Outputs
from Power Amplifier.
* See explanation following
BC Battery voltage (V) at ETAC
D Armature current (A)
BD Field current (A)
CD Armature PWM in %
BCD Status of power amplifier.
See Typical Statuses of
Power Amplifier on
page 5-23.
E Field resistance (Ohms),
used for thermal cutback.
A
B C D E
Figure
Segment
Function
A
B Input (J5-14): Arm Angle B
C Input (J5-15): Lift limit
D Input (J5-12): Arm Angle A
E Input (J5-2): Lower valve (lit if
valve is present and not powered)
F
G Input (J5-5): Brake (lit if brake is
present and not released)
DP
A
B C D E
A
D
B
C E
F
G
DP
Figure
Segments
Service Display
5-22 00700-CL340-05, Issued: 2 May 2005
The second most significant figure active
(marked with arrow).
Power amplifier outputs
The third most significant figure active (marked
with arrow).
Digital input from ETAC control
sensors
Figure
Segment
Function
A
B
C Output (J5-2): Lower valve
D
E Output (J5-4): Main contactor
interlock
F Output (J5-7): Horn
G Output (J5-5): Brake
DP Output (J5-6): Pump contactor
A
B C D E
A
D
B
C E
F
G
DP
Figure
Segments
Figure
Segment
Function
A
B
C
D ETAC input: lift forks
E ETAC input: lower forks
F (not used)
G (not used)
DP ETAC input: horn
A
B C D E
A
D
B
C E
F
G
DP
Figure
Segments
Service Display
00700-CL340-05, Issued: 2 May 2005 5-23
Typical Statuses of Power Amplifier
NOTE: The system mode shows details of power
amplifier activity, including normal
operation. It is different than, and does
not correspond to, the code from the
power amplifier status LED. See Power
Amplifier Fault Codes on page 5-24.
Throttle requests are not allowed for any
system mode of 32 and over.
Truck is in emergency shutdown for any
system mode of 128 and over.
Status Comments
13 No Activity: Main contactor open
because no output requested for
30 seconds or an error occurred.
24 Passive restraint (transitional)
16 Passive restraint
1 Motor drive, plug, or active
neutral braking
17 Active restraint while driving
(overspeed)
10 Regen
11 Regen taper (transitional)
4 Field reversal (transitional)
74 Emergency reverse (regen)
65 Emergency reverse (drive)
6 Disable (major fault, such as
severe overvoltage)
129 Emergency shutdown while in
drive
144 Emergency shutdown while in
passive restraint
Power Amplifier Fault Codes
5-24 00700-CL340-05, Issued: 2 May 2005
Power Amplifier Fault
Codes
An internal microcontroller automatically
checks the function of the power amplifier.
When this microcontroller detects a fault, the
status LED on the bottom of the power amplifier
flashes the appropriate code. See Table 5-7.
Under normal operation, the LED flashes a
single flash (heartbeat) at approx. one flash
every five seconds. A double flash indicates a
fault has been detected by the microcontroller.
Table 5-7 describes the fault codes that are
shown on the status LED or read using the
Programmable Maintenance Tool (PMT). See
Programmable Maintenance Tool (PMT) on
page 5-26. Correct faults by following the
Troubleshooting Flowcharts on page 5-31.
Table 5-7. Fault Codes
Fault Code PMT Display Possible Cause Explanation
LED
OFF
N/A
Open circuit at power
amplifier +24Vdc logic input
due to wire, fuse, or bad
power amplifier.
Power amplifier does not
have voltage at +24Vdc
logic power supply input.
Solid
ON
N/A Bad power amplifier.
Power amplifier is not
functioning correctly.
Single
flash
NO KNOWN FAULTS N/A
Normal heartbeat,
everything is okay.
1, 1 CURRENT SHUNT FAULT See Code E202 - Power Amplifier Sensor Error on
page 5-16.
1, 2 HW FAILSAFE
See Code E214 - Power
Amplifier CAN Time-out on
page 5-16 if ETAC is keyed
ON.
Power amplifier is
reporting that it is not
receiving CAN messages
from the ETAC, or that
selftest failed.
Otherwise, the controller is
reporting it is not receiving
CAN messages from the
ETAC, which is normal when
the truck is not turned ON.
1, 3 M SHORTED See Code E201 - M Error on page 5-16.
1, 4 SRO Bad power amplifier or ETAC.
setup or functioning
properly.
2, 1 THROTTLE FAULT 1
2, 2 EMR REV WIRING
2, 3 HPD Bad power amplifier or ETAC.
2, 4 THROTTLE FAULT 2 Bad power amplifier.
3, 1 CONT COIL/FLD SHORT See Code E106 - Digital Output or Field Overcurrent on
page 5-13.
3, 2 MAIN CONT WELDED Bad power amplifier or ETAC.
properly.
3, 3 FIELD OPEN See Code E200 - Field Open on page 5-15.
Power Amplifier Fault Codes
00700-CL340-05, Issued: 2 May 2005 5-25
3, 4 MISSING CONTACTOR Bad power amplifier or ETAC.
properly.
4, 1 LOW BATTERY VOLTAGE See Code C41 - Battery Undervoltage Warning on
page 5-11.
4, 2 OVERVOLTAGE See Code C42 - Battery Overvoltage Warning on
page 5-11.
4, 3 THERMAL CUTBACK See Code C43 - Power Amplifier Thermal Cutback on
page 5-12.
4, 4

ANTI-TIEDOWN Bad power amplifier or ETAC.

properly.
Table 5-7. Fault Codes
Fault Code PMT Display Possible Cause Explanation
Programmable Maintenance Tool (PMT)
5-26 00700-CL340-05, Issued: 2 May 2005
Programmable
Maintenance Tool (PMT)
The optional Programmable Maintenance Tool
(P/N 00590-49981-71) permits you to test and
diagnose the power amplifier in this pallet
truck.
The PMT is powered by the power amplifier
through a four-pin connector at the bottom of
the power amplifier. See Figure 5-9.
The Menu Navigation Key moves the screen
curser up or down through the Menu list (top or
bottom arrow), and opens or closes Sub-Menus
(right or left arrows).
The Data Inc/Key changes the value of the
parameter indicated by the curser.
The Bookmark Keys allow you to quickly go
back to your favorite selections without having
to navigate back through the Menu.
To select a position in the menu, hold a
Bookmark Key down for three seconds
until the bookmark set screen is
displayed.
To jump to a selected Bookmark position,
press the appropriate Bookmark Key.
NOTE: The Bookmarks are not permanently
stored in the PMT. They are cleared
when the PMT is unplugged.
The Main Menu is the starting point for the
PMT. The main menu displays menu titles:
Program (not used)
Monitor
Faults
Functions
Information
Programmer Setup
If there are no entries within a Menu, then the
Menu title will not be displayed.
Monitor Mode
Real-time status information is displayed in the
Monitor mode for various inputs, outputs,
temperature, etc. This information can be
helpful in troubleshooting many problems and
is useful for checking out the operation of the
controller during initial installation.
1. Press the red OFF (O) key on the keypad.
2. Remove the tractor cover.
3. Connect the PMT to the power amplifier.
Wait for the PMT to boot up before
proceeding to the next step.
4. Enter the PIN key code and press the
green ON (I) key on the keypad or turn key
switch ON.
5. Use the Menu Navigation Key to select
Monitor.
1665 037.tif
Figure 5-8. Programmable Maintenance Tool
Data Inc/Dec
Key
Bookmark
Keys
Menu
Navigation
Key
1665 037.tif
Figure 5-9. Connecting PMT to Power Amplifier
Connector
00700-CL340-05, Issued: 2 May 2005 5-27
6. Press the right arrow on the Menu
Navigation Key to enter the sub-menu.
7. Use the Up and Down Button arrows to
scroll through the sub-menu list of
monitor variables.
8. Use the right arrow to select and view a
single variable.
9. To change the value of the parameter use
the Data Inc/Dec Key. Alternately, you can
press the right arrow Menu Navigation Key
once more and enter the detail screen. A
bar graph appears as well as min and max
data points. Change the parameter value
by pressing the Data Inc/Dec Key. The
new value is set as soon as the Data
Inc/Dec Key is released.
To close a Monitor Menu, sub-menu, or detail
screen, press the left arrow on the Navigation
Key.
Faults Mode
In System Faults mode, currently active faults
detected by the controller are displayed.
In Faults History mode, the controllers
diagnostic history file is displayed. This field
includes a list of all faults observed and
recorded by the controller since the history was
last cleared.
NOTE: Each fault is listed only once, regardless
of the number of times it occurred.
switch ON.
5. To view the present status of the unit, use
the Menu Navigation Key to select
Faults -> System Faults
6. To access the log, use the Menu Navigation
Key to select Faults -> Fault History.
7. Use the Up and Down Buttons arrows on
the Menu Navigation Key to scroll through
list of multiple faults.
Clear
After you have diagnosed and corrected the
problem, clear the diagnostic history file. This
permits the power amplifier to accumulate a
new file of faults. By checking the new history
file at a later date, you can easily determine
whether the problem was completely fixed.
1. To clear the fault history of the unit, use
the Menu Navigation Key to select
Faults -> Clear Fault History.
2. Press the increment arrow (+) for yes and
the decrement arrow (-) to cancel and not
clear the fault history.
Table 5-10 on page 5-28 lists possible messages
you may see displayed when the PMT is
operating in either System Faults or Fault
History mode.
Information Mode
The Information Menu provides access to
product information describing the basic
revision level of the PMT.
To view, use the Menu Navigation Key to select
Information in the Main Menu. Remember to
press the right arrow to select a Menu. Press
the left arrow to exit.
Programmer Mode
Programmer mode permits you to perform a
variety of tasks.
switch ON.
5. Use the Menu Navigation Key to select
Programmer.
5-28 00700-CL340-05, Issued: 2 May 2005
6. Press the right arrow on the Menu
Navigation Key to enter the sub-menu.
7. Use the Up and Down arrows on the
Navigation Key to scroll through the
sub-menu list of Programmer displays.
8. Use the right arrow to select and view a
single variable.
Change the parameter value by pressing the
Data Inc/Dec Key. The new value is set as soon
as the Data Inc/Dec Key is released.
