PDF Service Manual TOYOTA Forklift 7LOP10CW 7LOP10CF - 1 MB
This factory service manual provides all the necessary information for servicing and repairing the Toyota 7LOP10CW and 7LOP10CF forklifts.
It offers detailed instructions on diagnostics, troubleshooting, and repair procedures for all major systems.
Technicians will find this guide invaluable for performing maintenance to factory standards.
Ensure your equipment operates reliably and safely with this expert resource.
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Service Manual
en
7LOP10CW, 7LOP10CF
Valid from serial number: 931876-
Order number: 232370-040
Issued: 2006-04-10 ITS
©TOYOTA Industrial Equipment Europe SARL Ancenis, France
--- Page 3 ---
Technical data
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
Table 1: Technical data
Model 7LOP10CW 7LOP10CF
Hydraulic system
Power, kW 2.2 2.2
Intermittence 5% 5%
Minimum carbon brush length, mm 12 12
Minimal commutator diameter, mm 4.75 4.75
Pressure at rated load, bar 180 180
Overflow pressure, bar 200 200
Pump flow, litres/minute 5.0 5.0
Tank volume, litre 4.5 4.5
Oil type ISO-HM32 ISO-HM32
at normal temperature ISO-VG32 ISO-VG32
at temperatures < -15oC
Power steering
Model Power steering Power steering
PST 24/10 PST 24/10
Power, W 240 240
Torque at rated load 0.68 Nm 0.68 Nm
Max. current 60 A 60 A
Resistance,Ω, phase to phase 0.075 0.075
Fuses
Control circuit, F50, F51 3 A, 7.5 A 3 A, 7.5 A
Drive motor, F1 160 A 160 A
Pump motor, F3 125 A 125 A
Power steering, F52 30 A 30 A
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 2- 3
--- Page 4 ---
Maintenance
Maintenance schedule
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
Table 4: Maintenance schedule
I: Inspect, adjust and replace if necessary. T: Tighten. C: Clean L: Lubricate.
M: Measure and adjust if necessary.
Pos. no. Work to be performed
Interval in hours - can vary depending on 5 20 500 1,000 3,000
application
Interval in days/weeks/months - can vary 1d 1w 6m 12 m 36 m
depending on application
3500. Wheels
3500.1 Remove strings, dirt, etc. I
3500.2 Inspect drive wheel and support wheels, wear I
and there mounting
4110. Steering unit
4110.1 Inspect any steering response restrictions and I
jogging
4110.2 Inspect any play in steering couplings and the I
return spring
4110.3 Inspect mechanical locking of the steering arm I
and its centre position
4110.4 Inspect the gear of the steering servo-unit I
4110.5 Inspect correct mounting of the steering linkage I
on both sides
5000. Electric functions
5000.1 Inspect correct operation of the micro brake I I
switch
5000.2 Inspect correct operation of the emergency stop I I
switch
5000.3 Check lifting/lowering the forks / cabin I
5000.4 Inspect correct operation of the platform switch I I
5000.5 Inspect correct operation of the horn I I
5000.6 Inspect cable wear I
5000.7 Inspect correct operation of operator controls I I
5000.8 Inspect the error code log, operating hours and I I
all segments in the display panel
5000.9 Inspect correct operation of the 0.1 meter switch I I
in the mast
5000.10 Inspect correct operation of the double 0.5 I I
meter switch in the mast
5000.11 Inspect correct operation of the end lift switch in I I
mast
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 3- 7
--- Page 5 ---
Tools
Molex connectors
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
4.3 Molex connectors
16
9
8
1
Figure Number Application
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 4- 5
--- Page 6 ---
Driving unit/gear – 2550
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
6- Driving unit/gear – 2550
2
1 3
18
4
5
6
10
16 17 7
15 8
9
14
11
12
13
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 6- 1
--- Page 7 ---
Support wheels – 3500
Main components
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
8- Support wheels – 3500
8.1 Main components
18
17
16
15
14
13
12
11
Pos. no. Description
11 Screw
12 Washer
13 Mounting axle with plate
14 Bush
15 Washer
16 Bearing
17 Wheel
18 Washer
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 8- 1
--- Page 8 ---
Electrical steering system – 4300
Replacing the potentiometer
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
• Separate the switch at the
Ergo arm (C) and pull the en-
tire cable assembly mount
straight up.
