SERVICE MANUAL

4,500 lb. Powered Pallet Walkie

Model 7HBW23

Serial No. 24,501 and up

00700-CL340-08, Issued: 06/20/2008

©2008 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.

1042390B
Toyota Model 7HBW23 Service Manual Table of Contents

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 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Programmable Maintenance Tool (PMT) . . . . . . . . . . . . . . . . . . . . . . 5-28
List of Troubleshooting Charts/Tables . . . . . . . . . . . . . . . . . . . . . . . 5-31
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Symptom Tables: Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Symptom Tables: Travel (Forward/Reverse) System . . . . . . . . . . . . . 5-42
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Alphabetical List of Components procedures . . . . . . . . . . . . . . . . . . . 6-2
Component Locator Photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tractor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Horn (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Power Amplifier (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Main Relay (K4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

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Table of Contents Toyota Model 7HBW23 Service Manual

Switches (General) . . . . . . . . . . ................. . . . . . . . . . . 6-25

Drive Unit . . . . . . . . . . . . . . . . . ................. . . . . . . . . . . 6-29
Electromagnetic Brake . . . . . . . ................. . . . . . . . . . . 6-35
Motors, General . . . . . . . . . . . . ................. . . . . . . . . . . 6-39
Drive Motor . . . . . . . . . . . . . . . . ................. . . . . . . . . . . 6-46
Pallet Forks and Load Wheels . . ................. . . . . . . . . . . 6-49
Hydraulic Components . . . . . . . ................. . . . . . . . . . . 6-51
Cold Storage Conditioning . . . . . ................. . . . . . . . . . . 6-59
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

iv 00700-CL340-08, Issued: 06/20/2008

How To Use
Toyota Model 7HBW23 Service Manual Section 1. How To Use This Manual

Section 1. How To Use This Manual

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Section 1. How To Use This Manual Toyota Model 7HBW23 Service Manual

Map of the Manual

Map of the Manual

How to Use This

Manual Map of the Manual

Manual Design
Safety

Start Page

Vehicle
Systems
Specifications
Overview

General System
Data
Scheduled
Maintenance

Theory of
Operations

Trouble Electrical &

Shooting Hydraulic T.S.
Guidelines

Definitions
Component Alphabetical List
Procedures of Component
Procedures
Fault Codes

Component
Location Photos
Appendix
Programmable
Maintenance Tool

Troubleshooting
Index Charts and
Symptom Tables

map.wmf

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Toyota Model 7HBW23 Service Manual Section 1. How To Use This Manual

Manual Design

Manual Design • “GEN1” on page 5-34 will guide you to

the individual troubleshooting
symptom chart you need.
The Toyota Model 7HBW23 Service Manual is
• When you are familiar with the
designed with the following objectives in mind:
symptoms listed, you may instead find
• Provide technical coverage for expected the symptom chart from the “List of
levels of user expertise Troubleshooting Charts/Tables” on
• Anticipate your needs and reduce your page 5-31.
decisions regarding maintenance • When you complete a troubleshooting
• Reduce page flipping through a “one-stop procedure, make sure to follow the
shopping” approach steps in the “END1: End of
Troubleshooting Procedure” on
The two-line running page header at the top of page 5-35.
each page tells you the following: • Component Procedures gives
• Name of the manual step-by-step procedures for testing,
(Toyota Model 7HBW23 Service Manual) removal, installation, and adjustment of
individual truck components. Components
• Current chapter title
are listed in an order that considers:
(example: this page How to Use This
Manual) • Frequency of attention
• Current topic • Physical attachment (example: brake
(example: this page Manual Design) must be removed before drive motor)
• Functional relation (for example: drive
We suggest you get in the habit of turning to the motor and drive unit components are
START page first when you use this manual. grouped together)
To find a component procedure, you may
The START page asks a few simple questions to
use one of three methods:
guide you to the correct chapter.
• Look up the component name.See
• How to Use This Manual explains the
“Component Procedures” on page 6-1
manual format and design and contains
the START page. • Find the component. See “Component
Locator Photo” on page 6-5
• Safety explains warning and caution
notes, general safety rules, and safety • Look up the component name in the
rules for batteries, static, jacking, and Index. See “Index” on page A-1
welding. • Appendix contains reference information
• Systems Overview includes truck such as torque values, lubricants, and
specifications and theory of operation schematics.
information. • Index lists subjects alphabetically.
• 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.

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Section 1. How To Use This Manual Toyota Model 7HBW23 Service Manual

Manual Design

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Toyota Model 7HBW23 Service Manual Section 1. How To Use This Manual

START Page
Section 1. How To Use This Manual

START Page

START: Why are you here?

To review Go to Section 2
safety Yes "Safety"
precautions?

No

To examine
Go to Section 3
specifications
Yes "Systems Overview"
or theory of
operations?

No

To do Go to Section 4
scheduled Yes "Scheduled Maintenance"
maintenance?

No

Go to Section 5
To troubleshoot Yes "Troubleshooting"
a problem?

List of Troubleshooting Charts

No

Go to Chart START Troubleshooting

START-2

startpg1.wmf

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Section 1. How To Use This Manual Toyota Model 7HBW23 Service Manual

START Page

START-2

To test,
inspect, adjust,
Go to Section 6 "Component
remove/install a Yes
Procedures"
component?

Alphabetical List of
No Component Procedures

Component Locator
To find
Go to the
general reference Yes
"Appendix"
information?

No

To locate an Go to the Index

object or procedure Yes
by name?

startpg2.wmf

1-6 00700-CL340-08, Issued: 06/20/2008

Safety
Toyota Model 7HBW23 Service Manual Section 2. Safety

Section 2. Safety

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Section 2. Safety Toyota Model 7HBW23 Service Manual

Definitions

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.

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Toyota Model 7HBW23 Service Manual Section 2. Safety

General Safety

General Safety

1864 002.eps

Do not operate or work on truck unless you are

1808 003.eps
trained, qualified, and authorized to do so and
have read the Owner/Operator Manual. Operate truck only from the operator’s position.

1808 004.eps

Know the truck’s controls and what they do.

Before working on a truck, always press the red
OFF key (O) on the keypad and disconnect the
truck’s battery connector (unless this manual
tells you otherwise).

1808 002.eps

Do not operate a truck if it needs repair or if it is

in any way unsafe.
1864 067.eps

Do not wear watches, rings, or jewelry when

working on this truck.

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Section 2. Safety Toyota Model 7HBW23 Service Manual

General Safety

schedmnt.eps spills.eps

Follow the scheduled lubrication, maintenance, Clean up any hydraulic fluid, oil, or grease that
and inspection steps. has leaked or spilled on the floor.

1808 005.eps

Follow exactly the safety and repair instructions Always park this truck indoors.
in this manual. Do not take “shortcuts.”

23L6S012.eps

Do not park a truck in a cold storage area

Do not use an open flame near the truck. overnight.

Do not use gasoline or other flammable liquids Do not wash a truck with a hose.
for cleaning parts.

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Toyota Model 7HBW23 Service Manual Section 2. Safety

General Safety

Do not add to or modify a truck until you

contact your local Toyota Industrial Equipment
Dealer to receive written manufacturer
approval.

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Section 2. Safety Toyota Model 7HBW23 Service Manual

Battery Safety

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 04G6S059.eps
can remain in or around the battery for
several hours after charging. Make sure Make sure a shower and eyewash station are
there are no open flames or sparks in nearby in case there is an accident.
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
23L6S012.eps
contact with your clothing or skin, flush
the area immediately with cold water. If A battery gives off explosive gases. Never smoke,
the solution gets on your face or in your use an open flame, or use anything that gives
eyes, flush the area with cold water and off sparks near a battery.
get medical help immediately.

04G6S058.eps

25L6SO16.eps

Keep the charging area well-ventilated to avoid

Wear personal protective equipment to protect hydrogen gas concentration.
eyes, face, and skin when checking, handling,
or filling batteries. Equipment includes goggles
or face shield, rubber gloves (with or without
arm shields), and a rubber apron.

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Toyota Model 7HBW23 Service Manual Section 2. Safety

Battery Safety

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
27Y7S013.tif
the battery terminals. A spark often occurs at
the point where a live circuit is broken. Keep plugs, terminals, cables, and receptacles
in good condition to avoid shorts and sparks.

Vent Hole

04G6S057.eps

Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.

09G6S047.tif

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 vent holes in the filler plugs are open

to permit the gas to escape from the cells.

Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.

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Section 2. Safety Toyota Model 7HBW23 Service Manual

Battery Safety

25L6S014.eps

Do not permit cleaning solution, dirt or any Follow the charging procedures in the Battery
foreign matter to enter the cells. Instruction Manual and in the Battery Charger
Instruction Manual.

Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect truck stability. See the truck’s
specification plate for more information.

1808 006.eps

Never plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.

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Toyota Model 7HBW23 Service Manual Section 2. Safety

Jacking Safety

Jacking Safety Tractor Section

1. Position the jack in the designated jacking
When it is necessary to jack the truck off the position.
floor to perform maintenance procedures, 2. Jack one side of the truck so that the drive
observe the following safety precautions: tire is off the floor no more than 1 in.
1. Lower the forks completely. Remove any (25.4 mm).
load. 3. Block that side of the truck in place.
2. Position all controls in neutral. 4. Jack the other side of the truck level with
3. Block the wheels to prevent movement of the first side.
the vehicle. 5. Block that side of the truck in place.
4. Press the red OFF key (O) on the keypad
NOTE: After working on a vehicle, test all
and disconnect the battery connector.
controls and functions to verify correct
5. Position the jack under the designated operation.
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.
4. Press the red OFF key (O) on the keypad
and disconnect the battery connector.

Figure 2-1: Blocking for Fork Section

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Section 2. Safety Toyota Model 7HBW23 Service Manual

Towing

Towing
To safely tow this truck:
1. Lower the forks and remove any load.
2. Press the red OFF key (O) on the keypad
and disconnect the battery connector.
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 mechanically released to move
this truck. See “Mechanically Releasing
the Brake” on page 6-36.