Table 5-10. Test Mode Menu
Test Mode
Display Explanation
THROTTLE% Throttle reading, in % of full throttle
ARM CURRENT Motor armature current, in amps
FIELD CURRENT Motor field current, in amps
ARM PWM Armature duty cycle (PWM) - applied as %
FIELD PWM Motor field duty cycle (PWM) - applied as %
BATT VOLTAGE Battery voltage (B+ and B connection) at key switch input
CAP VOLTAGE Voltage of power amplifier B+ (bus bar)
HEAT SINK TEMP Heat sink temperature - C
FORWARD INPUT Forward switch: on/off
REVERSE INPUT Reverse switch: on/off
MODE Power Amplifier operating mode: 1 to 4
INTRLCK INPUT Interlock (brake/deadman) switch: on/off
PEDAL INPUT (not used)
EMR REV INPUT Emergency reverse button: on/off
MOTOR RPM (not used)
MAIN CONT Main contactor: on/off
AUX CONT (not used)
REV OUTPUT (not used)
BRAKE OUTPUT (not used)
FAULT 1 OUTPUT (not used)
FAULT 2 OUTPUT (not used)
CONTROL STATE (not used)
MODSEL 1 Mode select 1 switch: on/off
MODSEL 2 Mode select 2 switch: on/off
List of Troubleshooting Charts/Tables
00700-CL340-05, Issued: 2 May 2005 5-29
Troubleshooting Charts
TS1: START TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-33
Hydraulic Symptom Tables
No Lift, Lift Motor Does Not Run, Travel is OK. . . . . . . . . . . . . . . . . . . . 5-35
No Lift or Slow Lift, Lift Motor Does Run. . . . . . . . . . . . . . . . . . . . . . . . 5-36
No Lower, Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Load Drifting/Settling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
No Lift or Lower. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Travel Symptom Tables
Slow Travel, Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . . 5-39
Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Green/Red LED on Keypad Not Illuminated When Key Pressed. . . . . . . 5-40
No Fast Travel Mode. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
No Travel Mode. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Horn Does Not Sound When Horn Button Pushed. No Fault Codes . . . . 5-41
5-30 00700-CL340-05, Issued: 2 May 2005

Troubleshooting Flowcharts
00700-CL340-05, Issued: 2 May 2005 5-31
Troubleshooting
Flowcharts
GEN1: General Troubleshooting
TS-1.wmf
Is a
Message or
Fault Code
displayed?
Find
Message or Code
in Chapter 5
Yes
Go to
Chart GEN-1
No
Is
symptom listed in
Symptom Tables in
Chapter 5?
No
Yes
Follow
Symptom Table
directions in
Chapter 5
5-32 00700-CL340-05, Issued: 2 May 2005
Gen1.wmf
GEN1: General Troubleshooting
Gather as much
information as you
can about the
problem.
Talk directly to the
operator or foreman.
Operate the truck
yourself.
Using the schematics
if necessary, identify
all components which
could cause the
problem.
What is the problem?
Where did it happen?
When did it happen?
What functions are affected?
What conditions trigger the problem?
Eliminate unlikely
causes.
Select and prioritize
the most likely
causes.
Check each likely
cause, using the tests
in this manual.
Check all other truck
functions before
returning the truck to
service.
00700-CL340-05, Issued: 2 May 2005 5-33
END1: End of Troubleshooting Procedure
End1.wmf
END1: End of Troubleshooting Procedure
Make sure ALL wires,
hoses, and cables that
you removed have been
re-attached correctly.
Make sure all panels are
properly reinstalled.
Make sure any
component that was
drained has been
refilled with the
correct level of fluid.
Create the same
conditions that occurred
when the problem first
happened.
Operate the truck as it
was being operated
when the problem
occurred. Verify the
problem does not recur.
Have the driver operate
the truck. Verify the
problem does not
recur.
Fill out any required
forms.
If you contacted
Field Service to discuss
the problem, call them
again to let them know
what fixed the problem.
This is especially
important if the
solution you found
is not in the
troubleshooting
chart.
End of Troubleshooting
5-34 00700-CL340-05, Issued: 2 May 2005

Symptom Tables: Lift/Lower System
00700-CL340-05, Issued: 2 May 2005 5-35
NOTE: If it is determined that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed the
hydraulic system. See Hydraulic Fluid
on page 6-52.
NOTE: Reference electrical schematics
beginning on Page A-9 and hydraulic
schematic beginning on page A-12.
No Lift, Lift Motor Does Not Run, Travel is OK
Possible Cause Action
Bad lift pump contactor With Master Control ON/OFF switch ON, the
PIN-key code entered, the green ON (I) key on
the keypad pressed and lift switch depressed,
does main contactor (K10) and pump
contactor (K30) energize (click)? If not,
measure voltage between pump contactor coil
terminals. If B+ voltage is present, replace the
pump contactor.
Bad control handle card (A2) With Master Control ON/OFF switch ON, the
the keypad pressed and lift switch depressed,
does pump contactor (K30) energize (click)? If
not, check for lift signal input at CAN. (See
Service Display on page 5-21.) If no signal is
detected, replace control handle card (A2).
NOTE: Check for mechanical problems in the
handle head before replacing control handle
card.
Bad wiring continuity or wiring shorts With Master Control ON/OFF switch OFF and
battery disconnected, check for continuity
and wiring shorts in wiring harness or cables.
Bad lift-limit switch With Master Control ON/OFF switch OFF,
battery disconnected and forks lowered, check
continuity through the lift-limit switch.
Replace if necessary.
Bad lift pump motor brushes... With Master Control ON/OFF switch ON, the
the keypad pressed and the lift switch
depressed, does pump contactor (K30)
energize (click)? If YES, measure voltage
between B and lift pump motor terminal. If
OK, check lift motor brushes...
...or bad lift pump motor... ...if brushes are OK, test the pump motor.
5-36 00700-CL340-05, Issued: 2 May 2005
No Lift or Slow Lift, Lift Motor Does Run
No Lower, Lift and Travel OK
Battery problems Replace battery with fully-charged good
battery.
Mechanical binding in lift mechanism Repair lift mechanism.
Low hydraulic pressure or relief valve
setting
Check hydraulic pressure setting and adjust if
necessary. See Adjusting Hydraulic Pump
Pressure Relief Valve on page 6-53.
Relief valve contaminated or bad.
(Unable to get the correct hydraulic
pressure)
With Master Control ON/OFF switch OFF and
battery disconnected, remove the pressure
relief valve. Check for damage or
contamination. Replace valve or flush system
and replace the hydraulic fluid. See
Hydraulic Fluid on page 6-52.
Bad lift pump motor or brushes Check the lift pump motor brushes. If OK,
replace the pump.
Contamination found in the pump Flush the system and replace hydraulic fluid.
Bad pump If lift motor is OK, remove motor from pump
and rotate pump by hand. Replace pump if
not OK.
Bad lower solenoid valve... With the Master Control ON/OFF switch ON,
cycle the lower switch. Does the lower
solenoid valve energize (click)? If YES,
disconnect the battery, then slowly loosen,
but DO NOT REMOVE the hydraulic line at
the hydraulic pump assembly. Permit the
forks to slowly lower. Have rags and drain pan
ready to catch fluid.
... if the forks do not lower, check for
mechanical binding in lift cylinder or
fork mechanism...
Replace lift cylinder or repair lift mechanism.
...if the forks lower, remove and inspect
the solenoid valve...
Inspect for free movement and for signs of
contamination. Clean the solenoid valve or
flush the system, clean the filter and replace
hydraulic fluid.
If no contamination is found, repair or replace
the solenoid valve or pump assembly.
00700-CL340-05, Issued: 2 May 2005 5-37
Unable to Pick Up a Load
Slow Lower
...check for bad control handle (ETAC)
card
With Master Control ON/OFF switch ON, the
the keypad pressed, and the lower button
depressed, check for lower signal input at
CAN. (See Service Display on page 5-21.) If
no signal is detected, replace control handle
card (A2). NOTE: Check for mechanical
problems in the handle head before replacing
control handle card.
Load too large for lift truck capacity Check load weight. Check lift pressure setting.
Battery problems Replace battery with fully-charged good battery.
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad pressure relief
valve
Check for contamination in hydraulic fluid.
If contamination is present, flush, fill and
bleed the hydraulic system. Clean the relief
valve.
If no contamination is found, replace relief
valve.
Bad lift pump or motor Replace lift pump or motor.
Bad lift/lower solenoid valve or wiring Repair or replace the solenoid valve or wiring.
Plugged or malfunctioning flow control
valve
bleed the hydraulic system and clean the
relief valve.
If no contamination is found, replace the flow
control valve.
Contamination in lowering solenoid
valve
Inspect solenoid for contamination or binding.
Mechanical binding in lift mechanism Adjust or replace mechanism.
Bad or misadjusted lift-limit switch Adjust or replace lift-limit switch (pump should
not hit relief if lift-limit switch is operating
properly).
NOTE: If the pump hits relief and lower is attempted, lowering will be slow. Release the
lower button momentarily, then continue to lower. Normal lower speed should
resume.
5-38 00700-CL340-05, Issued: 2 May 2005
Load Drifting/Settling
No Lift or Lower. No Fault Codes
'
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad check valve Check for contamination in hydraulic fluid.
bleed the hydraulic system. Clean the check
valve.
If no contamination is found, replace check
valve.
Leaking or contaminated lowering
solenoid valve
bleed the hydraulic system. Clean the
solenoid valve.
If no contamination is found, replace the
solenoid valve.
Load too large for lift truck capacity Check load weight. Check lift pressure setting.
Throttle magnet-actuator arm (in control
handle) out of adjustment
Check with service display and repair as
needed.
Bad ETAC. If no other problems are noted
but the ETAC does not detect the presence
of the magnet, replace the ETAC.
Lift contactor missing, open or short
circuit in lift circuit (contactor, wiring,
motor), Bad power amplifier
Perform standard electrical troubleshooting
procedures in the lift circuit.
Incorrect ETAC software installed. Note: this is only possible if ETAC was
recently replaced.
Lowering may not occur if incorrect software
was inadvertently installed (drive function
will also not function correctly). Check for
correct software part number and replace
ETAC if not correct.
Symptom Tables: Travel (Forward/Reverse) System
00700-CL340-05, Issued: 2 May 2005 5-39
NOTE: Reference electrical schematics
beginning on Page A-9 and hydraulic
schematic beginning on Page A-12.
Slow Travel, Lift/Lower OK. No Fault Codes
Truck Does Not Accelerate Correctly
Truck configured for slow acceleration Check truck configuration.
Battery problems Replace battery with fully-charged good
battery.
Binding drive wheel assembly/drive
motor
Jack and block truck. Disable brake.See
Mechanically Releasing the Brake on
page 6-34. Check that drive wheel spins
freely. If not, repair or replace.
Binding brake disc Check Air Gap Adjustment on page 6-33
Bad drive motor
(may test OK with no load, but fail
under load) or worn brushes
Repair or replace drive motor or brushes.