C
• Disassemble the pivot cov-
ers (D, E) and the keypad.
D E
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 9- 9
--- Page 9 ---
Electrical systems – 5000
Electrical equipment overview
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
10.2 Electrical equipment overview
B10
M3
B11
Y10
Y45
P1 Y69
Y10
Y1
M1
S65
S19
G1
X1 R1
A36 X1 X41
A5 K30
M6
A1
S45 F50
F51
F52
S32
H1
F1
F3 K10
S33
S31:1
S31:2
S32
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 3
--- Page 10 ---
1 2 3 4 5 6 7 8
A A
© TIEE SARL
232370-040
Order number
TRUCK WITH INITIAL LIFT
ELECTRONIC ASSY; "SPIDER"
A36
X27 X81 X80 X20 X29
24 24
Sh. 2 8 1 POWER SUPPLY 24VDC
Date
B X103 X103 B
P 163
11 INP. PRESSURE SENSOR, INITIAL FORKS
X29 X103
2006-04-10
40
Sh. 3 5
Y69 X103
1 2 89
16 OUT. INITIAL FORKS, LIFT/LOWER VALVE
S45 X81 X80 X100
C 1 2 85 C
19 INP. INITIAL FORKS, LIFT LIMIT
931876-
Service Manual
40
29 POWER SUPPLY 0VDC
X29
D 119 119 D
Sh. 3 5 27 CAN HIGH
Valid from serial number
X29
120 120
Sh. 3 5 42 CAN LOW
7LOP10CW, 7LOP10CF
E E
T-code
787, 788
F F
4 / 9 PROD A
217972
1 2 3 4 5 6 7 8
Electrical systems – 5000
Electrical wiring diagram
10- 13
--- Page 11 ---
Electrical systems – 5000
Functional description
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
Table 9: Functional description
Event: 10. Cabin lifting
Prior event(s) 2
Action(s) Press the lift cabin button
Influencing Cabin lift button [A2:S19]
elements Battery status ok (>20% charge left)
Lift height limit S33 [A1:INP.CABIN IN TOP POSITION] not activated
Resulting [A1:OUT.PUMP CONTACTOR] goes low
conditions [A1:OUT.CABIN LIFT/LOWER] goes low
Cabin hydraulic soft closing valve [Y45] activates.
Pump contactor [K30] activates
Pump motor [M3] starts
Event: 11. Cabin lowering
Prior event(s) 2
Action(s) Press the lower cabin button
Influencing Cabin lower button [A2:S20]
elements Lift height < 0,1 m, S32 [A1:INP. CABIN/FORKS LOWER THAN 100mm]
activated
Resulting [A1:OUT.LOWER VALVE] goes low
conditions [A1:OUT.CABIN LIFT/LOWER] goes low
Cabin lowering hydraulic valve [Y10] activates.
Cabin hydraulic soft closing valve [Y45] activates.
When S32 [A1: INP. CABIN/FORKS LOWER THAN 100mm] is not acti-
vated, pallet to ground protection or footprotection is active.
Event: 12. Initial forks lifting
Prior event(s) 2
Action(s) Press the lift forks button
Influencing Fork lift button [A2:S21]
elements Battery status ok (>20% charge left)
Lift height limit S45[A36:INP.INITIAL FORKS LIFT LIMIT] not activated
Resulting [A1:OUT.PUMP CONTACTOR] goes low
conditions [A36:OUT.INITIAL FORKS SOFT CLOSING VALVE] goes low
Forks hydraulic soft closing valve [Y69] activates.
Pump contactor [K30] activates
Pump motor [M3] starts
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 23
--- Page 13 ---
Electrical systems – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
10.5 Parameters & adjustments
10.5.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Operator parameters and Service parameters.