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Toyota Model 7HBW23 Service Manual Section 2. Safety

Welding Safety

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 1808 004.EPS

that the coating be removed in the

• Disconnect the battery before you attempt
vicinity where the operation(s) will be
to inspect, service, or repair the lift truck.
performed.
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).
Coating removal may be by mechanical
methods, chemical methods, or a • Do a test for shorts to frame. See
combination of methods. Flame cutting “Checking for Shorts from Components to
and/or welding operations must be Truck Frame” on page 5-3. If any shorts
carried out only in well ventilated areas are detected, remove them before you
using local exhaust if necessary. 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
04GSO59.eps
truck.
• When you are finished welding, perform all
Before working on this truck, make sure that: ground tests and electrical inspections
• Fire protection equipment is nearby. before the vehicle is operated.
• You know where the nearest eyewash
station is located.

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Section 2. Safety Toyota Model 7HBW23 Service Manual

Static Precautions

Static Precautions Wrist straps are available in quantities of 25, as

part number 00590-04848-71.

Electronic circuit boards and devices used on A wrist strap tester is available as part number
this truck can be damaged by the discharge of 00590-04850-71.
static electricity, called electrostatic discharge.
Contact your authorized Toyota Dealer for
Static charges can accumulate from normal information.
operation of the truck as well as movement or
contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles Wrist Strap Static-Dissipative
on shoes, styrofoam coffee cups, and so forth). Work Surface

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 Ground Cord
wrist strap connector.
2. Connect the ground strap to an Figure 2-2. Anti-Static Kit With Wrist Strap and Mat
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).

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 2-2 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.

2-12 00700-CL340-08, Issued: 06/20/2008

Systems
Overview
Toyota Model 7HBW23 Service Manual Section 3. Systems Overview

Section 3. Systems Overview

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Section 3. Systems Overview Toyota Model 7HBW23 Service Manual

Truck Model Identification

Truck Model
Identification

1581 001.tif
Figure 3-1. Model 7HBW23 Pallet Truck

Vehicle Specifications

The total weight of the load must include

the pallet and the container or the
device holding the load.

Category
Maximum Load Capacity 4,500 lbs. (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 lbs. (91 kg)
Maximum Battery Weight 660 lbs. (299 kg)
Truck Weight Without Battery 800 lbs. (362 kg)
Wheel: Drive 10 x 5 in. Rubber
Wheel: Load 3.25 x 5 in. Polyurethane (2)

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Toyota Model 7HBW23 Service Manual Section 3. Systems Overview

General Information

General Information

Control Handle
Page 6-17

Battery Drive Unit

Page 6-6 Page 6-29

Pallet Forks and

Load Wheels
Page 6-49

Figure 3-2. Model 7HBW23 General Information

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Section 3. Systems Overview Toyota Model 7HBW23 Service Manual

Special Tools

Special Tools
Programmable Maintenance Service Key
Tool

27y7s021.tif

Figure 3-3. Programmable Maintenance Tool Figure 3-4. Service Key

The optional Programmable Maintenance Tool Use the optional Service Key (See Figure 3-4.)
(PMT) (P/N 00590-49981-71) permits you to (P/N 00590-42683-71) directly on the truck to
test and diagnose the power amplifier in the troubleshoot and program the truck service
truck. See Figure 3-3. parameter settings. See “Programming Truck
Parameters” on page 5-17.
The PMT is powered by the host power amplifier
through the four-pin connector installed at the
bottom of the power amplifier.

See Programmable Maintenance Tool beginning

on Pages 5-28 for detailed information about
this tool.

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Toyota Model 7HBW23 Service Manual Section 3. Systems Overview

Theory of Operation

Theory of Operation
Truck Starting • lift limit switch (S36) transmits a lift-limit
signal to the power amplifier that removes
To start the truck, the battery is plugged in, the power to the lift motor when the forks
Main ON/OFF switch is in the ON position, the reach a preset lift-limit.
PIN-key code is entered in the keypad, and the
green ON (|) key pressed (or optional key switch When the lift button is released:
is ON). See “Parameters (P)” on page 5-17. • the pump contactor coil (K30) is
de-energized. That stops the lift motor and
Lift/Lower pump. The forks are held in position by
hydraulic fluid trapped in the cylinder by
the check valve, the static position of the
The lift/lower system consists of an electrically
relief valve, and the closed lowering
operated hydraulic pump assembly and related
solenoid valve (Y10).
components.
• the relief valve opens if the hydraulic
The hydraulic pump assembly consists of a pressure exceeds the preset limit.
positive displacement rotary gear pump with
reservoir mounted to an adapter. A DC electric Lower
motor is mounted to the opposite side of the
pump adapter. An adjustable relief valve, check When the battery is connected, the truck is ON,
valve, and a solenoid operated lowering valve and the lower button is pressed:
are installed within the adapter.
• lower signal is detected via hall effect
sensors, converted into the lower
With forks elevated, the normally closed
instruction, and transmitted via the CAN
solenoid valve and check valve prevent
to the power amplifier.
hydraulic fluid from returning to the reservoir.
• lowering solenoid valve (Y10) opens.
Lift • hydraulic fluid in the lift cylinder returns
to the hydraulic reservoir through the
When the battery is connected, the truck is ON, lowering valve and the flow control valve.
and the lift button pressed: The lowering speed is regulated by the flow
• a lift signal is detected via hall effect control valve.
sensors, converted into the lift instruction, • the forks lower.
and transmitted via the Controller Area
Network (CAN) to the power amplifier. Direction/Speed Control
• the lift pump contactor (K30) closes,
applying B+ to the lift pump motor (M3) The following descriptions assume the battery is
causing the lift pump to operate. charged and connected, the truck is ON, and
• hydraulic fluid is drawn into the lift pump. the main contactor (K10) is energized.
• as the pump rotates, oil is forced out the
pressure port through the lift hose to the Control Handle Positioning
lift cylinder. Oil cannot return to the
reservoir because of the closed pressure Control handle positioning determines the
relief valve and closed lowering solenoid travel speed of the truck. See “Arm Angle
valve. Switches” on page 5-6.
• hydraulic pressure in the lift cylinder
raises the forks.

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Section 3. Systems Overview Toyota Model 7HBW23 Service Manual

Theory of Operation

Travel Request, Tractor-First • the drive wheel starts to rotate in reverse

direction at a speed proportional to the
When the thumb controls are rotated in the voltage at M–.
forward direction (tractor-first) from neutral:
• a forward travel signal is detected via hall Emergency Reverse
effect sensors, converted into a travel
instruction in the ETAC (See “Electronic If the emergency reverse button (belly button) is
Tiller Arm Card (ETAC)” on page 3-7.) and closed with the control handle lowered in travel
transmitted via the Controller Area mode, the control system provides an
Network (CAN) to the power amplifier. immediate, rapid acceleration in the reverse
(forks-first) direction. The following occurs:
• the ETAC verifies that the emergency
reverse button is not activated before • the emergency reverse signal is converted
supplying the travel command to the into a reverse travel instruction and
power amplifier. transmitted via the CAN-bus to the power
amplifier.
• the ETAC verifies that switch S25 (Arm
Angle B) is engaged for slow speed mode. • travel and speed inputs are ignored.
• the ETAC verifies that both switch S24 • the power amplifier provides maximum
(Arm Angle A) and switch S25 (Arm Angle torque immediately after the emergency
B) are engaged for fast speed mode. reverse button is activated.
• the voltage at M– of the drive motor will • maximum reverse travel continues until
vary from 24V to 1V. The voltage is the emergency reverse button is released.
proportional to the position of the thumb
control. Power Amplifier
• the drive wheel starts to rotate in forward
direction at a speed proportional to the The basic functions of the power amplifier
voltage at M–. include:
• the direction control section that controls
Travel Request, Forks-First the drive motor direction by manipulating
the drive motor field polarity according to
When the thumb control are rotated in the the directional signal inputs from the
reverse direction (forks-first) from neutral: ETAC.
• reverse travel signal is detected via hall • the speed control section that controls the
effect sensors, converted into a travel. drive motor speed and torque by
instruction in the ETAC, and transmitted monitoring the position change of the Arm
via the CAN-bus to the power amplifier. Angle A and Arm Angle B switches.
• the ETAC verifies that the emergency Variable motor speed is accomplished by
reverse button is not activated before separate control of field and armature
supplying the travel command to the currents.
power amplifier. • the emergency reverse circuitry in the
• the ETAC verifies that switch S25 (Arm ETAC that provides the directional travel
Angle B) is engaged for slow speed mode. control commands to the power amplifier.

• the ETAC verifies that both switch S24 • the control circuit section that controls all
(Arm Angle A) and switch S25 (Arm Angle truck inputs and outputs (excluding
B) are engaged for fast speed mode. handle head inputs).

• the voltage at M– of the drive motor will

vary from 24V to 1V. The voltage is
proportional to the position of the thumb
control.

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Toyota Model 7HBW23 Service Manual Section 3. Systems Overview

Theory of Operation

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 control 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.

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Section 3. Systems Overview Toyota Model 7HBW23 Service Manual

Theory of Operation

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 Planned
Maintenance
Toyota Model 7HBW23 Service Manual Section 4. Planned Maintenance

Section 4. Planned Maintenance

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Section 4. Planned Maintenance Toyota Model 7HBW23 Service Manual

Maintenance Guidelines

Maintenance Guidelines
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 manufacturer’s
supplements for components not listed on the
following pages.

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Toyota Model 7HBW23 Service Manual Section 4. Planned Maintenance

Maintenance Guidelines

Every Two Months or 250 Operating Hours

Perform daily checks plus the following:

Item Every Two Month or Every 250 Operating Hours

Grease Fittings Lubricate all grease fittings.

Forks Check lift-limit switch for lift motor cut-out. Adjust if necessary.