Truck configured for slow acceleration Check truck configuration.
Battery problem Verify a correct, fully-charged good battery
(24V) is installed in truck.
Binding or mechanical problem Jack and block truck. Turn Master Control
ON/OFF switch ON. Check brake, wheel
bearings and load wheels to see if there is a
mechanical problem. Repair or replace.
Bad motor brushes or motor With Master Control ON/OFF switch OFF
and battery disconnected, check drive
motor brushes and motor. See Drive Motor
Brush Inspection on page 6-35. Repair or
replace.
Bad power amplifier If all other possible causes check out, replace
power amplifier.
5-40 00700-CL340-05, Issued: 2 May 2005
Green/Red LED on Keypad Not Illuminated When Key Pressed
No Fast Travel Mode. No Fault Codes
No Travel Mode. No Fault Codes
No power supplied to the ETAC. Check for open circuit in wires or connectors
in tiller arm, F50 open, keyswitch jumper
not connected.
Faulty Connectors Repair and replace faulty connectors (check
connector J11 at control handle arm base,
connector into ETAC, and connector J5 to
motor controller).
F50 Open Ensure control fuse has not tripped.
Key switch jumper not connected Connect keyswitch jumper.
Bad LED(s) Check LED(s) if truck functions normally but
LED(s) not lighting correctly.
Open Arm Angle Switch Check for correct operation of arm angle
switch A and correct if necessary, check
wiring, power amplifier, and switch
adjustment. Arm Angle switch A is
open-circuited. See Arm Angle Switches
on page 5-6.
Open Arm Angle Switch Check arm angle switch adjustment, wiring,
power amplifier. Arm Angle switch A or B is
open-circuited. See Arm Angle Switches
on page 5-6.
Throttle magnet-actuator arm (in control
handle) out of adjustment
Check with service display and repair as
needed.
Bad ETAC. If no other problems are noted
but the ETAC does not detect the presence
of the magnet, replace the ETAC.
00700-CL340-05, Issued: 2 May 2005 5-41
Horn Does Not Sound When Horn Button Pushed. No Fault Codes
Bad horn switch/wiring in handle head Repair or replace as necessary.
Bad horn Replace horn.
Bad power amplifier Check fuse and replace if necessary.
5-42 00700-CL340-05, Issued: 2 May 2005

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures
00700-CL340-05, Issued: 2 May 2005 6-1
Section 6. Component Procedures
A
Arm Angle Switches ............................ 6-24
B
Battery ................................................. 6-4
Adding Water .................................. 6-7
Charging ........................................ 6-6
Exterior Cleaning ............................ 6-5
Maintenance Free ........................... 6-8
Specific Gravity .............................. 6-7
Storage ........................................... 6-8
Voltage Check ................................. 6-7
Battery Pack
Swingout ........................................ 6-4
Brake ................................................. 6-33
C
Circuit Breaker .................................. 6-13
Contactors ......................................... 6-20
Control Handle ................................... 6-14
Cover, Tractor ...................................... 6-9
D
Drive Unit .......................................... 6-27
Brake, Electromagnetic ................. 6-33
Drive Housing Lubrication ............ 6-30
Drive Motor .................................. 6-42
Drive Wheel .................................. 6-31
Transmission Assembly ................ 6-27
Drive Wheel ........................................ 6-31
E
Electromagnetic Brake ....................... 6-33
F
Fuses ................................................. 6-12
G
Gear Oil ............................................. 6-30
H
Horn ................................................... 6-18
Hydraulic Components
Cylinder ........................................ 6-47
Fluid ............................................. 6-52
Hydraulic Unit .............................. 6-49
Filter Screen ............................ 6-50
Pump ...................................... 6-51
Relief Valve Adjustment ........... 6-53
Reservoir ................................. 6-50
Solenoid .................................. 6-49
Suction Tube ........................... 6-50
K
Key Switch (Optional) ......................... 6-26
L
Lift Motor ........................................... 6-51
Lift-Limit Switch ................................. 6-25
Load Wheel
Pull Rod Adjustment ..................... 6-45
Load Wheels ....................................... 6-45
Lubrication
Drive Housing ............................... 6-30
M
Master Control ON/OFF Switch .......... 6-23
Motors
Brush Spring Tension ................... 6-36
Brushes ........................................ 6-35
Commutator ................................. 6-36
Drive ............................................. 6-42
General ......................................... 6-35
Lift ................................................ 6-51
Tests ............................................. 6-39
P
Power Amplifier .................................. 6-19
Power Cables ...................................... 6-10
Pump, Hydraulic ................................ 6-51
Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
6-2 00700-CL340-05, Issued: 2 May 2005
S
Switches
Arm Angle .....................................6-24
General .........................................6-49
Key Switch (Optional) ....................6-26
Lift-Limit .......................................6-25
Master Control ON/OFF ................6-23
W
Wheels
Load ..............................................6-45
Wiring Harness ...................................6-11
Component Locator Photo
00700-CL340-05, Issued: 2 May 2005 6-3
Component Locator Photo
Figure 6-1. Tractor Interior
Drive Unit
page 6-27
Main
Contactor
page 6-20
Hydraulic Cylinder
page 6-47
Fill/Vent
Plug
Hydraulic
Reservoir
page 6-50
Horn
page 6-18
Battery
Connector
Power
Amplifier
page 6-19
Master
Control
Relay
page 6-21
Battery
6-4 00700-CL340-05, Issued: 2 May 2005
Battery
The pallet truck may be equipped with a
multiple (swingout) battery pack or a
maintenance-free battery and charger.
Before working on the battery, batteries
can weigh more than 500 pounds. Use
extreme care during replacement. Use a
suitable battery replacement device or
hoist for lifting. See Battery Safety on
page 2-6.
Swingout Battery Pack
NOTE: For replacement parts information refer
to Parts Catalog.
Removal (single battery)
1. After the truck is stopped and the handle
is returned to the full up position, press
the red OFF (O) key on the keypad.
2. Disconnect the battery connector found at
the top of the tractor cover. Remove the
battery cover.
3. Lift up on the top battery frame to get
access to the lower two batteries.
4. As the frame is lifted, swing the battery
toward the center of the forks.
5. The cables may now be disconnected from
the battery terminals and the batteries
may be serviced or replaced if necessary.
See Figure 6-2.
Installation (single battery)
1. Position the fully-charged and tested
batteries in the battery pack.
2. Reconnect the battery cables to the battery
terminals in accordance with the battery
wiring hookup shown on the decal in the
battery frame.
3. Reconnect the battery connector, reinstall
the battery cover, press the green ON (I)
key on the keypad, and test the operation
of the pallet truck.
Removal (entire battery pack)
2. Disconnect the battery connector found at
the top of tractor cover.
3. Position the battery replacement device
above the battery and attach it to the
battery manufacturers designated lift
points.
4. Remove the battery with the lifting device.
5. Put the discharged battery on the charging
stand.
1790 001.eps
Figure 6-2. Multiple Battery Wiring Hookup
Battery
00700-CL340-05, Issued: 2 May 2005 6-5
Installation
1. With a fully charged and tested battery on
the lifting device, position the lifting device
in accordance with the manufacturers
recommendations.
2. Position the battery in the compartment.
Make sure the battery has no more than
1/2 in. (13 mm) of free play movement in
the battery compartment in any direction.
3. Remove the lifting device from the area.
4. Reconnect the battery connector, turn the
key switch ON, and test the operation of
the truck.
Maintenance-Free Batteries
to Parts Catalog.
The truck may be equipped with a
maintenance-free battery and charger pack.
The specific gravity need not be measured on a
maintenance-free battery. Please follow
manufacturers recommendations for service of
these batteries.
A maintenance-free battery still requires some
care. The battery must be kept clean and dry
and may be washed to remove any accumulated
foreign matter. See Exterior Cleaning on
page 6-5.
Battery Maintenance
Exterior Cleaning
1. Inspect the battery.
a. Make sure the cables are not frayed or
loose.
b. Make sure there is no foreign material
inside the connector.
c. Make sure the filler plugs are tight and
the vent holes in the filler plugs are
open. See Figure 6-3.
2. Keep the top of the battery clean and dry.
Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create grounds.
Do not clean the top of the battery with
the soda solution while it is installed in
the truck. Water will seep into the
electrical compartments and cause
serious damage.
3. Disconnect the battery connector, and
remove the battery from the truck before
you clean it.
4. Tighten the battery filler plugs.
5. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
of 1 lb. (0.45 kg) of baking soda added to
1/2 gal (1.9 liters) of hot water.
6. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
7. Rinse the battery with clean water.
8. Dry the battery completely before
re-installing it.
9. Apply a thin coat of petroleum jelly to the
battery posts and cable terminals.
09g6s047.tif
Figure 6-3. Battery Filler Plugs and Vent Holes
Cable
Filler Plug
Vent Hole
Battery
6-6 00700-CL340-05, Issued: 2 May 2005
Charging
To charge a battery, direct current is passed
through the battery cells in the direction
opposite to that of discharge. Charging time is
5% to 20% longer than discharge time.
The most important element in battery service
and prolonging battery life is correct charging.
Make sure you follow the approved method for
each application, following the battery and
battery charger manufacturers instructions.
The vent holes in the filler plugs must be
open to permit hydrogen gas to escape
from the cells. When you charge the
battery, make sure the polarity
connections are correct. The positive
lead of the charger must be connected to
the positive terminal, and the negative
lead must be connected to the negative
terminal.
1. Familiarize yourself with the following:
Charging rate, starting rate, and finish
rate
Time available for charge
Overheating, excessive gassing, or
overcharging
Variations between cell voltage
2. Battery performance varies depending on
the type of application. If you use more
than one truck, one battery, and one
charger, keep the same batteries and
charger assigned to each truck. This
makes it easier to diagnose any battery or
charging problem.
3. Consult your battery and battery charger
manufacturers manual for specific
charging procedures.
4. Wear personal protective equipment, See
Battery Safety on page 2-6.
5. Press the red OFF (O) key on the keypad,
and disconnect the battery.
6. Inspect the battery.
7. Examine the electrolyte level in each cell.
Electrolyte must cover the top of the
battery plates. If electrolyte level is below
the plates, add just enough water to cover
the plates. Do not fill to level yet.
Electrolyte level will increase during
charging. See Adding Water on page 6-7.
8. Using a hydrometer, measure and record
the specific gravity of each cell. See
Specific Gravity on page 6-7.
9. Measure and record the voltage of each
cell.
10. To get the maximum use out of each
battery, recharge only when effectively
discharged. Routinely recharging batteries
when only partially discharged will
decrease battery life. At maximum
recommended discharge, the specific
gravity must read 1.140 to 1.160 or less.
