PDF Service Manual TOYOTA 7PM18 7PM20 7PML20 Forklift - 2 MB
This comprehensive service manual provides detailed instructions for the TOYOTA 7PM18, 7PM20, and 7PML20 series forklifts.
It contains all the necessary information for maintenance, troubleshooting, and major repairs.
Following the procedures in this guide will help you keep your equipment operating at peak performance.
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--- Page 1 ---
Servic Manual
en
7PM18, 7PM20, 7PML20
Valid from serial number: 723984-
Order number: 222995-040
Issued: 2005-10-28 ITS
©TOYOTA Industrial Equipment Europe SARL Ancenis, France
--- Page 3 ---
Introduction Maintenance – P1
Safety regulations with maintenance work
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
3- Introduction Maintenance – P1
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with TOYOTA’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time:08.00-17.00 (20 hr./week)
- 2-shifts:06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts:06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work
are carried out.
3.1 Safety regulations with
maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 3- 1
--- Page 4 ---
Oil and grease specifica tion – P3
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
5- Oil and grease specifica tion – P3
Pos. Type of lubri- Specification Application
cant > -15° C < -15o C
A Grease 26777 (Spray) 26777 (Spray) Bearings and bushes
B Hydraulic oil ISO-L-HM32 ISO-L-VG 32 Hydraulic system
C Transmission oil Hypoid oil SAE Hypoid oil SAE Gears
80W/90 75W
D Grease Staburags Staburags Guide bearing
NBU 8EP NBU 8EP
E Grease 73942XX5 73942XX5 Lubricating nipples,
TOTAL N3942 TOTAL N3942 Contact pressure spring
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 5- 1
--- Page 5 ---
Engine suspension– 0450
Component parts
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
8- Engine suspension– 0450
8.1 Component parts
1
6680
2
3
21
20
4 5
6
19
7 8
18 11
9
14 13 12 10
15
17
16
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 8- 1
--- Page 6 ---
Mechanical drive gear unit – 2550
Component parts
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
Pos Description Note
23 Gasket
24 Gear wheel Motor gear
25 Washer
26 Nut Tightening torque 30 Nm
Locked with punch mark
Lock with Loctite 603
27 Screw Motor and gear housing
28 Nut Tightening torque 26.6 Nm
Lock with Loctite 242
29 Conical roller bearing
30 Shims
31 Seal
32 Drive shaft
10.1.1 Technical data
Type of truck 7PM18, 7PM20, 7PML20-8
7PML20-6
Type of gear 2-step angle gear 2-step angle gear
Gear ratio 19,14:1 16,29:1
Oil volume, litres 1,0 1,0
Oil type Hypoid oil Hypoid oil
Viscosity, normal tem- SAE 80W/90 SAE 80W/90
perature
Viscosity, <-15°C SAE 75W SAE 75W
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 10- 3
--- Page 7 ---
Steering system – 4000
Tiller arm handle
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
13.3 Tiller arm handle
28
29
27 26
24 14
25 14
23 22
17
21 18
20 16
19 15
14
30 14
31 13
12
10 11
32 9
8
35 33
34
5 6 7
4
1 2
3
Pos Description Note
1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic card
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
15 Spring
16 Pushbutton Not used
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 13- 3
--- Page 8 ---
1 2 3 4 5 6 7 8
© TIEE SARL
222995-040
A ONLY KEY BOARD ELECTRONIC CARD, TILLER ARM A
Order number
A2
KEY
S17 X5
20 22
Sh. 1 X3 2 INP. +24VDC
X5
119 119
Sh. 2 X3 3 CAN, HIGH
Date
X5
B 120 120 B
Sh. 2 X3 7 CAN, LOW
2005-10-28
X5
40 40
Sh. 2 6 X3 6 INP. 0VDC
X9 S17
20 1 BELLY BUTTOM
C 40 2 C
723984-
Service Manual
S1-S9 S10-S18
SPEED REF. VALUE
X41 119 3
1 20
120 4 S19
2 40 FORK LIFT
CAN CONNECTION
3 119
S20
FORK LOWER
D 4 120 D
Valid from serial number
CAN, SERVICE CONNECTOR
S18:1
X4 1 INP. HORN 1
1 2
7PM18, 7PM20, 7PML20
X4 2 OUT. 0 VDC HORN 1
S18:2
E X1 1 INP. HORN 2 E
1 2
T-code
X1 2 OUT. 0 VDC HORN 2
677, 678, 679
F F
Electrical System – 5000
Symbol List and Wiring Diagram
1 2 3 4 5 6 7 8
14- 7
--- Page 10 ---
1 2 3 4 5 6 7 8
© TIEE SARL
222995-040
A A
Order number
Date
PLATFORM STAYING DOWN, WITH GATES
B B
2005-10-28
TRANSISTOR REGULATOR
A1
S19
24 1 2 65
Sh. 6 8 11 INP. MAN ON PLATFORM
3
C C
723984-
Service Manual
S59
1 2 66
13 INP. PLATFORM NOT FOLDED UP
3
D D
Valid from serial number
S53
1 2 58
14 INP. GATES UP
3
40
7PM18, 7PM20, 7PML20
Sh. 6 8
E E
T-code
677, 678, 679
F F
7/11 PROD B
221397
Electrical System – 5000
Symbol List and Wiring Diagram
1 2 3 4 5 6 7 8
14- 17
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Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
Code C42
Description Warning of high battery voltage
Possible error Battery voltage > 33 volt.