Lubrication Points Lubricate all levers, shafts, and linkage points.

Lift Cylinder Check lift cylinder for leaks. Repair or replace cylinder if necessary.
See “Hydraulic Cylinder” on page 6-51.

Hydraulic System NOTE: Mixing different types of cold storage fluid can cause
premature pump failure. See Caution on Page 6-57.
Check fluid level with forks fully lowered. Fluid should be 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 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 6-53.

General Check for loose hardware. Tighten if necessary.

Check tightness of drive unit mounting bolts. Tighten if necessary.

Electrical System Visually inspect all cables for damage. Replace if necessary. See
“Power Cables” on page 6-12.
Check for electrical shorts to frame. See “Checking for Shorts from
Battery to Truck Frame” on page 5-3.

Main Relay Check contacts for welded condition. See “Inspection/Test” on

page 6-24.

Drive Wheel Check the tightness of mounting bolts on drive wheel. Torque to 55
ft. lbs. (75 Nm). See “Drive Wheel” on page 6-33.
Visually inspect lug nuts for signs of looseness.
Check to see if one or more studs protrude through the lug nut
farther than the others or if studs are damaged. Replace if
necessary. See “Drive Wheel Studs” on page 6-33.

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 6-29.
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 6-35.

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Section 4. Planned Maintenance Toyota Model 7HBW23 Service Manual

Maintenance Guidelines

Battery System Clean the battery and the truck. See “Battery Maintenance” on
page 6-7.

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Toyota Model 7HBW23 Service Manual Section 4. Planned Maintenance

Maintenance Guidelines

Annually or Every 1500 Operating Hours

Perform every two month checks plus the
following:

Item Annually or Every 1500 Hours

Drive Housing Change the oil in the drive housing.

See “Transmission Housing Lubrication” on page 6-32.

Grease Fittings

Grease Fitting

Figure 4-1: Load Wheel Axle (Cold Storage and

Corrosion Protection Options only)

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Section 4. Planned Maintenance Toyota Model 7HBW23 Service Manual

Maintenance Guidelines

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Troubleshooting
Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Section 5. Troubleshooting

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

How to Use This Chapter

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 "Troubleshooting Flowcharts"
on page 33 to guide you to individual
symptom chart you need.
• When you’re familiar with the symptoms
listed, you may instead simply look up
symptom chart from "List of
Troubleshooting Charts/Tables" on page
31.

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 steps in the
"END1: End of Troubleshooting Procedure"
on page 35.

If troubleshooting symptom tables do not isolate

problem, or if symptoms are not consistent or
repeatable, go to "GEN1: General
Troubleshooting" on page 34. This chart will
help you approach problem in a systematic and
logical manner.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Electrical Troubleshooting Guidelines

Electrical • negative (–) lead to an unpainted,

grounded surface on the truck frame
Troubleshooting • positive (+) lead to positive battery
terminal
Guidelines Voltmeter must show no more than 3V.
3. Now attach leads as follows:
Many problems are caused by a faulty or dirty
battery. Make sure battery is clean. Check • negative (–) lead to negative battery
electrolyte level and state-of-charge. See terminal
“Battery” on page 6-6. Block truck whenever a • positive (+) lead to an unpainted,
troubleshooting procedure requires turning key grounded surface on the truck frame
switch ON. This avoids accidents caused by
Voltmeter must show no more than 3V.
unexpected truck travel.
4. If you get more than a 3V reading in Steps
2 or 3:
a. Remove battery from the truck. See
Unless otherwise directed, disconnect
“Battery” on page 6-6.
the battery connector when you check
electrical circuits or components with an b. Thoroughly clean battery. See “Battery
ohmmeter. Electrical current can cause Maintenance” on page 6-7.
damage to the ohmmeter. c. Reinstall battery.
Save time and trouble by looking for simple d. Repeat steps 2 and 3 to see if this has
causes first. eliminated the problem.
e. If excessive voltage is still found, have
Visually inspect all wiring and electrical battery checked for internal leakage.
components for:
• loose connections or connectors Checking for Shorts from
• loose or broken terminals Components to Truck Frame
• damaged terminals, blocks, or strips
1. Press red OFF (O) key on keypad and
• broken wiring and shorted conditions disconnect battery connector.
(especially those that are close to metal
2. Use an ohmmeter and measure resistance
edges or surfaces)
to an unpainted grounded surface on the
frame at B+, B–, and all fuses.
Use an ohmmeter to check for wiring continuity
and shorts. A resistance reading of less than
1000 ohms indicates a serious short to
For information on pin, connector, and harness frame. If this condition exist, find the
connections, See “Wiring Harness” on source of low resistance or short to frame
page 6-13. and "List of Electrical Symbols" on using step 6. Do not continue until this
page 5-8. condition is corrected.
3. Remove battery from the truck. See
Checking for Shorts from “Battery” on page 6-6.
Battery to Truck Frame 4. Connect battery lead to truck.
5. Use an ammeter to measure leakage
1. Press red OFF (O) key on keypad and
current to an unpainted grounded surface
disconnect battery connector.
on the frame at B+, B–, all fuses, and all
2. Using a voltmeter set on a 50Vdc scale, motors. If current is less than 0.001
attach leads as follows: ampere (1mA), the truck system passes. If
current exceeds 1mA, go to step 6.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Electrical Troubleshooting Guidelines

6. To find the cause of low resistance,

disconnect power cables from each motor
or major subassembly one at a time, to
determine if that item is causing the low
resistance.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Hydraulic Troubleshooting Guidelines

Hydraulic
Troubleshooting
Guidelines
When checking 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

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Definitions

Definitions Continuity
A continuous and uninterrupted path between
Acceleration two or more locations in an electrical circuit,
typically having a resistance of less than 1 ohm.
Process where truck’s acceleration
characteristic is determined when the truck Creep Speed
starts from a stop. This is an operator
parameter (Acceleration). Range is from 30% to Creep speed is a service parameter that defines
90% in increments of 5%. Default is 80%. A speed at low throttle positions. Creep speed
lower number gives less aggressive acceleration. range is adjustable from –10 to 10. The factory
See “Parameters (P)” on page 5-17. default value is –5. A negative number
enhances low speed maneuverability. A positive
Arm Angle Switches number makes the truck more responsive. See
“Parameters (P)” on page 5-17.
Arm Angle Switches (S24 and S25) determine
brake activation and truck travel speed. Each Current Limiting
switch is activated by the control handle
position. Control handle must be positioned A protective function of the power amplifier that
between B1 and B2 of operation range to permit prevents excessive current levels from
travel. See Figure 5-1. damaging drive components.

Deceleration
Process where truck’s braking (regenerative)
characteristic is determined by any reduction in
throttle, including neutral. This is an operator
parameter (Deceleration). See “Parameters (P)”
on page 5-17. Range is from 40% to 90% in
increments of 5%. Default is 65%. A lower
number gives less aggressive deceleration.
1820 001.EPS

Figure 5-1. Arm Angle Switches and Brake Actuation Emergency Reverse
When the control handle is in position B1,
Emergency Reverse is activated when
parking brake engages. When control handle is
emergency reverse button is pressed while the
in position T1, brake disengages, Arm Angle B
control arm is in a drive position. After button
switch (S25) closes and enables slow travel. See
is released, normal operation is resumed.
Table 5-2. When control handle is placed in
position T2, Arm Angle A switch (S24) also
closes, enabling fast travel. When control ETAC (Electronic Tiller Arm Card)
handle is placed in position B2, Arm Angle
switch B opens, activating parking brake. Programmable motor control functions are
Table 5-2. Control Handle/Switch Positions performed by electronic circuitry (ETAC)
housed within control handle. See “Electronic
Position A Switch B Switch Function
Tiller Arm Card (ETAC)” on page 3-7.
B1 Open Open Top Brake
T1 Open Closed Slow Travel
T2 Closed Closed Fast Travel
B2 Closed Open Bottom Brake

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Definitions

Fault Codes Speed Limiting

ETAC provides fault information by displaying ETAC limits maximum speed:
fault codes via LED display built into the handle • “Max speed, Slow Mode” parameter
head. See “Power Amplifier Fault Codes” on determines maximum speed value sent by
page 5-26. ETAC to the power amplifier (max. PWM)
for both directions of travel while in Slow.
Open Circuit This is a programmable parameter.
• “Max speed, Fast Mode” parameter
A lack of a continuous path between two or determines maximum speed value sent by
more electrical connections; usually greater ETAC to the power amplifier (max. PWM)
than one megohm resistance. for both directions of travel while in Fast.
This is a programmable parameter.
Overvoltage Cutoff
Thermal Cutback (Power
Occurs when there is very high voltage (greater Amplifier)
than 34V) at power amplifier B+ connection.
Code C42 or E142 may be displayed and truck Thermal cutback of the power amplifier is below
must be restarted. –13°F (–25°C) or above 185°F (85°C). At 185°F
to 203°F (85°C to 95°C), PWM drive current
PIN-Key Code limit is linearly decreased from full set current
down to zero. At –13°F to –40°F (–25°C to
Trucks produced with a standard handle –40°C). Current limit is reduced to approx. half
mounted keypad are protected from the set current, resulting in reduced travel
unauthorized operation by Personal speed. Below –40°F (–40°C) or above 203°F
Identification Number (PIN) keypad entry codes. (95°C), the allowed PWM is 0%.
Up to 10 operators can be assigned their own
individual PIN-key code (of one to four digits) for Tractor
access to the truck. Each operator can also set
individual driver parameters. Default operator Body section of the truck that contains motors,
PIN-key code is number 1. drive unit, controls, and handle.