11. Make sure that the filler plugs are clean
and the vent holes are open. Tighten all
filler plugs.
NEVER plug the battery charger into the
truck. This will severely damage the
trucks electrical system. Plug the
charger ONLY into the connector from
the battery.
12. Charge the battery, following specific
instructions in your battery and battery
charger manufacturers manual.
13. Using a hydrometer, measure the specific
gravity of each cell. No amount of charging
will increase battery capacity or increase
specific gravity above its fully charged level
(specific gravity 1.280 to 1.300).
14. If, after charging, the electrolyte level is
below the fill port, add water to move it to
the fill level. Do not overfill the cells or
permit electrolyte to spill on the battery
case. See Adding Water on page 6-7.
In general, a lead-acid battery may be charged
at any rate in amperes that does not cause
excessive gassing or produce electrolyte
temperatures above 110F (43C).
Temperatures of 120F (49C) are permitted
only for short periods of time.
Battery
00700-CL340-05, Issued: 2 May 2005 6-7
Adding Water
Water must be added to battery cells
periodically. Frequency and quantity depend on
the water level above the plates and the amount
of gassing during charge.
Guidelines:
Wear personal protective equipment. Use
only distilled water or water approved by
the battery manufacturer. See Battery
Safety on page 2-6.
Before charging, make sure battery plates
are covered with electrolyte. Add water, if
necessary, only to cover plates.
Electrolyte level increases during charging.
To prevent overflow, add water to fill port,
if necessary, after charging, and after
hydrometer and voltmeter readings are
taken.
Keep the outside of the battery case clean
and dry.
Specific Gravity
Specific gravity readings for lead acid batteries
with electrolyte temperatures at 80F (27C)
change with the state-of-charge as follows:
Most industrial deep-cell discharge batteries
are considered discharged when 20% of the
charge remains (specific gravity 1.140).
NOTE: Maintenance-free batteries do not
require specific gravity measurements.
Procedure
1. Wear personal protective equipment. See
Battery Safety on page 2-6.
2. Insert the nozzle of the hydrometer into
the battery cell and draw enough
electrolyte into the tube to permit the float
to ride free.
3. Leave the hydrometer nozzle in the battery
and read the specific gravity of the cell.
4. If there is not enough electrolyte in the
battery to get a hydrometer reading then:
Add just enough water to cover the
battery plates
Charge the battery, then take readings
5. Record the specific gravity reading on the
battery maintenance chart.
Voltage Check
Take a voltage check on each cell after
performing the specific gravity check. Attach a
voltmeter to the positive and negative terminals
of each cell. Voltage readings will change with
the state-of-charge. See Specific Gravity on
page 6-7.
Record the voltage reading for each cell on the
battery maintenance chart. There must be a
difference of less than 0.2V between cells.
Charge Specific Gravity
100% 1.280 to 1.300
75% 1.250 to 1.260
50% 1.200 to 1.210
25% 1.150 to 1.160
0% 1.080
Charge Voltage Reading
100% 2.14
75% 2.07
50% 1.95
25% 1.80
Battery
6-8 00700-CL340-05, Issued: 2 May 2005
Storage
Before storing a battery, make sure electrolyte
is at the correct level in every cell, filler plugs
are tight, and battery is fully charged.
Store the battery in a clean, cool, dry location
away from radiators and other sources of heat.
Measure the electrolyte level and the specific
gravity every 30 days during storage. Whenever
the specific gravity is less than 1.230, charge
the battery.
Tractor Covers
00700-CL340-05, Issued: 2 May 2005 6-9
Tractor Covers
to Parts Catalog.
The tractor covers are designed to be easily
removed and re-installed for service and
maintenance.
Removal
1. Grasp top cover at location shown. Lift
cover upward to disengage captivating
clasps. See Figure 6-4.
2. Remove two captivating screws located at
the top of the cover then remove bottom
cover.
Installation
1. Install the bottom cover and secure with
two captivating screws located at the top of
the cover.
2. To install the top cover, slide it back into
the original position, and secure by
engaging the captivating clasps located on
the top of the cover.
Figure 6-4. Top Cover Removal (decals omitted)
Grasp Top
Cover Here
Bottom Cover
Power Cables
6-10 00700-CL340-05, Issued: 2 May 2005
Power Cables
to Parts Catalog.
Power cables are used to connect power from
the battery to the drive motor and lift motor.
Examine the power cables for damage,
including:
Evidence of overheating
Burned spots in the cable
Nicks in the insulation
Damaged or overheated terminal lugs
Damaged mounting hardware or brackets
Repair or replace damaged cables or mounting
hardware as necessary.
The terminal lugs must be crimped tightly and
securely on the wire. Replace the lug if
overheating is evident. Repair or replace bad
connectors as necessary.
Figure 6-5. Power Cables
Wiring Harness
00700-CL340-05, Issued: 2 May 2005 6-11
Wiring Harness
to Parts Catalog.
The wiring harness is designed to connect the
electrical components of the pallet truck.
All wires in the harness are marked with a wire
identification number. These numbers
correspond to wire identification given in the
schematic. All connectors are represented by
J followed by a number. See Schematics on
page A-9.
Inspection
Whenever working on the truck, use care
around wiring harnesses.
Do not pull on wires
Carefully mate and unmate all connectors
Do not pry apart connectors with
unspecified tools
Examine and maintain any added
materials used to dress or protect the wire.
This includes spiral wrap, brackets, cable
ties, fasteners, flexible conduit, and so
forth.
Examine harness wires for abrasions,
scrapes, nicks in the wire, damage from
overheating or burns, or other general
insulation damage
Replace terminations with exposed wire
visible at the connectors. Damaged
terminations, exposed wires, or damaged
connectors can cause operational failure of
the truck
During troubleshooting and repairs, it is
sometimes necessary to unmate a connector,
move a harness, cut a cable tie, or remove the
wire from a bracket. Note carefully the location
of the wire and all protective or securing
attachments before moving the harness.
After repair, return or replace all protective
and/or securing hardware to its original
condition. Protective materials are necessary to
provide reliable performance of the interconnect
system.
In addition to the wire identification number
printed every 1 to 1.5 in. (25.4 to 38.1 mm) on
the wire, there is a wire marker at each
termination. If the marker is missing or
unreadable, remark the wire to permit easier
identification.
NOTE: It is normal to find unused connectors
for uninstalled options that have had
heat shrink applied over them and have
been strapped to the harness.
Figure 6-6. Wiring Harness
Fuses
6-12 00700-CL340-05, Issued: 2 May 2005
Fuses
to Parts Catalog.
Under extreme operating conditions, fuses
(F50, F51) protect the electrical circuits and
components from excessive current or voltage
overloads.
Test/Inspection
Examine each fuse for signs of overheating,
discoloration, cracking, or other physical
damage. Replace the fuse if you find damage.
See Figure 6-7.
To test a fuse, remove it or isolate it from the
electrical circuit. Do this by removing the fuse
from the truck or by removing all the
connections from one side of the fuse.
Use an ohmmeter set to Rx1 scale and measure
the resistance across the fuse. The resistance
must be less than 1 ohm.
1665 031.tif
Figure 6-7. Fuse/Circuit Breaker Location
Fuse F50
Fuse F51
Circuit Breaker
00700-CL340-05, Issued: 2 May 2005 6-13
Circuit Breaker
to Parts Catalog.
Under extreme operating conditions the current
demand on the battery may exceed the rating
for the main circuit breaker (CB1) and force it
open. This causes the truck to become
inoperable until the circuit breaker
automatically resets itself.
Test/Inspection
Examine the circuit breaker for signs of
overheating, discoloration, or other physical
damage. Replace the circuit breaker if you find
damage. See Figure 6-8.
To test a circuit breaker, remove the circuit
breaker from the truck or isolate it from the
electrical circuit by removing all the
connections from one side. Let it cool (or reset
itself).
Use an ohmmeter set to Rx1 scale and measure
the resistance across the circuit breaker. The
resistance must be less than 1 ohm.
Figure 6-8. Circuit Breaker Location
Circuit Breaker
CB1
Control Handle
6-14 00700-CL340-05, Issued: 2 May 2005
Control Handle
to Parts Catalog.
1
2
3
8
4
7
6
5
9
16
15
14
13
12
11
10
23
21
20
19
18
17
22
24
25
26
27
28
29
30
31
32
33
34
35
36
31
35
Control Handle
00700-CL340-05, Issued: 2 May 2005 6-15
Control Handle Disassembly
1. Remove screw [1], then unplug and
remove the keypad [2].
2. Remove the four screws [3] that secure the
top cover assembly to the handle. Hold the
top cover [15] firmly while removing
screws.
3. Disconnect the cable connected to the
electronic circuit board [13].
4. For access to the electronic circuit board
[13], remove the screws [10] securing the
lower cover [12].
Static electricity! Risk of static discharge
that can damage the electronics. Make
sure to take the necessary precautions
before working with the electronics.
5. Carefully lift off the lower cover [12].
NOTE: Place your finger between the lower
cover [12] and button [18] to hold the
control switch [30] in place.
Changing Horn Button/Switch
[26, 27]
1. Remove the horn button. See Figure 6-9.
Do not use excessive force when prying
on the button or you can damage the
locking tabs.
2. Disconnect the connection for the switch
on the electronic circuit board [13].
Pos Description Pos Description Pos Description
1 Screw 13 Electronic circuit board 25 Gasket
2 Keypad 14 Push button (option) 26 Signal button
3 Screw, 2 x M5 x 45 -
2 x M5 x 60
15 Top cover 27 Push button (option)
4 Handle 16 Display card 28 Wire, hold down
5 Cover, keypad (Optional) 17 Push button 29 Screw
6 Top plate 18 Emergency reverse button 30 Control switch
7 Screw 19 Push button (not used) 31 Sliding bearing
8 Bottom plate 20 Plate 32 Control stop
9 Grommet 21 Holder 33 Arm
10 Screw, M4 x 40 22 Push button, lift/lower 34 Axle
11 Spring 23 Arm 35 Spring holder
12 Lower cover 24 Display glass 36 Spring
Figure 6-9. Horn Button Removal
Control Handle
6-16 00700-CL340-05, Issued: 2 May 2005
3. Press out the switch from its mounting in
the top cover assembly.
Changing Lift/Lower Button [22]
1. Remove the button by placing a
screwdriver in the hole [A]. See
Figure 6-10.
2. Unscrew the holder [21] so that the arm
[23] comes loose.
Changing Push Button [19]
1. Press the push button sideways.
2. Insert a screwdriver and carefully pry the
button loose. See Figure 6-11.