cause Energy return feed to battery during motor braking
with a fully-charged battery.
Action 1. The fault disappears after a few lifts, once
the battery has been run down slightly.
2. Check the cabling, the battery contact and
the contact points on main contactor K10.
Code C43
Description The travel regulator shuts off due to excess or
subnormal temperature.
Possible error Too intensive operation or ambient temperature
cause too cold.
Error in the travel regulator.
Temperature levels below -25oC or above +85oC
reduce running speed.
Action 1. Check that the M12 fan is functioning. (Ap-
plies to P 24)
2. Check that the travel regulator is installed
with good contact with the chassis.
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 14- 27
--- Page 12 ---
Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
Parameter Description Unit Min Max Step Std Description
10 PIN-code 0 9999 1 1 Facility for specifying up to 10
PIN codes (10 different driv-
ers).
14 Crawling -10 10 1 0 The amount of power the mon-
speed itor should emit when you
reach the first speed sensor
can be specified here.
-10: low speed for the first
speed sensor.
10: high speed for the first
speed sensor
15 Non-config- See “Option parameters” on page 39
urable option
0 to 9
16 Configurable See “Option parameters” on page 39
option #1
17 Configurable
option #2
18 Configurable
option #3
19 Configurable
option #4
20 Hour meter 1 5 1 2 Select hour meter.
option
21 Battery size 1 20 1 5 Selection of battery size.
22 Inductive 0 1 1 1 0: Mechanical switch
sensor 1: Inductive sensor
25 Service inter- 1h 0 2000 50 100 Option for setting service timer
val
28 Lift button 1 3 1 1 Button selection
selection
39 Password 1 12 1 1 States which level of authoriza-
tion the driver has for the
parameters.
Odd values specify open driver
parameters, even values spec-
ify that driver parameters must
be opened using the CAN key
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 14- 37
--- Page 13 ---
Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
Instructions for verifying parameter setting
• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Remove the battery from the truck and allow to rest for at least two
hours. NB! No charging or discharging during this period.
• Measure the acid weight of the battery at room temperature. If the
acid weight is less than 1.15 g/cm3, the parameter value must be
reduced. If the value significantly exceeds 1.15 g/cm3, the risk of
damage to the battery is reduced. At the same time, the operating
time of the truck is reduced. If a longer operating time is required, the
parameter value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 14- 47
--- Page 14 ---
Electrical System – 5000
Troubleshooting
Order number Date Valid from serial number T-code
222995-040 2005-10-28 723984- 677, 678, 679
STATUS LED Text on hand Explanation Possible cause
unit
4,3 ¤¤¤¤ ¤¤¤ THERMAL CUT- Too high/too low 1. Temp. > 85oC or < -25oC
BACK temperature reduc- 2. The truck is overloaded.
tion. 3. Incorrectly installed transistor
regulator.
4. Operation under extreme con-
ditions.
14.9.2 Reset error
When you want to clear an error, first turn S17 to the “OFF” position and
then “ON” again.
Error Reset when
OVERVOLTAGE The battery voltage is below 33 V.
THERMAL CUTBACK The temperature is within the permitted
interval.
THROTTLE FAULT 1, 2 The fault has been dealt with.
LOW BATTERY VOLT- When the battery voltage exceeds 16
AGE V.
14.9.3 Safety
The regulator is a heavy current component. When it is used on a bat-
tery-powered vehicle, all necessary safety measures must be taken.
This means, among other things, that the driver must have suitable
training, use goggles, avoid loose clothing, take off watches and jewel-
lery and only use insulated tools. It may also be necessary to take other
measures.
WARNING !
Risk of short circuiting
Remove watches, jewellery and always use insulated tools only.
© TIEE SARL Service Manual 7PM18, 7PM20, 7PML20 14- 57
--- Page 15 ---
Battery charger (Inbuilt) – 8340