Short Circuit or “Short” Truck Off Delay (Keypad only)

A short circuit is an unspecified path in a
Sets the truck OFF delay time (energy saving
circuit that provides unwanted full or partial
feature). If this time delay passes while truck is
continuity between two or more locations in an
in a brake position and the truck is idle (no
electrical circuit.
inputs requested), ETAC powers the truck OFF.
Driver parameter settings are 0 to 20 minutes.
Example 1: Two insulated wires are physically
When parameter is set to 0, or truck has key
next to each other and insulation has worn off
switch option, the truck never powers OFF.
each of the wires. Conductors are now touching
each other, causing a short circuit.
Undervoltage Cutoff
Example 2: Insulation has worn away on a
power cable from battery to a junction post in Occurs when there is very low voltage (less than
the truck. Wire conductors are touching tractor 13V) at power amplifier B+ connection. Code
frame, causing a short circuit of the battery C41 is displayed and truck must be restarted.
cable.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

List of Electrical Symbols

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 Trucks with keypad

maintenance modes

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 Main ON/OFF

S24 Switch Arm Angle A

S25 Switch Arm Angle B

S36 Switch Lift limit

Y1 Coil Brake

Y10 Coil Lower valve

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Control Handle Display and Programming

Control Handle Display and Programming

The display located on the top of the control 3. Choose the desired time to be displayed by
handle displays operator and machine-specific pressing the thumb controls:
register. • 1 = A. (key time)
5

• 2 = b. (activity time (drive, lift, lower)

A Explanation of
• 3 = c. (drive motor time)
Symbols:
• 4 = d. (pump motor time)
A • 5 = S. (time to service)
A = Numerical Field
B = Hour Meter Press the thumb control to step between
Indicator the different functions. The display shows
C = Parameter the number of hours for each function. See
Indicator “Parameter 20” on page 5-21.
D = Battery
E D C B Indicator
4. Press the red OFF (O) key on the keypad to
end the hour meter display.
E = Error Indicator

E D C B Error Codes (E)

Figure 5-4. Control Handle Display When an error occurs, a code is displayed. See
“Caution and Error Codes” on page 5-10.
Special Truck Mode
Error Code History
To enter a special truck mode:
To access Error Code History:
1. Press and hold horn button (S18) at the
same time turn key switch ON, or enter 1. Enter the special truck mode.
operator-specific PIN-key code on the 2. Press and hold the horn button until “E” is
keypad, then press the green ON (I) key on displayed. The error indicator (wrench
the keypad. icon) is illuminated. See Figure 5-4.
2. Continue to hold the horn button while • Use the thumb control to scroll the last
the display (see Figure 5-4) cycles through 50 error codes. The latest fault is
the following functions: shown first. The display first shows the
• H = Hour Meter error code and then the hour the fault
• E = Error Codes occurred.
• P = Parameters • The error codes are divided into two
• Pn = Hardware and Software Part groups: C = caution and E = error.
Numbers • The C error codes are not stored. It is
3. Release the horn button at the selected only a caution and is highlighted on the
display. display as long as the fault exists.
• For example, if you only have one fault
Hour Meter (H) registered in the memory, the second
empty place is shown like this: Fault: E
To change Hour Meter settings: and time.
1. Enter the special truck mode. 3. End displaying the error code history by
pressing the red OFF (O) key on the
2. Continue to hold the horn button until “H”
keypad.
is displayed. The hour meter indicator
(hourglass icon) is illuminated. See
Figure 5-4.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

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 Travel is not allowed until code is cleared.
Limits:
How to Clear Code: Code is cleared as soon as Control Handle is put in Top Brake position.
Possible Causes Control Handle stuck in down position:
and Corrective • Check up-stop.
Actions/Checks: Arm angle input maybe stuck ON:
• Check switch.
• Check input to power amplifier.

Code C19 - Default Parameter Warning

Reason: Parameter(s) out-of-range (see above), or incompatible with software version.
Performance Truck functions are not allowed until after this code is cleared.
Limits:
How to Clear Code: Parameter area is automatically corrected and then code is cleared.
Possible Causes ETAC parameter area is corrupt.
and Corrective • If code does not clear after 10 seconds, try restarting truck.
Actions/Checks:

Code C20 - Thumb Control Warning

Reason: Thumb control was not in neutral position at power ON, or throttle position
sensor failure was detected.
See “Code E160 - Error In Reversing Circuit” on page 5-16.
Performance Truck functions may not be allowed until code is cleared.
Limits:
How to Clear Code: Code is cleared after problem is corrected.
Possible Causes 1. Thumb controls stuck in drive position.
and Corrective 2. ETAC is bad.
Actions/Checks:
3. Faulty reverse button.

Code C28 - Main ON/OFF Switch Warning

Reason: Power amplifier could not be reset via the CAN-bus at power ON, or power
amplifier reports Main ON/OFF switch is open.
Performance Truck functions are not allowed after this code has been set.
Limits:
How to Clear Code: Code can only be cleared after problem is resolved and truck is turned OFF
then ON.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Control Handle Display and Programming

Code C28 - Main ON/OFF Switch Warning

Possible Causes 1. Main ON/OFF switch activate.
and Corrective 2. Low voltage to power amplifier (especially while lifting or driving)
Actions/Checks: possibly due to over-current or short-circuit. Try driving using
known-good battery.
3. 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.
4. Wire #24 at 0V.
a. Check J5 not connected, fuse and wiring.
b. Check for 24V at J5-16.
5. Short or open circuit in CAN wiring, or electrical noise in CAN wiring
due to bad connection or outside interference, both at power ON.
a. Check CAN wiring.
b. Try operating truck in different environment.
6. Faulty power amplifier.
a. Check power amplifier for error code.
b. Check power wiring.

Code C29 - Time To Service Warning

Reason: See Parameter 25 on page 5-19.
Performance None
Limits:
How to Clear Code: See Parameter 25 on page 5-19.
Possible Causes 1. Time to service.
and Corrective 2. Service interval not reset after last service.
Actions/Checks:

Code C41 - Battery Undervoltage Warning

Reason: Voltage at power amplifier B+ connection less than 17V (when main
contactor is closed). Low voltage can also cause problems such as electrical
components not powering up/staying activated and CAN errors.
Performance Truck functions are allowed unless the voltage was below 13V in which case
Limits: the truck must be restarted (error code 28 may be displayed).
How to Clear Code: Code is cleared when voltage recovers.
Possible Causes 1. Low Battery voltage. Check for proper voltage: charge battery if
and Corrective necessary, charge battery.
Actions/Checks: 2. Battery parameter not adjusted correctly.
3. Circuit breaker open due to overloading or short circuit. Check brake
adjustment.
4. Open circuit to power amplifier B+ connection. Check cabling.
5. Faulty power amplifier.
a. Check power amplifier to error code.
b. Check power wiring.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Code C42 - Battery Over Voltage Warning

Reason: Voltage at power amplifier B+ connection over 30V.
Performance Truck functions are allowed unless the voltage was above 34V in which the
Limits: truck must be restarted (error Code E142 may be displayed).
How to Clear Code: Code is cleared when voltage recovers.
Possible Causes 1. High battery voltage.
and Corrective 2. Check for proper voltage: battery may be overcharged.
Actions/Checks:
3. Extreme regenerative motor braking.
4. Battery charger attached to truck.

Code C43 - Power Amplifier Thermal Cutback

Reason: High or low temperature above 185°F (85°C) or below -13°F (–25°C) at power
amplifier heat sink.
Performance Truck functions may be allowed.
Limits:
How to Clear Code: Code is cleared when power amplifier heat sink temperature recovers.
Possible Causes 1. Operating in extreme environment:
and Corrective 2. Excessive load on vehicle:
Actions/Checks:
a. Check brake adjustment.
b. Reduce the value of parameters 2, 3, and/or 4 to help decrease
motor temperature.
3. Incorrect power amplifier mounting.
4. Faulty power amplifier. Check power amplifier for error code.

Code C44 (“hot” is displayed) - Traction Motor Thermal Cutback

Reason: High traction motor temperature detected.
Performance Truck functions are allowed, but maximum speed value sent to power
Limits: amplifier is reduced.
How to Clear Code Code is cleared when temperature recovers.
Possible Causes 1. Operating in extreme environment.
and Corrective 2. Excessive load on vehicle:
Actions/Checks:
a. Check brake adjustment.
b. Reduce the value of parameters 2, 3, and/or 4 to help decrease
motor temperature.
3. Airflow to motor restricted.
4. Problem with motor wiring.
5. Faulty traction motor.

Code C46 - Severe Traction Motor Thermal Cutback

Reason: Very high traction motor temperature or extreme operation detected.
Performance Same as error code 44.
Limits:
How to Clear Code: Same as error code 44.
Possible Causes Same as error code 44.
and Corrective
Actions/Checks:

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Control Handle Display and Programming

Code E101 - Power Amplifier Does Not Correspond with the Type of Truck
Reason: Power amplifier is not compatible with ETAC software.
Possible Cause with Incorrect power amplifier installed in truck.
Corrective
Action/Checks:

Code E104 - Brake Output Error

Reason: Power amplifier could not detect presence of brake coil.
Possible Cause with 1. Open circuit in brake circuit. Check brake and wiring.
Corrective 2. Main relay missing or stuck open.
Actions/Checks:
3. Main contactor open circuit (especially after it has closed).
4. Communication error due to power amplifier handset. Unplug handset
from power amplifier, allow handset to completely boot before turning
truck on.
5. Faulty power amplifier. Check power amplifier for error code.

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 with Short circuit in power amplifier output circuit.
Corrective 1. Check main contactor coil, traction motor field winding, digital
Actions/Checks: outputs, and associated wiring.
2. Replace power amplifier.

Code E110 - Braking System Fault

Reason: Power amplifier detected problem with braking functions.
Possible Cause with 1. Short-circuit in brake circuit. Check brake and wiring.
Corrective 2. Faulty power amplifier. Check power amplifier for error code.
Actions/Checks:

Code E112 - Arm Angle Sequence Fault

Reason: Improper sequence of arm angle inputs.
Possible Cause with 1. Arm angle input stuck ON or OFF.
Corrective 2. Problem with arm angle input wiring.
Actions/Checks:
3. Problem with Control Handle. Check for proper sequence of arm angle
switches.
4. Communication error due to Power Amplifier handset.
a. Unplug handset from power amplifier; allow handset to completely
boot before turning truck on.