3. Unscrew the buttons holder and arm.
Control Handle Stem
to Parts Catalog.
Removal
Disconnect the battery connector.
2. Remove the hex head cap screw securing
the stem mount cover. See Figure 6-12.
3. Disconnect the wiring harness connector
and arm angle switch connections. See
Figure 6-13.
Figure 6-10. Lift/Lower Button Removal
Figure 6-11. Push Button Removal
A
A
1581 010.tif
Figure 6-12. Removing Cover
Figure 6-13. Cover Removed
Cover
Cap Screw
Wiring Harness
Connector
Arm Angle
Switch
Connections
Control Handle
00700-CL340-05, Issued: 2 May 2005 6-17
Before removing the cap screws in the
next step, make sure you are holding
the handle. When the cap screws are
removed, the handle will fall.
4. Remove the three Allen head cap screws
located at the base of the control handle
stem. See Figure 6-14.
5. Carefully remove the control handle stem
and mount.
Reassembly
1. During reassembly, make sure that the
brake release cam assembly is in the
correct position before installing.
2. Position the control handle mounting base
on the pivot assembly.
3. Reinstall the three Allen head cap screws.
4. Thread the wiring harness through the
handle base.
5. Reattach the control handle head unit if
removed.
6. Reconnect the handle harness connector
and arm angle switch connections. Install
the cable ties in their original locations on
the handle harness.
7. Install the control handle cover.
8. Connect the battery connector. Press the
green ON (I) key on the keypad.
9. Test the operation of the truck.
Figure 6-14. Allen Head Cap Screws
Allen Head
Cap Screws
Horn (H1)
6-18 00700-CL340-05, Issued: 2 May 2005
Horn (H1)
to Parts Catalog.
Removal
3. Disconnect the two wires from the horn.
See Figure 6-15.
4. Remove the horn mounting bolt.
Installation
1. Attach the horn to the electrical panel and
tighten the mounting bolt.
2. Attach the two wires.
3. Reconnect the battery connector, press the
green ON (I) key on the keypad, and test
operation.
5. Install the tractor cover.
6. Reconnect the battery connector.
1665 031.tif
Figure 6-15. Horn Location
Horn (H1)
Power Amplifier (A1)
00700-CL340-05, Issued: 2 May 2005 6-19
Power Amplifier (A1)
to Parts Catalog.
The power amplifier is installed in the tractor
compartment. See Figure 6-16.
Do not open the power amplifier.
Opening the power amplifier could
damage it and will void the warranty.
Cleaning
3. Discharge the capacitors in the power
amplifier by connecting a load (such as a
contactor coil) across the power amplifiers
B+ and B terminals.
4. Clean the power amplifier with a moist
rag. Let it dry before connecting the
battery.
5. Make sure the power cable connections
are tight. Do not stress the cable
connections or put strain on internal
components.
Removal
3. Discharge the capacitors in the power
amplifier by connecting a load (such as a
contactor coil or a horn) across the power
amplifiers B+ and B terminals.
4. Push the locking tab and disconnect the
J5 connector from the power amplifier. See
Figure 6-16.
5. Disconnect the three power cables
(terminals B+, B and M) on the power
amplifier. Do not stress the power cable
connections. Disconnect wiring harness
connectors (terminals F1 and F2).
6. Remove the three hex head cap screws
securing the power amplifier to the
electrical panel. Remove the power
amplifier.
Installation
NOTE: All power amplifiers are preset to factory
default specifications.
1. Secure the power amplifier to the electrical
panel with the three previously removed
hex head cap screws.
2. Reconnect the three power cables
(terminals B+, B and M) on the power
amplifier. Torque screws to 12 ft. lb.
(16.3 Nm) maximum. Do not stress the
cable connections and put strain on
internal components.
3. Connect the J5 connector and wiring
harness connectors (terminals F1 and F2)
to the power amplifier.
4. Connect the battery connector and press
the green ON (I) key on the keypad.
5. Test operation of the truck.
1665 031.tif
Figure 6-16. Power Amplifier Location
J5 Connector
Power
Amplifier
Contactors
6-20 00700-CL340-05, Issued: 2 May 2005
Contactors
to Parts Catalog.
Contactors (K10 and K30) control the
transmission of battery power to the drive and
lift motors.
Main Contactor (K10)
Removal
3. Disconnect the wires from the X and Y
terminals on the contactor coils. See
Figure 6-17.
4. Remove the nuts securing the bus bar and
cables to the contactor. Note the location
for assembly later. See Figure 6-17.
5. Remove the two screws holding the
contactor assembly to the electrical panel.
Installation
1. Secure the contactor to the electrical panel
with the two screws removed earlier.
2. Secure the bus bar and cable to the
contactor with the nuts.
3. Connect the wires to the X and Y
terminals.
5. Connect the battery connector. Press the
Lift Motor Contactor (K30)
See Hydraulic Components on page 6-47.
Figure 6-17. Main Contactor K10
X and Y
Terminals
Bus Bar
Figure 6-18. Lift Motor Contactor K30
Lift Motor
Contactor
Master Control Relay (K4)
00700-CL340-05, Issued: 2 May 2005 6-21
The master control relay (K4) should be
regularly tested for proper operation.
Inspection/Test
2. With the battery connected, press the
3. Use a voltmeter to check the voltage
between wire #26 (terminal 4) and wire
#24 (terminal 2).
The voltmeter should read approximately
24V.
4. Move the control handle down into the
operating position. The voltmeter should
now read 0V. If not, replace the master
control relay.
1665 031.tif
Figure 6-19. Master Control Relay (K4)
Wire #26 Wire #24
6-22 00700-CL340-05, Issued: 2 May 2005

Switches (General)
00700-CL340-05, Issued: 2 May 2005 6-23
Switches (General)
to Parts Catalog.
Refer to the schematic in the Appendix to
identify the electrical circuit location of the
switch. See Schematics on page A-9.
Test/Inspection
Examine the switch for signs of arcing,
overheating, discoloration, cracking, or other
physical damage. Replace the switch if you see
such damage.
To test a switch, isolate it from the electrical
circuit. Do this by removing all the connections
from the switch, making sure all wires are
labeled and identified for later reconnection.
Use an ohmmeter set to a low resistance scale
to measure the resistance across the switch. In
the closed position, the switch must have a
resistance of less than 1 ohm. In an open
position, the switch must show a resistance
greater than 10 megohms.
Master Control ON/OFF Switch
A Master Control ON/OFF switch (S21) is
provided on the truck. In the OFF (O) position,
battery power to all control functions is
interrupted. In the ON (I) position, battery
potential is provided to all control functions via
the power amplifier. See Figure 6-20.
Inspection
1. With the battery plugged in and the Master
Control ON/OFF switch in the ON
position, battery voltage B+ must be
present on the two terminals of the switch.
2. Test the Master Control ON/OFF switch
with an ohmmeter after disconnecting the
battery and removing the wires from the
switch terminals.
In the OFF position, the ohmmeter must
read greater than 1 megohm, and in the
ON position, the ohmmeter must read less
than 1 ohm. If not, replace the switch.
Removal
1. Disconnect the battery connector.
3. Disconnect the wires from the switch.
4. Remove the Master Control ON/OFF
switch.
Installation
1. Install the new Master Control ON/OFF
switch.
2. Connect the wires to the new Master
Control ON/OFF switch terminals.
3. Reconnect the battery connector and verify
operation.
1581 004.tif
Figure 6-20. Master Control ON/OFF Switch Location
Master Control
ON/OFF Switch
Switches (General)
6-24 00700-CL340-05, Issued: 2 May 2005
Arm Angle Switches
The Arm Angle Switches (S24 and S25)
determine brake activation and truck travel
speed. Each switch is activated by the control
handle position. The control handle must be
positioned between 5 of vertical and 5 of
horizontal in order for the switches to be closed,
permitting travel. See Arm Angle Switches on
page 5-6.
Adjustment
The arm angle switches are found at the base of
the control handle stem. See Figure 6-21.
Use extreme care when the truck is
After the truck is jacked, DO NOT rely on
the jack alone to support the truck. For
details, See Jacking Safety on
page 2-9.
2. Jack the truck and block the frame.
3. Remove the stem mount cover.
4. Loosen the two screws holding the bracket
on the stem mount. Slide the bracket out
as far as possible. See Figure 6-22.
5. Slide the switch back in until the switch
clicks. Move the switch out (approx.
1/32 in. [0.7 mm]) until it clicks again.
Retighten the screws.
6. Make sure that the cam arm makes solid
contact with the switch lever.
7. Verify that the switch clicks near the
middle of the cam movement.
8. Switch S25 must operate within 5 of the
full up or down handle position. Make
sure the switch does not bottom out when
fully compressed.
9. Install the stem mount cover. See
Figure 6-23.
10. Remove the blocks, connect the battery
connector and press the green ON (I) key
on the keypad.
1581 007.tif
Figure 6-21. Arm Angle Switches
Arm Angle Switches
1581 008.tif
Figure 6-22. Arm Angle Switch Screws
Figure 6-23. Control Handle Cover Installed
Screws
Switches (General)
00700-CL340-05, Issued: 2 May 2005 6-25
Removal
1. Lower the forks completely.
3. Remove the stem mount cover.
4. Disconnect the wires on the switch.
5. Remove the mounting bracket from the
stem mount.
6. Remove the screws holding the switch on
the mounting bracket.
7. Remove the switch.
Installation
1. Mount the switch to the mounting bracket.
2. Connect the wires to the switch.
3. Install the mounting bracket.
4. Reconnect the battery connector. Press the
5. Test drive the truck.
6. Adjust the switch if necessary.
8. Install the stem mount cover.
9. Reconnect the battery connector.
Lift-Limit Switch
When the forks are fully raised, the lift-limit
switch (S36) turns the hydraulic pump motor
off. This keeps the pump from trying to extend
the lift cylinder beyond its maximum travel. See
Figure 6-24.
Adjustment
1. Raise the forks until they reach their fully
raised position. If the lift-limit switch does
not shut the pump down when the lift
cylinder reaches its upper limit, the relief
valve on the hydraulic pump will make a
high-pitched squeal, indicating that the
relief valve is opening.
3. Loosen the bolt and slide the switch
bracket up or down to activate (cut power
off) when the lift is 1/2 to 1 in. (13 to 25.4
mm) before the fully raised position.
4. Tighten the bolt.
5. Reconnect the battery connector. Press the
green ON (I) key on the keypad. Lower the
forks and then lift them until they reach
their fully raised position. The lift-limit
switch must cut power off to the pump
when the lift cylinder reaches 1/2 to 1 in.