• Operator parameters (1 to 7) - These parameters are used to tailor
the driving characteristics of a truck for a specific operator or opera-
tion. A maximum of 10 operator parameter sets, so called operator
profiles, can be stored in a truck. Operator parameters can be ad-
justed directly without the requirement for a suitable CAN service
key.1
• Service parameters (10 to 40) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as operator parameters. Service
parameters can ONLY be adjusted when a suitable CAN service key
is plugged into the truck.2
10.5.2 Displaying parameters - without the
CAN service key
Proceed as follows to display parameters when a CAN service key is
not connected:
• Ensure the battery is connected.
• Ensure the truck is switched off. Press on the keypad.
• Press and hold horn button S18 for at least 1 second, enter a valid
PIN code and then press on the keypad.
• Hold S18 depressed until “P” is displayed, then release S18. Fig. 5
Parameters symbol lights.
Fig. 5
The different parameters are now displayed by repeatedly operating
speed control L1. Operator parameters can be both viewed and
changed.1
1.Operator parameters can only be set without a CAN key if parame-
ter #39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Log-in
method & operator parameter access on page 47.
2.Service parameters can be viewed without a CAN key being
plugged in but they cannot be adjusted.
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 33
--- Page 14 ---
Electrical systems – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
# 20 - Hour meter selection
This parameter determines which hour meter mode to display during
normal use.
Table 17: Hour meter parameter selection
Value Description Display
1 Key time:
Total time truck has been switched on
2 Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
3 Drive motor time:
Total time drive motor has been in operation
4 Pump motor time:
Total time pump motor has been in operation
5 Remaining time to next service
(Parameter #25 controls the initial value)
See # 25 - Service interval on page 45
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 43
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Electrical systems – 5000
Parameters & adjustments
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
Parameters symbol lights (stops flashing).
• Select argument #1 by operating speed control L1.
After 1 second the value of argument #1 will be displayed.
• Press horn button S18.
Parameter symbol flashes..
• Set argument #1 value by repeatedly operating speed control L1 up or
down. Refer to base option list Table 21:
• Press horn button S18 once to confirm the new setting.
Parameters symbol lights (stops flashing).
Adjust arguments #2, #3 and #4 using the same method as above.
• Switch off the truck by pressing on the keypad.
The special option shall now be activated.
• Ensure the special option operates correctly before returning the truck
for normal use.
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 53
--- Page 16 ---
Electrical systems – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
10.6 Diagnostic and troubleshooting
10.6.1 General
means constantly on means flashing.
The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 9.
Fig. 9
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C50 to C99 will limit the truck’s maximum speed to creep-
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C3 to C43 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely, i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 63
--- Page 17 ---
Electrical systems – 5000
Diagnostic and troubleshooting
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
10.6.5 Built-in Test Function
The truck’s control system provides a number of useful built-in test
functions
• Connect CAN-key in X41 and press [A17].
• Battery status is shown.
• Press Horn S18 repeatedly to choose Built-in Test mode.
NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!
Table 30: Built-in test modes
Mode Flashing symbol Displayed data
1 Speed reference value sent to Curtis.
2 Digital inputs/outputs can be tested. See Table
31:, Table 32: & Table 33:for more information.
3 Battery voltage (V)
4 Armature current (A)
5 Field current (A)
6 PWM Armature in %
7 Status Curtis
8 Signal from pressure sensor [B10] (Hydraulic
pressure in lift circuit) (V)
9 Digital inputs/outputs of expansion unit [A36].
Seetable 34 on page 76
10 Signal from pressure sensor [B11] (Hydraulic
pressure in initial lift circuit) (V)
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 10- 73
--- Page 18 ---
Hydraulic system – 6000
7LOP10CF
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
11.2.2 Hydraulic drawing and symbol list
n
2
1
5
4
3
6
6
© TIEE SARL Service Manual 7LOP10CW, 7LOP10CF 11- 5
--- Page 19 ---
Fork carriage – 7420
Included components
Order number Date Valid from serial number T-code
232370-040 2006-04-10 931876- 787, 788
13- Fork carriage – 7420
13.1 Included components