Code E114 - Traction Motor Speed Fault

Reason: Controller detected stalled traction motor.
Possible Cause with 1. Traction motor stalled.
Corrective 2. Excessive traction motor load at low speed. Check brake adjustment.
Actions/Checks:
3. Faulty Power amplifier. Check power amplifier for error code.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Code E115 - Contactor Off, Welded or Missing, or Faulty Power Amp

Reason: Controller could not close contactor (contactor OFF), contactor welded, or
contactor missing.
Possible Cause with Contactor did not close (contactor OFF).
Corrective 1. Problem with main contactor tips.
Actions/Checks:
a. If contactor clicks prior to getting this code, try polishing the
contactor tips with a clean pencil eraser. If this does not work or
there is permanent contactor damage, replace the contactor.
2. Low voltage.
a. Try closing the contactor with a good battery.
3. Short in the contactor coil.
a. Replace the contactor

Contactor welded.
1. Main contactor tips welded.
2. Short circuit in contactor circuit.
a. Check the contactor wiring (coil) and cabling.

Contactor missing.
1. Open circuit in the contactor circuit.
a. Check the contactor wiring (coil) and cabling.
2. Faulty power amplifier.
a. Check the power amplifier for error code.
b. Check the power wiring.

Code E118 - K4 MCR Welded

Reason: MCR detected welded at startup.
Possible Cause with 1. MVR tips welded.
Corrective 2. Short circuit in MCR circuit.
Actions/Checks:
a. Check MCR Wiring (coil and tips).

Code E140 - Checksum Error

Reason: ETAC software detected that check sum was invalid.
Possible Cause with 1. Faulty software. If applicable, try downloading new software.
Corrective 2. Faulty ETAC.
Actions/Checks:

Code E141 - Software Problem

Reason: ETAC found problem with software.
Possible Cause with 1. Missing of faulty software. If applicable, try downloading new software.
Corrective 2. Faulty ETAC.
Actions/Checks:

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Control Handle Display and Programming

Code E142 - Power Amplifier Disable Error

Reason: Power amplifier detected a major fault.
Possible Cause with 1. Severe over voltage (especially at main contactor close). Check for
Corrective proper voltage.
Actions/Checks: 2. High current through a digital output:
a. Check power amplifier outputs and wiring.
b. Replace power amplifier.
3. Open circuit in traction motor field circuit:
a. Check traction motor field wiring and windings in motor.
b. Replace power amplifier.

Code E150 - Drive Communication Rx Error

Reason: ETAC did not receive CAN data from the power amplifier.
Possible Cause with 1. Short or open circuit in CAN wiring.
Corrective 2. Electrical noise in CAN-bus wiring due to bad connection, outside
Actions/Checks: interference, or low voltage:
a. Check CAN wiring.
b. Try driving with a known-good battery.
c. Try driving in a different environment.
3. Faulty power amplifier. Faulty ETAC.

Code E151 - Drive Communication Tx Error

Reason: ETAC could not send CAN data to the power amplifier.
Possible Cause with 1. Short or open circuit in CAN wiring.
Corrective 2. Electrical noise in CAN wiring due to bad connection, outside
Actions/Checks: interference, or low voltage (especially while lifting or driving) possibly
due to over-current or short-circuit:
a. Check CAN wiring.
b. Try driving with a known-good battery.
c. Try driving in a different environment.
3. Faulty ETAC.

Code E157 - CAN-bus Off Error

Reason: ETAC detected problem with the CAN-bus.
Possible Cause with 1. Short or open circuit in CAN-bus wiring.
Corrective 2. Ensure wiring is correct as compared to schematic.
Actions/Checks:
3. Electrical noise in CAN-bus wiring due to bad connection, outside
interference, or low voltage:
a. Check CAN-bus wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
4. Faulty ETAC.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Code E159 - Over Run Error

Reason: ETAC detected problem with the CAN-bus.
Possible Cause with 1. Short or open circuit in CAN-bus wiring.
Corrective 2. Electrical noise in CAN-bus wiring caused by bad connection, outside
Actions/Checks: interference, or low voltage:
a. Check CAN-bus wiring.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
3. Faulty power amplifier. Check power amplifier.
4. Faulty ETAC.

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” on page 5-10.
Possible Cause with Faulty ETAC.
Corrective
Actions/Checks:

Code E161 - Lower Valve Error

Reason: Power amplifier could not detect presence of lower valve coil.
Possible Cause with 1. Lower valve missing.
Corrective 2. Open or short-circuit in lower valve or wiring.
Actions/Checks:
3. Main relay missing or stuck open.
4. Main contactor open circuit (especially after it has closed).
5. Communication error due to power amplifier handset. Unplug handset
from power amplifier, allow handset to completely boot before turning
truck ON.
6. Faulty power amplifier. Check power amplifier for error code.

Code E200 - Field Open

Reason: Power amplifier detected open field.
Possible Cause with Open circuit in traction motor field circuit.
Corrective 1. Check traction motor field wiring and field windings in motor.
Actions/Checks:
2. Replace power amplifier.

Code E201 - M– Error

Reason: Power amplifier detected an armature circuit fault.
Possible Cause with 1. Incorrect traction motor cabling.
Corrective 2. Faulty power amplifier. Check power amplifier for error code.
Actions/Checks:

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Control Handle Display and Programming

Code E202 - Power Amplifier Sensor Error

Reason: Power amplifier reported an armature current sensor fault.
Possible Cause with 1. Abnormal vehicle operation.
Corrective 2. Low battery voltage or undersized battery.
Actions/Checks:
3. Faulty power amplifier. Check power amplifier for error code.

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 with 1. Short or open circuit in CAN-bus wiring.
Corrective 2. Electrical noise in CAN-bus wiring caused by bad connection, outside
Actions/Checks: interference, or low voltage.
a. Try driving using a known-good battery.
b. Try driving in a different environment.
3. Faulty power amplifier. Check power amplifier for error code.
4. Faulty ETAC.

5. Change parameter value by pressing the

Parameters (P) thumb control up or down. Release the
thumb control to neutral when the desired
parameter number is shown.
6. Press horn button again to confirm the
change. The parameter indicator on the
Modifying specific truck parameters will display stops flashing and remains
change the driving characteristics of the illuminated.
truck.
7. End programming by pressing the red OFF
(O) key on keypad.
Programming Truck Parameters
8. The truck parameter change is complete.
To program the trucks operating parameters Next time truck is started, the new
follow directions below (also See “Setting parameter is in effect.
Individual PIN-key codes” on page 5-19.):
1. Enter special truck mode. See “Special
Truck Mode” on page 5-9.
2. Release the horn button when the “P” is
displayed. The parameter 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 horn button once to access the
parameter. The parameter indicator on the
display starts flashing.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Table 5-5. Truck Parameters
Range
Parameter Name Units Steps Default Description
(Step)
1 Max speed, % 10 to 40 2 20 10: low speed
slow mode (2) 40: full speed
2 Max speed, % 10 to 98 2 94 70: low speed
fast mode (2) 98: full speed
3 Acceleration % 30 to 90 5 80 30: low speed
(5) 90: full speed
4 Deceleration % 30 to 90 5 65 Defines the truck’s automatic plug
(5) braking characteristic when the
throttle is reduced (including to
neutral). A lower number results in a
less aggressive deceleration.
5 Truck OFF % 0 to 20 1 0 Set truck off delay (energy saving
delay (1) features). If this amount of time
(with optional passes while the control handle is in a
keypad only) brake position and the is idle (no
outputs requested), the VM powers
the truck OFF. When this parameter
is set to “0” the truck never powers
OFF. If parameter 39 is 1 or 2 (truck
doesn’t have an optional keypad). the
truck never powers OFF.

Programming Service Parameters display flashes, now you can make

changes to the value of the first driver’s
1. Connect the service key at J41. Make sure PIN code.
(S21) is in the ON position. See “Special
Tools” on page 3-4. NOTE: All parameters can be viewed; however,
not all parameters can be changed.
2. Turn the truck ON while holding the horn
Individual operator parameters (1
button until desired parameter is
through 5) may or may not be accessed,
displayed (the display will cycle through H,
depending on the value of parameter 39.
E, P, and Pn).
3. Release the horn button at desired
parameter to enter parameter mode. (If the 6. Rotate the thumb control in the fork
horn button is released at the wrong time, direction to increase the value, or in the
turn the truck OFF at the keypad and operator direction to decrease it. Holding
start over.) The parameter symbol on the the thumb control in a direction for a time
display is illuminated. See Figure 5-4. quickly advances numbers.
4. Rotate the thumb control in the fork
direction to progress forward through the
parameters. While the thumb control is
held and briefly after it is released, both
the parameter number and the driver
number are displayed. Stop at parameter
10 (PIN code) for the first driver; the
default value of “l” will be displayed. See
Table 5-6.
5. Press the horn button once to access the Service Parameter Display
parameter. The parameter symbol on the

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Control Handle Display and Programming

When parameters 1 through 5, and 10 are display flashes. Now you can make
viewed with the service key, both the parameter changes to the value of the first operator’s
number (left side of display) and the first PIN-key code.
operator number (right side of display) are
shown.