(13 to 25.4 mm) before its fully raised
position.
1581 014.tif
Figure 6-24. Lift-Limit Switch
Lift-Limit Switch
Switches (General)
6-26 00700-CL340-05, Issued: 2 May 2005
Key Switch (Optional)
A two-position (ON/OFF) key switch (S17),
located on the main console, energizes all truck
control functions when in the ON position,
provided the Master Control ON/OFF switch is
in the ON position.
Inspection
2. With the battery plugged in and the key
switch ON, battery voltage B+ must be
present on the two terminals of the switch.
3. Turn the key switch to OFF, disconnect
the battery and remove the wires from the
switch terminals.
4. Test the key switch for continuity with an
ohmmeter.
In the OFF position, the ohmmeter must
read greater than 1 megohm, and in the
ON position, the ohmmeter must read less
than 1 ohm. If not, replace the switch.
Drive Unit
00700-CL340-05, Issued: 2 May 2005 6-27
Drive Unit
The drive unit includes the drive motor,
electromagnetic brake assembly, drive wheel,
and transmission assembly.
to Parts Catalog.
Transmission Assembly
Removal
1. Lower the forks, press the red OFF (O) key
on the keypad. Disconnect the battery
connector.
Use extreme care whenever the truck is
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on
page 2-9.
4. Remove the stem mount cover. Disconnect
the handle harness and arm angle
sensors.
5. Remove the three Allen head cap screws
that secure the control handle assembly to
the drive unit assembly. See Figure 6-25.
6. Disconnect the cables/wire from the
terminal block on the transmission. See
Figure 6-26.
7. Remove the ten Allen head bolts that
secure the transmission and bearing
assembly to the frame.
NOTE: Remove four Allen head bolts to remove
only the transmission but not the steer
bearing.
1665 045.tif
Figure 6-25. Control Handle Assembly Removal
Figure 6-26: Terminal Block
Allen Head
Cap Screws
Terminal Block
Connections
Drive Unit
6-28 00700-CL340-05, Issued: 2 May 2005
Transmission assembly may fall free
from mounting after bolts are removed.
8. Remove the transmission and steer
bearing assembly by lowering through the
pivot-frame mount.
9. Feed the control wiring harness and power
cables through the transmission pivot
mount.
Disassembly
1. After draining the gear case lubricant,
thoroughly clean the outside with solvent
or other non-corrosive cleaning fluid. Air
dry all parts, and proceed with the
disassembly of transmission.
2. Remove the drive wheel. See Drive Wheel
on page 6-31.
3. Remove the nine hex head cap screws
securing the gear case cover. Remove the
gear case cover.
4. Remove the retaining ring that secures the
top (pinion) gear.
5. Remove the top (pinion) gear and Woodruff
key attached to the drive motor armature
shaft.
6. Remove the drive motor if required. See
Drive Motor on page 6-42.
7. Remove the drive motor bearing, bearing
shim, and seal from the gear case if
required.
8. Remove the 2nd stage gear set from the
gear case.
9. Remove the retaining ring from the drive
axle then remove the output gear.
10. Press the drive axle through the inner and
outer gear case bearings.
11. Remove the old bearings, spacers, and
seals from the gear case. Thoroughly clean
the case.
Assembly
1. Install the new bearings in the gear case
and cover for the 2nd stage gear set.
2. Install the new bearings, spacer, and seal
in the gear case for the drive axle.
3. Place the case in a fabricated assembly
base and carefully press the drive axle in
the gear case.
4. Position the transmission on the work
bench with the gear case side up. Install
the output gear in the case and secure
with the retaining ring.
5. Install the 2nd stage gear set.
6. Install the drive motor bearing, bearing
shim, and seal in the gear case if removed
previously.
NOTE: The seal must be installed correctly with
its open side and seal ring positioned
towards the bearing.
7. Carefully slide the drive motor armature
shaft into the gear case if removed
previously. See Drive Motor on
page 6-42.
Make sure that the motor end cap is
installed before proceeding to the next
step.
8. Install the pinion gear, woodruff key, and
the retaining ring on the armature shaft.
9. Use gasket eliminator (Loctite 515 or GE
Weicon Silmate) on the mating surface and
install the gear case cover. Torque the
cover bolts to 30 ft. lb. (42 Nm).
Drive Unit
00700-CL340-05, Issued: 2 May 2005 6-29
Legend:
W08175b.eps
Figure 6-27. Transmission Assembly, Exploded View
3
4
12
1
9
2
17
10
5
13
27
25
21
13
11
16
18
19
7
20
1 Housing, Gearbox 15 Seal, Motor (not shown)
2 Cover, Gearbox 16 Seal
3 Screw 17 Drive Axle
4 Pinion, Drive 1st Stage 18 Bearing, Sealed
5 Gear Set, 2nd Stage 19 Spacer, Bearing
7 Gear Set, Output 20 Ring, Retaining
9 Bearing, Steering Outer Race 21 Key, Woodruff
10 Plug, Fill/Level 22 Cap Screw, Allen Head
11 Plug, Drain 23 Hub, Wheel (not shown)
12 Bearing, Sealed 25 Axle, 2nd Stage
13 Bearing Set, Cup & Cone 26 Key, Output (not shown)
14 Bearing, Motor (not shown) 27 Ring, Retaining
Drive Unit
6-30 00700-CL340-05, Issued: 2 May 2005
Installation
Make sure the Master Control ON/OFF
switch is OFF and the battery connector
is disconnected before you start.
1. Install the steer bearing assembly if
removed previously.
2. Reinstall the drive unit assembly through
the pivot frame while feeding the harness
and cables through the pivot frame mount.
3. Secure the assembly with the ten Allen
head bolts removed previously.
4. Feed the wire harness and power cables
through the pivot tube.
5. Reconnect the cables/wire to the terminal
block on the transmission.
6. Install the drive wheel. See Drive Wheel
on page 6-31.
7. Unblock and lower the truck.
8. Install the control handle.
9. Reconnect the wiring harness.
10. Ensure the drive unit is filled to the
correct level with gear oil. Install the
fill/level plug.
11. Install the stem mount cover and tractor
cover.
12. Install the battery, reconnect the battery
connector and the turn the Master Control
ON/OFF switch ON. Press the green ON (I)
key on the keypad.
13. Check the controls for correct operation.
Drive Housing Lubrication
Gear Oil Level
1. Remove the fill/level plug. See
Figure 6-28.
2. Check the oil level. When the truck is level,
the oil must be up to the bottom of the
plug opening.
3. If necessary, add the specified oil through
the plug opening, but do not overfill.
4. Install the fill/level plug securely.
Changing Gear Oil
1. Remove the drain plug from the bottom of
the gear housing and permit the oil to
drain. See Figure 6-28.
2. After the oil has drained completely, flush
the housing with a suitable solvent and
allow it to drain.
3. Install the drain plug.
4. Fill the drive housing with the specified
gear oil through the fill/level plug opening
in the cover of the transmission.
1665 039.tif
Figure 6-28. Transmission Assembly Fill/Drain Plugs
Drain Screw
Fill/Level Plug
Drive Unit
00700-CL340-05, Issued: 2 May 2005 6-31
Drive Wheel
to Parts Catalog.
Removal
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on
page 2-9.
2. Jack and block the truck under the tractor
frame.
3. Remove the five drive wheel mounting
nuts. See Figure 6-29.
4. Remove the drive wheel.
Tire Replacement
Any misalignment of the tire and hub while the
tire is being pressed on the hub can cause
damage to the hub. For this reason, chamfers
are provided on the outside edge of the hub and
on the end of the inside diameter of the tires
metal insert. The chamfers help to center the
hub and tire during pressing and to reduce the
possibility of misalignment.
To prevent damage, the hub must be
installed on the circular ram with the
chamfered side up.
1. Check the inside surface of the metal
insert on the new tire. Remove any scaling
or rust with sandpaper. Clean the inside of
the metal insert.
2. Place a circular ram on the press table.
The length of the ram must be longer than
the width of the old tire to permit complete
removal of the old tire. The outside
diameter of the ram must be small enough
to fit loosely in the insert of the tire but
must be large enough to rest squarely on
the flat surface on the outer edge of the
hub. See Figure 6-30.
1581 007.tif
Figure 6-29. Drive Wheel Nuts
Drive
Wheel
Nuts (5)
tire.pcx
Figure 6-30. Tire Replacement
Drive Unit
6-32 00700-CL340-05, Issued: 2 May 2005
3. If the outside edge of the hub is not flush
with the edge of the metal insert in the old
tire, measure how far the hub is recessed
inside the tire. The new tire must be
placed in the same position the old tire
was installed on the hub. You can use a
spacer (slightly smaller in diameter than
the inside diameter of the tire insert and
the same thickness as the depth of the
recess) to obtain the correct amount of
recession.
4. Position the hub assembly with the old tire
on top of the circular ram so the outside of
the wheel is positioned upward. The
outside edge of the hub has a chamfer to
help guide the new tire on the wheel. The
chamfered edge must always be the
leading edge when a tire is pressed on the
hub.
5. Center the hub assembly on top of the ram
and make sure they mate squarely.
6. Position the new tire with its chamfered
insert facing the hub. Align the new tire
and the hub so they are concentric.
7. Begin pressing the new tire on the hub
and the old tire off the wheel. Run the
press slowly for the first few inches of
travel because this is the critical step of
the operation. If the tire starts to cock,
stop the press immediately and realign the
tire. Use a soft-headed mallet to realign
the tire on the hub.
NOTE: If the new tire does not press on with a
minimum pressure of 5 tons
(68,947 kPa), replace the hub.
8. Release the press. Remove the wheel, tire
assembly and the old tire from the press
table. Inspect the wheel and tire assembly.
9. Install the wheel and tire assembly on the
drive axle of the truck. Reinstall the five
drive wheel mounting nuts. Torque to
55 ft. lbs. (75 Nm).
Electromagnetic Brake
00700-CL340-05, Issued: 2 May 2005 6-33
to Parts Catalog.
Allow the brake to cool completely
before servicing.
Brake Disc Location
The electromagnetic brake assembly is
mounted directly to the drive motor. See
Figure 6-31.
Air Gap Adjustment
The nominal gap between the coil housing and
the pressure plate in the applied position is
0.008 to 0.010 in. (0.2 to 0.25 mm).
After the truck is jacked, Do NOT rely on
the jack alone to support the truck. See
Jacking Safety on page 2-9.
3. Remove the drive unit cover.
4. Loosen the three 4 mm Allen head brake
assembly mounting bolts. See Figure 6-32.
5. Turn the adjusting screws while checking
the air gap at several points with a
0.008 in. (0.2 mm) feeler gauge.
6. Tighten the mounting bolts to 50 in. lb.
(5.6 Nm). Recheck the gap with the feeler
gauge.
1581 009.tif
Figure 6-31. Brake Location
Electromagnetic
Brake
1665 053.tif
Figure 6-32. Brake Gap Adjustment
0.008 - 0.010 in.
(0.2 - 0.25 mm)
Pressure Plate
Adjusting
Screw
Coil Housing Friction Disc
Mounting
Bolt
Air gap
6-34 00700-CL340-05, Issued: 2 May 2005
Friction Disc Replacement
Replace the friction disc when its total
thickness is reduced to 0.20 in. (5.5 mm).
1. Loosen and remove the three 4 mm
mounting bolts and remove the brake coil
assembly. See Figure 6-33.
2. Replace the friction disc on the hub.
Inspect friction plate for wear. Replace the
friction plate if the surface is worn
unevenly.
3. Install the brake coil assembly on the
motor end. Adjust the gap and torque
mounting bolts. See Air Gap Adjustment
on page 6-33.
Mechanically Releasing the
Brake
If the brake cannot be electrically released,
perform the following:
1. Remove the drive unit cover.
2. Loosen the three 4 mm Allen head
mounting bolts evenly until the clamping
force on the friction disc is low enough to
allow the truck to roll.
3. Move the truck to the desired location.
4. Adjust the gap and torque mounting bolts.
See Air Gap Adjustment on page 6-33.
5. Install the drive unit cover.
Figure 6-33: Friction Disc Replacement
Mounting Bolt (x3)
Brake Coil Assy Friction Disc
Adjusting Screw (x3)
Motors, General
00700-CL340-05, Issued: 2 May 2005 6-35
Motors, General
to Parts Catalog.
Drive Motor Brush Inspection
Conduct a partial inspection of the drive motor
after every 1,000 hours of truck operation. If
you work in an abnormally severe or caustic
environment or if you have a rigorous duty
cycle, inspect the motor more frequently.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency
from the electrical equipment.
Each partial inspection of the motor must
include the following:
1. Inspect the brushes for wear and for
correct contact with the commutator.
Record the level of wear on the brushes.
This history will give you an indication of
whether a brush must be changed or if it
can wait until the next inspection. Refer to
page 6-36 for acceptable brush length and
general motor information.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.
2. Check brush spring tension. See Drive
Motor Brush Spring Tension on
page 6-36.
3. Clean brushes and holders. Wipe the
commutator with a dry, lint-free cloth. DO
NOT USE lubricants of any kind on or
around the commutator.
4. Check brush holders for solid connection
to the mounting support. Tighten the
mounting screws as necessary.
5. Check the cap screws holding the brush
cross connectors to the brush holder body.
6. Make sure the motor terminals are
secured tightly to the motor frame. Be
careful not to strip the threads or crush
the insulating parts.
7. Check all the cap screws around the frame
for tightness.
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.
Replacement
If one brush needs replacement, always replace
the entire set of brushes.
Use only genuine Toyota brushes. Using
another type of brush could damage the
commutator or cause excessive brush wear.
If the end of the brush is not already contoured
to fit the commutator, use the following
procedure to seat the brush to the commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone.
1. Move the motor brush springs out of your
way.
2. Wrap a piece of 00 sandpaper around the
commutator. DO NOT use emery cloth to
seat brushes.
3. Move the brushes back down in their
holders so that the face of the brushes
matches the curve of the commutator.
MTRBRUSH.tif
Figure 6-34. Drive Motor Brush, Typical Location
Motors, General
6-36 00700-CL340-05, Issued: 2 May 2005
4. Remove the sandpaper.
5. Blow any dust out of the motor with clean,
compressed air at a maximum of 30 psi
(207 kPa).
Drive Motor Brush Spring
Tension
Inspection
2. Remove the drive motor cover.
3. Slide the brush up slightly in its holder.
4. Insert a paper strip between the brush
face and the commutator. See Figure 6-35.
5. Place a small leather loop around the coil
spring for the brush. If the brush spring
has a loop at the brush, hook the spring
scale directly to the spring.
6. Attach a 5 lb. (2.27 kg) spring scale to the
leather loop.
7. While gently pulling the scale outward,
slowly pull the paper strip in the direction
that the commutator normally rotates.
8. When the paper strip starts to move freely,
the spring scale will read the spring brush
tension.
9. Refer to the table below for correct spring
tension.
10. Repeat steps 3 through 9 for the
remaining brushes.
Motor Commutator
Inspection
The commutator should be inspected for
surface condition and high mica. Most
armatures have the mica undercut. If the
armature on your motor does not, do not
attempt to cut it. See Figure 6-36.
The commutator must be smooth and clean to
provide maximum brush wear. When
commutators are not properly maintained,
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.
TENSION.tif
Figure 6-35. Motor Brush Spring Tension Inspection
Paper
coil spring
leather
loop
Motor
Minimum
Brush Length
Spring
Tension
Drive
Motor
0.59 in.
(15 mm)
20 oz. min.
(568 grams)
1881 003.tif
Figure 6-36. Mica Inspection
Mica
Segments
NORMAL
UNDERCUT
HIGH MICA
High Mica
Motors, General
00700-CL340-05, Issued: 2 May 2005 6-37
Good commutation is indicated by a dark
brown polished commutator and an evenly
polished brush wearing surface. See Table 6-1,
Commutator Surfaces.
If the commutator appears rough, pitted, or has
signs of burning or heavy arcing between the
commutator bars, remove the motor for
servicing.
Table 6-1: Commutator Surfaces
Condition Probable Cause Commutator Surface
Good Condition-Light
Film
Uniform coloring indicates satisfactory
operation of machine and brushes. Film
color is largely an effect of thickness;
therefore, provided the film is uniform, it is
perfectly acceptable.
Satisfactory
Condition-Light and
Dark Pattern
This is not a good condition, but in our
experience it is known that machines
having this commutator pattern have
operated with satisfactory results for long
periods of time. This condition can appear
in alternating bars as shown or every 3rd
or 4th bar and so on. This is related to the
winding design of the armature. Difficulty
caused from split windings crossing in the
same slot.
Unsatisfactory
Condition-Streaky Film
With No Commutator
Wear
Frequently due to under-loaded operation,
machine grossly over-brushed or brush
grade incorrect for particular machine
application. Atmosphere and
environmental conditions can contribute.
Unsatisfactory
Condition-Uneven Film
Patchy colors of varying densities and
shape. Due to unclean operating
conditions or incorrect physical condition
of commutator.
Unsatisfactory
Condition- Film With
Dark Areas
These areas can be isolated or regular.
Commutator out of round. This can be
caused by vibration or mechanical
deficiencies in equipment operation,
bearings, couplings, etc.
Unsatisfactory
Condition-Example of
Poor Commutator
Machining
Bars are low on entry and leaving edges
giving rise to the brushes riding on the
middle of the bars.
Unsatisfactory
Condition-Example of
Poor Commutator
machining
Bars are low in the middle giving rise to the
brushes riding on entry and leaving bar
edges. This and the previous illustration
indicate the need for better maintenance.
Motors, General
6-38 00700-CL340-05, Issued: 2 May 2005
Servicing
If the commutator requires service, you will
need to remove the armature from the motor.
DO NOT use a stone to even out high and low
spots on the commutator. Use only a suitable
abrasive rubber polisher.
Servicing a motor for an abnormal commutator
surface condition and high mica or mica
undercutting requires special equipment at a
motor rebuilding facility.
Unsatisfactory
Condition-Streaky Film
With commutator Wear
This is a further development of the third
example. Brush grade, machine
applications, and working environment are
all suspect. Earlier corrective action
should have been taken.
Unsatisfactory
Condition-Double Pole
Pitch
Darkening of commutator in sequences two
pole pitches apart is due to armature fault,
bad coil, riser bars, or equalizer
connections.
Unsatisfactory
Condition-Brush
Contact Mark
Storage of machines, for lengthy periods,
with brushes in position. This can also
result from operation of machine in
prolonged stall conditions.
Unsatisfactory
Condition-Bar Edge
Burning-Cause High
Mica
Illustration shows high mica in every slot.
Same effect can occur on one bar only.
Similar conditions can be caused by a high
or low bar.
Unsatisfactory
Condition-Small Bright
Spots
Related to over-loaded machines and low
brush pressure. Due to sparking under
brush that gives rise to spots being of a
random distribution. If not corrected, will
result in scored commutator.
Table 6-1: Commutator Surfaces
Condition Probable Cause Commutator Surface
Motors, General
00700-CL340-05, Issued: 2 May 2005 6-39
Terminal Nuts
Whenever you disconnect and reconnect any
power leads to a motor, always tighten the
motor cable securing nuts with a torque wrench
to prevent over-tightening them and damaging
the motor. Use a second wrench on the stud
terminal securing nut to avoid twisting the
stud. See Figure 6-37.
Check these torques each time you check motor
brushes.
Electric Motor Tests
Motor Types
A shunt-wound motor, such as the drive
motor, has four external connections: two
armature (A) and two field (E). See
Figure 6-38.
A compound motor, such as the lift motor,
has only two external connections because
the armature and field windings are
connected internally.
Open Circuit Motor Test
An open circuit is one where the electrical
circuit within the motor has been broken. This
can be caused by:
Bad brushes or brush springs
A broken wire in the field or armature
winding
A loose or bad connection
Test using the following procedure:
1. Isolate the motor from the truck circuit by
removing the power cables. Use two
wrenches to avoid twisting the terminal
stud.
CABLENUT.eps
Figure 6-37. Motor Terminal Nuts
Stud Size
Motor Cable
Securing Nut
Stud
Terminal
Securing Nut
3/8 in.
(M10)
100-120 in. lb.
(11.2-13.6 Nm)
140-160 in. lb.
(15.8-18.1 Nm)
5/16 in.
(M8)
90-110 in. lb.
(10.2-12.4 Nm)
110-140 in. lb.
(12.4-15.8 Nm)
1/4 in.
(M6)
40-50 in. lb.
(4.5-5.6 Nm)
50-60 in. lb.
(5.6-6.8 Nm)
Flat
Washer
Fiber
Washer
Motor
Housing
Motor
Cable
Securing
Nut
Stud
Terminal
Securing
Nut
Terminal
Stud
Dschem.eps
Figure 6-38. Motor Circuits
Shunt-Wound Motor
A2
A1
MD
S2/E2/D2
S1/E1/D1
Compound Motor
MX
A
S/D
Motors, General
6-40 00700-CL340-05, Issued: 2 May 2005
2. With the motor at room temperature,
connect the leads of a digital ohmmeter
between the individual circuits in the
motor.