As the service parameter number display Changing the 1st operator’s PIN-key
progresses through parameters 1, 2..., 10, the code will alter default operation. You
display will roll over to the next operator (the will not be able to press “1” and green
operator number increases). If a parameter is ON (l) to power the truck unless an
changed, it is valid only for the operator shown. operator’s PIN-key code is set to a value
After all operators and operator parameters are of “1”.
scrolled through, service parameters 11
through 40 are displayed. 6. Rotate thumb control in fork first direction
to increase the PIN-key code value, or in
To quickly display/access a service parameter operator direction to decrease the value.
rotate the thumb control away from the forks Holding the thumb control in a direction
(sequence backwards through the for a time will help quickly advance to
parameters/operators). larger numbers (for example, codes greater
than 100). PIN-key code can be from one
to four digits long. Release the thumb
Setting Individual PIN-key codes
control when desired value is reached.
1. Connect the service key at J41. (See 7. Press the horn button again to confirm
Figure 5-9 For J41 location.) Make sure new PIN-key code value. The parameter
that the Main ON/OFF switch is ON. symbol on display stops flashing.
2. Turn the truck ON while holding the horn 8. To enable additional operators; rotate the
button until “P” is displayed (while the thumb control in the fork direction to roll
horn button is held, the display will cycle over to the second operator, and stop at
through H, E, P, and Pn). parameter 10. The default value of “0” will
3. Release the horn button at “P” to enter be displayed. (By default, all drivers except
parameter mode. See “Special Truck the first have a PIN code value of “0” which
Mode” on page 5-9. (If the horn button is disables that driver.)
released at the wrong time, turn the truck 9. Follow the previous steps for the desired
OFF at the keypad and start over.) The number of different PIN-key codes you
parameter symbol on the display is want to set up. There are a total of ten
illuminated. operator PIN-key codes available.
4. Rotate the thumb control in the fork NOTE: Disabling all operators (all PIN-key code
direction to progress forward through the values = 0) prohibits truck operation
parameters. While the thumb control is without the service key.
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- only occurs when using service
key to display driver’s parameters) are
displayed. Stop (release the thumb control)
at parameter 10 (PIN-key code) (See
“Parameter 10” on page 5-21.) for the first
operator; the default value of “1” will be
displayed.
5. Press the horn button once to access this
parameter. The parameter indicator on the

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Table 5-6. Service Parameters

Parameter Parameter Range
Units Default Description
Number Name (Step)
10 PIN-key 0 to 9999 1 1 Capability to assign up to 10 PIN-key codes
code (for 10 different operators)
14 Creep speed –10 to 10 1 1 Defines how much output the power amplifier
(1) gives when you reach the first speed sensor.
-10 = low speed when reaching first speed
sensor
10 = high speed when reaching first speed
sensor
15 Click-to- 0 or 1 1 0 Enable creep travel with the control arm in the
Creep (1) fully raised or lowered position.
0: Disabled
1: Enable
16 Configurable 0 to 15 1 0 Sets travel alarm
Output (1) 0: OFF
15: Lifting or Lowering or Traveling Fork Lead
or Fork Trail
20 Hour Meter 1 to 5 1 2 1: (A) key time
Selection (1) 2: (b) activity time (drive, lift, or lower)
3: (c) drive motor time
4: (d) coast drive time
5: (S) time to service
21 Batter Size 1 to 20 1 8 Battery size section
(1)
25 Service 0 to 2000 Hours 0 Sets/resets service timer, C29 displays when
Interval (50) time is up. To reset timer, access this
parameter without changing the value.
39 Access Code 1 to 4 1 3 Defines whether truck has a key switch or a
(1) keypad and what access level service
personnel will have to parameters:
1 = key switch only (no keypad) and driver
parameters are open.
2 = key switch only (no keypad) and driver
parameters are closed.
3 = keypad and driver parameters are open.
4 = keypad and driver parameters are closed.
(When driver parameters are closed, the
service key is required to access driver
parameters).

Parameter Description Parameter 2

Parameter 1 Top Speed - Reduces speed value sent from the

ETAC to the power amplifier while in Fast mode
Maximum speed value sent to the power (all throttle positions).
amplifier while in Slow mode except during
Turtle Torque (gives torque boost if high load is
encountered).

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Control Handle Display and Programming

Parameter 3 Parameter 15
(starting with software version 3.6)
Acceleration - Defines the truck’s acceleration
characteristic when the truck starts from a Enables creep travel with the control handle in
stop. A high number gives maximum the fully raised or lowered position: “0” disables
acceleration, a lower number gives less the options and “1” enables the option.
aggressive acceleration. Activate click-to-creep by quickly clicking the
speed control in either direction twice with the
Parameter 4 arm in the brake position. “SLO” blinks on the
display when in the mode.
Auto-Plug Braking in Neutral - Defines the Deactivate by clicking the speed control twice
truck’s automatic plug-braking characteristic more. Also the mode deactivates automatically
when throttle is reduced (including to neutral). after 10 seconds or immediately if the
A lower number gives less aggressive Emergency Reverser switch is pushed.
deceleration.
Parameter 16
Parameter 5 (starting with software version 3.6)
The travel alarm can be set as follows:
Automatic Time Off Interval (touch pad only).
0 = OFF; 1 = Traveling Forks
The time until the truck is switched OFF
Leading (FL); 2 = Forks Lead
(energy saving feature) when the truck is idle
Trailing (FT); 3 = Forks Trail
and the brake is applied. Time is counted from
4 = Lifting
when the latest power output is requested. If
5 = Lifting or Traveling FL
truck has key switch option, the truck never
6 = Lifting or Traveling FT
powers OFF. Range is from 1 minute to 20
7 = Lifting or Traveling FL or Traveling FT
minutes (a setting of “0” disables automatic
8 = Lowering
time off).
9 = Lowering or Traveling FL
10 = Lowering or Traveling FT
Parameter 10
11 = Lowering or Traveling FL or Traveling FT
12 = Lifting or Lowering
All trucks with a touch pad have a temporary
13 = Lifting or Lowering or Traveling FL
key code set at the factory. By default the first
14 = Lifting or Lowering or Traveling
operator’s PIN-key code is the single digit
15 = Lifting or Lowering or Traveling FL or
number “1” and all other operator’s PIN-key
Traveling FT
codes are “0” which disables that operator. The
key code logic has ten (10) registers for
Parameter 20
individual operator key codes. To add additional
operators, change these PIN-key codes to
Choose hour meter you want to display.
numbers other than “0.” See “Setting Individual
1 = A. (key time)
PIN-key codes” on page 5-19. A Service Key is
required to assign up to 10 operators their own 2 = b. (activity time, drive, lift, lower)
PIN-key code (one to four digits) for access to 3 = c. (drive motor time)
the truck.
4 = d. (lift motor time)
Parameter 14 5 = S. (time to service)

Defines the speed at low throttle positions. A

negative number enhances low speed
maneuverability. A positive number makes the
truck more responsive.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Control Handle Display and Programming

Click here for info on
Parameter 21 Parameter 39
Nexus Battery setting
Data must be provided about the battery This parameter determines whether the truck
installed in the truck. has a key switch or keypad and what access
level service personnel will have to the operator
The battery state-of-charge reset voltage is parameters. This parameter is adjustable:
25.2V and the lift cutout occurs when the 1 = key switch connected, driver
display shows 0% state-of-charge. parameters open.
2 = key switch connected, driver
To adjust the disconnection point of the battery parameters must be opened with service
discharge indicator, measure: key.
• the acid concentration of a fully-charged 3 = keypad connected, driver parameters
battery (must be between 1.27 and open.
1.29 SG)
4 = keypad connected, driver parameters
• at lift cutout, acid concentration should be must be opened with service key.
about 1.14 SG.
NOTE: Acid concentration varies with different Display Part Numbers (Pn)
battery brands.
1. Enter the special truck mode.
2. Press and hold the horn button until “Pn”
is displayed.
Make sure that you have the correct 3. Use the thumb control to scroll and
parameter setting. Otherwise the display the following information:
battery can be destroyed. • HPn = Hardware part number
• HSn = Hardware serial number
Parameter 25
• SPn = Software part number
With this parameter you can set a time limit to 4. End displaying the part number by
next service from 0 to 2000 hours in steps of 50 pressing the red OFF (O) key on the
hours. When it is time for service, you will get keypad.
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.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Service Display

Service Display Digital Inputs/Outputs from Power

Amplifier
• Connect service key (See “Special Tools” on
page 3-4.) in connection point J41 and See table below for when the first figure
press green ON key (l) to start lift truck. segment is active. (Marked with arrow).
• The battery status is displayed and the
symbol “D” is lit continually. Power Amplifier Inputs
• Press horn button (S18) to toggle between
display modes. See table below: A
Displayed Data

A
Flashing E D C B
Symbols

E D C B
Figure
Segments

Flashing Symbol Displayed Data

B Speed reference value sent

to power amplifier.

C Highlight three segments of

figure (A) to display digital
Figure
inputs/outputs from power Function
Segment
amplifier and ETAC. See
“Digital Inputs/Outputs A (not used)
from Power Amplifier” on
page 5-23. B Input (J5-14): Arm Angle B

BC Battery voltage (V) at ETAC C Input (J5-15): Lift limit

D Armature current (A) D Input (J5-12): Arm Angle A

BD Field current (A) E Input (J5-2): Lower valve (lit if

valve is present and not powered)
CD Armature PWM in %
F (not used)
BCD Status of power amplifier.
See “Status of the Power G Input (J5-5): Brake (lit if brake is
Amplifier” on page 5-25. present and not released)

E Field resistance (Ohms), DP (not used)

used for thermal cutback.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Service Display

See table below for when the second figure See table below for when the third figure
segment is active (Marked with arrow). segment is active (Marked with arrow).