3. Observe the measurements given in
Table 6-2.
4. If the meter indicates high resistance in
the armature, check the condition of the
brushes before replacing the motor.
5. If an open circuit is found in a compound
motor, the motor must be disassembled by
a motor rebuilding facility to isolate the
problem to the field or armature circuit.
Table 6-2: Motor Resistance Readings
Motor Terminals
Acceptable
Resistance
Readings
Unacceptable
Resistance Readings
Traction
(Drive)
Armature A1 to A2 0.01 to 0.10 ohms Greater than
0.10 ohms
Field E1 to E2
(S1 to S2)
0.8 to 1.7 ohms Less than 0.5 ohms
or Greater than
2.0 ohms
Lift A to S 0.020 to 0.030 ohms Greater than
0.1 ohms
NOTE: Measure all readings at room temperature.
See Figure 6-38 on page 6-39.
Motors, General
00700-CL340-05, Issued: 2 May 2005 6-41
Grounded Motor Test
In a grounded motor, an electrical circuit exists
between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.
The ground may be caused by:
Insulation breakdown
Brush leads touching the motor housing
Build-up of carbon dust or other materials
To test a motor for grounds:
Isolate the motor from the truck circuit by
removing the power cables. Use two wrenches
to avoid twisting the terminal studs.
Attach one lead of a digital ohmmeter to a motor
terminal and the other lead to an unpainted
surface of the motor housing. Set the ohmmeter
to the highest scale.
If the ohmmeter reads resistance of less than
100,000 ohms, the motor is grounded. Clean,
repair, or replace the motor as necessary.
Short-Circuited Winding
A short-circuited winding is one where the
insulation on the field or armature has broken
down at two or more points. The breakdown
creates a low resistance path, permitting
current to flow from one turn of the coil to
another adjacent coil turn, without actually
flowing through the coil wire. The result is a
decrease in total resistance of the motor
winding and an increase in the current flow.
The severity of the short circuit depends on its
location.
A shorted motor may be indicated by:
Slow or sluggish operation
Running faster than normal
Overheating
Blowing a power fuse
Severe burning or discoloring on one or
two commutator segments every 90 of
rotation
These symptoms can also be caused by
problems other than the motor itself, such as:
Brake too tight or dragging
Wheel bearings too tight
Faulty transmission
Binding in an attached pump
Testing a motor for short-circuited windings
requires special equipment at a motor
rebuilding facility.
Short-Circuited Armature
A short circuit in the armature will cause
heating, and will probably result in burning of:
The armature coil
Brush wires
Commutator segments
Visual inspection may reveal these conditions.
Positive determination of a short-circuited
armature requires special equipment at a motor
rebuilding facility.
Drive Motor
6-42 00700-CL340-05, Issued: 2 May 2005
Drive Motor
to Parts Catalog.
Brush Replacement
2. Remove the tractor covers.
3. Remove any shields around the motor end
cover to expose the brushes. See
Figure 6-39.
4. Lift the spring off the brush, pull the
brush out of the holder.
5. Follow the brush replacement
instructions. See Drive Motor Brush
Inspection on page 6-35.
6. Replace the shields around the motor end
that were removed in step 3.
Motor Disassembly
2. Remove the tractor covers.
3. Disconnect the power cables from the
terminal block on the drive motor, noting
their correct position.
4. Follow steps 1 through 5 in Disassembly
on page 6-28 to remove the top (pinion)
gear attached to the motor armature shaft.
5. Remove the electromagnetic brake
assembly by removing the three mounting
bolts that secure the assembly to the
motor end bell cover.
6. Remove the brake disc from the brake
hub.
7. Remove the retaining ring that secures the
brake hub. Remove the hub and woodruff
key.
8. Remove the four screws and lock washers
holding the brush end bell to the housing.
9. Separate the end bell from the motor
housing. The armature will come out with
the end bell.
10. To remove the end bell from the armature,
remove the snap ring that holds the
bearing in the end bell. If needed, press off
the bearing and replace.
Installation
1. Thoroughly clean all parts with solvent or
other non-corrosive cleaning fluid. Air dry
all parts.
NOTE: Assemble the drive motor in a dirt-free
area.
2. If previously removed, install the drive
motor bearing, bearing shim, and seal in
the gear case.
NOTE: The seal must be replaced any time the
motor is removed from the housing.
The seal must be installed correctly with
its open side and seal ring positioned
towards the bearing.
3. Reinstall the end bell cover, with the brush
plate attached, on the motor armature
shaft.
4. Carefully slide the drive motor armature in
the motor housing.
5. Attach the end bell cover to the motor
housing with the four cap screws.
6. Install the pinion gear, woodruff key, and
the retaining ring on the armature shaft.
7. Use Permatex gasket eliminator on the
mating surface and install the gear case
cover.
Figure 6-39: Drive Motor Brush Shield
Brush
Shield
Drive Motor
00700-CL340-05, Issued: 2 May 2005 6-43
8. Make sure the drive unit is filled to the
correct level with gear oil. Install the
fill/level plug. See Drive Housing
Lubrication on page 6-30.
9. Install the brake hub and woodruff key,
and secure with the retaining ring.
10. Install the brake disc on the hub.
11. Install the brake coil assembly and attach
with three hex head cap screws.
12. Reattach the power cables and
electromagnetic brake wiring connections
to the terminal block.
13. Before testing operation, move the handle
from extreme left to right and down into
operating position and back several times.
Check for any wire and cable interference.
Repair or adjust as necessary.
14. Install the battery, reconnect the battery
connector and the turn the Master Control
ON/OFF switch ON. Enter your PIN-key
code then press the green ON (I) key on the
keypad.
Drive Motor
6-44 00700-CL340-05, Issued: 2 May 2005

Pallet Forks and Load Wheels
00700-CL340-05, Issued: 2 May 2005 6-45
Pallet Forks and Load
Wheels
to Parts Catalog.
Load Wheels
Load wheels are installed on each pallet fork
and are designed to support the rated load at
the forks fully raised height.
Removal and Replacement
1. Lift the forks to maximum height and
block them. See Jacking Safety on
page 2-9.
2. Remove the axle set screw. See
Figure 6-40.
3. Drive the axle out of the load arm casting
with a hammer and brass drift pin.
4. Push the wheel out.
5. If the bearings are to be reused, insert a
brass drift pin into each end of the load
wheel and knock the bearings out.
6. Install the bearings in the new load wheel
with the shields facing out.
7. Place the new load wheel upright on a flat
surface. Position the bearing over the load
wheel. Put a flat metal plate over the
bearing, and hammer the bearing in
position with a plastic mallet. Make sure
the bearing is fully seated in the load
wheel.
8. Align the wheel with the holes in the load
arm casting.
9. Drive the axle through the load arm
casting and wheel. Align the dimple in
the axle with the set screw hole.
10. Install and tighten the set screw.
Load Wheel Pull Rod
Load wheel pull rods are installed on each fork
and are designed to transfer the hydraulic
cylinder lifting action at the tractor end to the
load wheel fork.
Removal and Replacement
NOTE: It may be easier to work with the truck
upside down. Remove the battery before
turning the truck over. Some oil may
leak from the hydraulic reservoir.
1. Extend the load wheel forks. Remove the
set screw and shaft connecting the wheel
fork to the pallet fork. See Figure 6-41.
2. Remove the pivot pin locking bolt and
drive the pivot pin out with a brass drift
pin.
3. With the lower links out of the lift frame
channels, the links can be separated and
the pull rod removed from the link pin.
Each link has one set screw at opposite
27y7s173.tif
Figure 6-40. Removing Set Screw
Axle Set
Screw
Figure 6-41. Wheel Fork Set Screw Location (top view)
Wheel fork
Set Screw
Pallet Forks and Load Wheels
6-46 00700-CL340-05, Issued: 2 May 2005
ends. The link can be pulled apart without
removing any other set screws.
4. Press new bushings in the pull rods, if
necessary.
5. Reassemble the pull rods on the lower
links and press the links together so they
will fit in the frame channel.
6. Reinstall the pivot shaft and the retaining
bolt in the lower links.
7. Reconnect the pull rod to the wheel fork.
8. Place the truck upright and install the
battery. Connect the battery. Check the
reservoir fluid level. Test the operation of
the lift frame.
Carrier Frame Linkage
to Parts Catalog.
The bushings on the lower links can be replaced
by removing the links from one side at a time
and pressing in new bushings.
1. To separate the lift and carrier frames,
remove all battery connections before
removing the links.
2. Remove the upper and lower linkages and
lift the lift frame off the carrier frame. See
Figure 6-42.
Figure 6-42: Lower Links
00700-CL340-05, Issued: 2 May 2005 6-47
General Guidelines
To prolong the life of your Toyota Pallet Truck,
follow these guidelines:
Keep all fittings and connections tight to
prevent leaks. Do not over-tighten brass
fittings or they may become damaged or
distorted.
Before you remove any component from
the hydraulic system, wash the
component and surrounding area with
cleaning solvent to prevent foreign matter
from entering the system. Cap and plug all
openings immediately.
Whenever you remove a fitting with a pipe
thread, use a sealing compound on the
outside of the threads before you reinstall
the fitting. (Do not use Teflon
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
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.
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
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
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.
Figure 6-45. Hydraulic Cylinder Disassembly
Barrel
Inlet Port
Seal
Wiper
Retaining Ring Rod
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.
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.
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.
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
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.
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
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
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
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
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
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.
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
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.
7. Run the hydraulic pump by pressing the
lift button until all the hydraulic fluid is
pumped from the system.
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
11. Replace the vent plug.
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.
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
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.
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.
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
Cold Storage Conditioning
6-56 00700-CL340-05, Issued: 2 May 2005

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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
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
Bearings and
Bushings
Grease Mystic JT-6
NLGI Grade 2
00590-04844-71
(10 cartridges per
case)
00590-04845-71
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.
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
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
Decimal Equivalent Chart
00700-CL340-05, Issued: 2 May 2005 A-5
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
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
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
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
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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
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Figure A-3. Hydraulic Schematic
Motor
Pump
Filter
Reservoir
Flow Control Check
Valve
Solenoid
Valve
Pressure
Relief
Valve
Lift
Cylinder

I
n
d
e
x
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
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

7hbw23 RM Manual

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00700-CL340-05, Issued: 2 May 2005

4,500 lb. Powered Pallet Walkie

ANTI-TIEDOWN Bad power amplifier or ETAC.

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