Power Amplifier Outputs Digital Input from ETAC Control

Sensors

A
A

E D C B
E D C B

Figure
Segments Figure
Segments

Figure
Function Figure
Segment Function
Segment
A (not used)
A (not used)
B (not used)
B (not used)
C Output (J5-2): Lower valve
C (not used)
D (not used)
D ETAC input: lift forks
E Output (J5-4): Main contactor
interlock E ETAC input: lower forks

F Output (J5-5): Horn F (not used)

G Output (J5-5): Brake G (not used)

DP Output (J5-6): Pump contactor DP ETAC input: horn

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Service Display

Status of the Power Amplifier

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

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 5-26.
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.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Power Amplifier Fault Codes

Power Amplifier Fault Table 5-7 describes the fault codes that are
shown on the status LED or read using the
Codes Programmable Maintenance Tool. See
“Programmable Maintenance Tool (PMT)” on
page 5-28. Correct faults by following the
An internal microcontroller automatically "Troubleshooting Flowcharts" on page 5-33.
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. Fault Codes

Fault Code PMT Display Possible Cause Explanation

Open circuit at power Power amplifier does not
LED
amplifier +24Vdc logic input have voltage at +24Vdc
Solid N/A
due to wire, fuse, or bad logic power supply input.
OFF
power amplifier.
LED Power amplifier is not
Solid N/A Bad power amplifier. functioning correctly.
ON
Single Normal “heartbeat”,
¤ NO KNOWN FAULTS N/A
flash everything is okay.
1, 1 ¤¤ CURRENT SHUNT FAULT See “Code E202 - Power Amplifier Sensor Error” on
page 5-17..
See “Code E214 - Power Power amplifier is
Amplifier CAN Time-out” on reporting that it is not
page 5-17 if ETAC is keyed receiving CAN messages
ON. from the ETAC, or that
1, 2 ¤ ¤¤ HW FAILSAFE self-test 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.
2, 1 ¤¤ ¤ THROTTLE FAULT 1
Bad power amplifier. Power amplifier is not
2, 2 ¤¤ ¤¤ EMR REV WIRING setup or functioning
correctly.
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..
Power amplifier is not
3, 2 ¤¤¤ ¤¤ MAIN CONT WELDED Bad power amplifier or ETAC. setup or functioning
correctly.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Power Amplifier Fault Codes

Table 5-7. Fault Codes

Fault Code PMT Display Possible Cause Explanation

3, 3 ¤¤¤ ¤¤¤ FIELD OPEN See “Code E200 - Field Open” on page 5-16.
Power amplifier is not
3, 4 ¤¤¤ ¤¤¤¤ MISSING CONTACTOR Bad power amplifier or ETAC. setup or functioning
correctly.
4, 1 ¤¤¤¤ ¤ LOW BATTERY VOLTAGE See “Code C41 - Battery Undervoltage Warning” on
page 5-11.
4, 2 ¤¤¤¤ ¤¤ OVERVOLTAGE See “Code C42 - Battery Over Voltage Warning” on
page 5-12.
4, 3 ¤¤¤¤ ¤¤¤ THERMAL CUTBACK See “Code C43 - Power Amplifier Thermal Cutback” on
page 5-12.
Power amplifier is not
¤¤¤¤
4, 4 ANTI-TIEDOWN Bad power amplifier or ETAC. setup or functioning
¤¤¤¤
correctly.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Programmable Maintenance Tool (PMT)

Programmable The Main Menu is the starting point for the

PMT. The main menu displays menu titles:
Maintenance Tool (PMT) • Program (not used)
• Monitor
• Faults
Data Inc/Dec • Functions
Key
• Information
• Programmer Setup
Bookmark
Keys If there are no entries within a menu, then the
menu title will not be displayed.

Connector
Menu J41
Navigation
Key
1665 037.tif

Figure 5-8. Programmable Maintenance Tool

The optional Programmable Maintenance Tool

(P/N 00590-49981-71) permits you to test and
diagnose the power amplifier in this pallet
truck. See Figure 5-8.

The PMT is powered by the power amplifier

through a four-pin connector at the bottom of
1665 037.tif
the power amplifier. See Figure 5-9.
Figure 5-9. Connecting PMT to Power Amplifier at J41

The Menu Navigation Key moves the screen

curser up or down through the Menu list (top or Monitor Mode
bottom arrow), and opens or closes Sub-Menus
(right or left arrows). Real-time status information is displayed in the
Monitor mode for various inputs, outputs,
The Data Inc/Key changes the value of the temperature, and so forth. This information can
parameter indicated by the curser. be helpful in troubleshooting many problems
and is useful for checking operation of the
The Bookmark Keys allow you to quickly go controller during initial installation.
back to your favorite selections without having 1. Press the red OFF (O) key on the keypad.
to navigate back through the Menu.
2. Remove the tractor cover.
• To select a position in the menu, hold a
3. Connect the PMT to the power amplifier.
Bookmark Key down for three seconds
Wait for the PMT to “boot up” before
until the bookmark set screen is
proceeding to the next step.
displayed.
4. Enter the PIN key code and press the
• To jump to a selected Bookmark position,
green ON (I) key on the keypad or turn key
press the appropriate Bookmark Key.
switch ON.
NOTE: The Bookmarks are not permanently 5. Use the Menu Navigation Key to select
stored in the PMT. They are cleared Monitor.
when the PMT is unplugged.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Programmable Maintenance Tool (PMT)

6. Press the right arrow on the Menu 7. Use the Up and Down Buttons arrows on
Navigation Key to enter the sub-menu. the Menu Navigation Key to scroll through
7. Use the Up and Down Button arrows to list of multiple faults.
scroll through the sub-menu list of
monitor variables. Clear
8. Use the right arrow to select and view a
single variable. After you have diagnosed and corrected the
problem, clear the diagnostic history file. This
9. To change the value of the parameter use permits the power amplifier to accumulate a
the Data Inc/Dec Key. Alternately, you can new file of faults. By checking the new history
press the right arrow Menu Navigation Key file at a later date, you can easily determine
once more and enter the detail screen. A whether the problem was completely fixed.
bar graph appears as well as min and max
data points. Change the parameter value 1. To clear the fault history of the unit, use
by pressing the Data Inc/Dec Key. The the Menu Navigation Key to select
new value is set as soon as the Data Faults -> Clear Fault History.
Inc/Dec Key is released. 2. Press the increment arrow (+) for yes and
the decrement arrow (-) to cancel and not
To close a Monitor Menu, sub-menu, or detail clear the fault history.
screen, press the left arrow on Menu Navigation
Key. Table 5-10 on page 5-30 lists possible messages
you may see displayed when the PMT is
operating in either System Faults or Fault
Faults Mode History mode.
In System Faults mode, currently active faults
detected by the controller are displayed. Information Mode
In Faults History mode, the controller’s The Information Menu provides access to
diagnostic history file is displayed. This field product information describing the basic
includes a list of all faults observed and revision level of the PMT.
recorded by the controller since the history was
last cleared. To view, use the Menu Navigation Key to select
Information in the Main Menu. Remember to
NOTE: Each fault is listed only once, regardless
press the right arrow to select a Menu. Press
of the number of times it occurred.
the left arrow to exit.
1. Press the red OFF (O) key on the keypad.
2. Remove the tractor cover. Programmer Mode
3. Connect the PMT to the power amplifier.
Wait for the PMT to “boot up” before Programmer mode permits you to perform a
proceeding to the next step. variety of tasks.
4. Enter the PIN key code and press the 1. Press the red OFF (O) key on the keypad.
green ON (I) key on the keypad or turn key 2. Remove the tractor cover.
switch ON.
3. Connect the PMT to the power amplifier.
5. To view the present status of the unit, use Wait for the PMT to “boot up” before
the Menu Navigation Key to select proceeding to the next step.
Faults -> System Faults
4. Enter the PIN key code and press the
6. To access the log, use the Menu Navigation green ON (I) key on the keypad or turn key
Key to select Faults -> Fault History. switch ON.
5. Use the Menu Navigation Key to select
Programmer.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Programmable Maintenance Tool (PMT)

6. Press the right arrow on the Menu 8. Use the right arrow to select and view a
Navigation Key to enter the sub-menu. single variable.
7. Use the Up and Down arrows on the
Navigation Key to scroll through the Change the parameter value by pressing the
sub-menu list of Programmer displays. 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, in °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

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

List of Troubleshooting Charts/Tables

Section 5. Troubleshooting

List of Troubleshooting Charts/Tables

Troubleshooting Charts
TS1: START TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Hydraulic Symptom Tables

No Lift, Lift Motor Does Not Run, Travel is OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
No Lift or Slow Lift, Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
No Lower, Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Load Drifting/Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Travel Symptom Tables

No Lift, Lift Motor Does Not Run, Travel is OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
No Lift or Slow Lift, Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
No Lower, Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Load Drifting/Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
No Lift or Lower. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Slow Travel, Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Green/Red LED on Keypad Not Illuminated When Key Pressed . . . . . . . . . . . . . . . . . 5-43
No Fast Travel Mode. No Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
No Travel Mode. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Horn Does Not Sound When Horn Button Pushed. No Fault Codes . . . . . . . . . . . . . . 5-43

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

List of Troubleshooting Charts/Tables

5-32 00700-CL340-08, Issued: 06/20/2008

Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Troubleshooting Flowcharts
Section 5. Troubleshooting

Troubleshooting
Flowcharts
TS1: START TROUBLESHOOTING

T S 1 : S t a r t T r o u b le s h o o tin g

Is a
M essage or
Yes
F a u lt C o d e
d is p la y e d ?

F in d
M essage or C ode
No in C h a p te r 5

Is
s y m p to m lis te d in
No
S y m p to m T a b le s in
C h a p te r 5 ?

G o to
C h a rt G E N -1

Yes

F o llo w
S y m p to m T a b le
d ir e c tio n s in
C h a p te r 5

TS-1.wmf

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Troubleshooting Flowcharts

GEN1
GEN1: General Troubleshooting

G E N 1 : G e n e r a l T r o u b le s h o o tin g

G a th e r a s m u c h
in f o r m a t io n a s y o u c a n E lim in a t e u n lik e ly
W h a t is t h e p r o b le m ?
about causes.
t h e p r o b le m .

W h e r e d id it h a p p e n ?

W h e n d id it h a p p e n ?

S e le c t a n d p r io r it iz e
W h a t f u n c t io n s a r e a f f e c t e d ? t h e m o s t lik e ly
causes.

W h a t c o n d it io n s t r ig g e r t h e p r o b le m ?

C h e c k e a c h lik e ly
T a lk d ir e c t ly t o t h e
c a u s e , u s in g t h e t e s t s
o p e ra to r o r fo re m a n .
in t h is m a n u a l.

C h e c k a ll o t h e r t r u c k
O p e ra te th e tr u c k f u n c t io n s b e f o r e
y o u r s e lf . r e t u r n in g t h e t r u c k
t o s e r v ic e .

U s e t h e s c h e m a t ic s
if n e c e s s a r y a n d id e n t if y
a ll c o m p o n e n t s w h ic h
c o u ld c a u s e t h e
p r o b le m .

Gen1.wmf

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Troubleshooting Flowcharts
END1: End of Troubleshooting Procedure

E N D 1 : E n d o f T r o u b le s h o o tin g P r o c e d u r e

O p e r a te th e tr u c k a s it w a s
M a k e s u r e A L L w ir e s ,
b e in g o p e r a te d w h e n th e
h o s e s , a n d c a b le s th a t
p r o b le m o c c u r r e d . V e r ify
y o u re m o v e d h a v e b e e n
r e - a tta c h e d c o r r e c tly . th e p r o b le m d o e s n o t r e c u r.

H a v e th e d r iv e r o p e r a te
M a k e s u r e a ll p a n e ls a r e
p r o p e r ly r e in s ta lle d . th e tr u c k . V e r ify th e
p r o b le m d o e s n o t r e c u r.

M a k e s u re a n y
c o m p o n e n t th a t w a s F ill o u t a n y r e q u ire d
d r a in e d h a s b e e n fo r m s .
re fille d w ith th e c o r r e c t
le v e l o f flu id .

T h is is e s p e c ia lly
If y o u c o n ta c te d T o y o ta im p o r ta n t if th e
C r e a te th e s a m e
F ie ld S e r v ic e to d is c u s s s o lu tio n y o u
c o n d itio n s th a t o c c u r r e d
th e p r o b le m , c a ll th e m fo u n d is n o t in
w h e n th e p r o b le m fir s t
a g a in to le t th e m k n o w th e
happened.
w h a t fix e d th e p r o b le m . tr o u b le s h o o tin g
c h a r t.

E n d o f T r o u b le s h o o tin g

End1.wmf

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Troubleshooting Flowcharts

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Symptom Tables: Lift/Lower System

Section 5. Troubleshooting

Symptom Tables: Lift/Lower System

NOTE: If it is determined that a component failed as NOTE: Reference electrical schematics beginning on
a result of hydraulic fluid contamination, page A-9 and hydraulic schematic beginning
replace the failed component and flush, fill, on page A-12.
and bleed the hydraulic system. See
“Hydraulic Fluid” on page 6-56.
Click here for more
information on Diagnosis
of Lift Pump and
No Lift, Lift Motor Does Not Run, Travel is OK
Contactor
Possible Cause Action
Bad lift pump contactor With Main 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 (ETAC) card (A2) With Main ON/OFF switch ON, the PIN-key code
entered, the green ON (I) key on 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 5-23.)
If no signal is detected, replace control handle
(ETAC) card (A2).
NOTE: Check for mechanical problems in the
handle head before replacing control handle
card.
Bad wiring continuity or wiring shorts With Main ON/OFF switch OFF and battery
disconnected, check for continuity and wiring
shorts in wiring harness or cables.
Bad lift-limit switch With Main ON/OFF switch OFF, battery
disconnected and forks lowered, check continuity
through lift-limit switch. Replace if necessary.
Bad lift pump motor brushes With Main ON/OFF switch ON, the PIN-key code
entered, the green ON (I) key on the keypad
pressed, and 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 lift pump motor.

No Lift or Slow Lift, Lift Motor Does Run

Possible Cause Action
Battery problems Replace battery with fully-charged 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 6-57.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Symptom Tables: Lift/Lower System

Possible Cause Action

Relief valve contaminated or bad. (Unable to With Main ON/OFF switch OFF and battery
get the correct hydraulic pressure) 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 6-56.
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.

No Lower, Lift and Travel OK

Possible Cause Action
Bad lower solenoid valve With the Main ON/OFF switch ON, cycle the lower
switch. Does the lower solenoid valve activate? If
YES, disconnect the battery, then slowly loosen,
but do not remove hydraulic line at the hydraulic
pump assembly. Permit forks to slowly lower. Have
rags and drain pan ready to catch fluid.
If the forks do not lower, check for Replace lift cylinder or repair lift mechanism.
mechanical binding in lift cylinder or fork
mechanism
If the forks lower, remove and inspect the Inspect for free movement and for signs of
solenoid valve 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.
Check for bad control handle (ETAC) card With Main ON/OFF switch ON, the PIN-key code
entered, the green ON (I) key on keypad pressed
and the lower button depressed, check for lower
signal input at CAN. (See “Service Display” on
page 5-23.) If no signal is detected, replace control
handle (ETAC) card (A2).
NOTE: Check for mechanical problems in handle
head before replacing control handle ETAC
card.

Unable to Pick Up a Load

Possible Cause Action
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.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Symptom Tables: Lift/Lower System

Possible Cause Action

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.

Slow Lower
Possible Cause Action
Bad lift/lower solenoid valve or wiring Repair or replace the solenoid valve or wiring.
Plugged or malfunctioning flow control 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 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 correctly).
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.

Load Drifting/Settling
Possible Cause Action
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad check valve Check for contamination in hydraulic fluid.
If contamination is present, flush, fill and bleed the
hydraulic system. Clean the check valve.
If no contamination is found, replace check valve.
Leaking or contaminated lowering solenoid Check for contamination in hydraulic fluid.
valve If contamination is present, flush, fill and 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.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Symptom Tables: Lift/Lower System

No Lift or Lower. No Fault Codes

'

Possible Cause Action

Throttle magnet-actuator arm (in control Check with service display and repair as needed.
handle) out of adjustment 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 Perform standard electrical troubleshooting
lift circuit (contactor, wiring, motor), bad procedures in the lift circuit.
power amplifier
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.

BDI Does Not Reset to 100%

Possible Cause Action

M1-1 cable on top post and M1-2 cables on Cables maybe mislabeled or on wrong post on
bottom post. main contactor. Using Schematics, troubleshoot
cables for correct location and relabel.
Static Voltage at battery Measure the static voltage in the battery.
Voltage is below 25.2 volts after charge cycle Charge battery pack 5 times consecutively.
Voltage is at or above 25.2 volts and display Drive the truck with a meter attached and record
still reads 0% the voltage drop. If the voltage drops below 25.2
volts, charge the battery pack 5 times
consecutively
BDI resets to 100% but then drops back to 0% Drive the truck with a meter attached and record
the voltage drop. If the voltage drops below 25.2
volts, charge the battery pack 5 times
consecutively
NOTE: The voltage must remain at or above 25.2
volts for 20 seconds while driving for the
truck to reset and stay at 100%.
Voltage does not stay at or above 25.2 volts for Battery charger or battery suspected.
20 seconds while driving and battery has
been charged consecutively 5 times
Voltage remains at or above 25.2 volts while Refer to Maintenance Manual 00700-CL340-05,
driving for 20 seconds and BDI does not follow procedures under “Service Display.” Use the
reset to 100% table as a reference, toggle through the menu until
“BC” is represented by the hour glass (B) icon and
the parameter control (C) icon lit together.The
control handle will display the voltage received by
the ETAC that is approximately equal to battery
Voltage.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Symptom Tables: Lift/Lower System

Possible Cause Action

Voltage difference is greater than 0.5 volts and Troubleshoot wiring between battery (+) and J11-1
cables have connected correctly on the ETAC card and between B- and J11-3 on
the ETAC card. Repair as necessary. If no problem
is found, replace ETAC card.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Symptom Tables: Travel (Forward/Reverse) System

Symptom Tables: Travel (Forward/Reverse) System

NOTE: Reference electrical schematics beginning on
Page A-9 and hydraulic schematic on
Page A-12.

Slow Travel, Lift/Lower OK. No Fault Codes

Possible Cause Action
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 6-36. Check that drive wheel spins freely. If
not, repair or replace.
Binding brake disc Check See “Air Gap Adjustment” on page 6-35.
Bad drive motor (may test OK with no load, Repair or replace drive motor or brushes.
but fail under load) or worn brushes

Truck Does Not Accelerate Correctly

Possible Cause Action
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 Main 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 Main ON/OFF switch OFF and battery
disconnected, check drive motor brushes and
motor. See “Drive Motor Brush Inspection” on
page 6-39. Repair or replace.
Bad power amplifier If all other possible causes check out, replace
power amplifier.

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Toyota Model 7HBW23 Service Manual Section 5. Troubleshooting

Symptom Tables: Travel (Forward/Reverse) System

Green/Red LED on Keypad Not Illuminated When Key Pressed

Possible Cause Action
No power supplied to the ETAC Check for open circuit in wires or connectors in
Control Handle, F50 open, key switch 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 Make sure control fuse has not tripped.
Key switch jumper not connected Connect key switch jumper.
Bad LED(s) Check LED(s) if truck functions normally but
LED(s) not lighting correctly.

No Fast Travel Mode. No Fault Codes

Possible Cause Action
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.

No Travel Mode. No Fault Codes

Possible Cause Action
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 Check with service display and repair as needed.
handle) out of adjustment Bad ETAC. If no other problems are noted but the
ETAC does not detect the presence of the
magnet, replace the ETAC.

Horn Does Not Sound When Horn Button Pushed. No Fault Codes
Possible Cause Action
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.

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Section 5. Troubleshooting Toyota Model 7HBW23 Service Manual

Symptom Tables: Travel (Forward/Reverse) System

5-44 00700-CL340-08, Issued: 06/20/2008

Component
Procedures
Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Section 6. Component Procedures

00700-CL340-08, Issued: 06/20/2008 6-1

Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Alphabetical List of Components procedures

Alphabetical List of G

Components procedures Gear Oil ..............................................6-32

A H

Arm Angle Switches ............................6-26 Horn ...................................................6-21

Hydraulic Components
Cylinder ........................................6-51
B Fluid .............................................6-56
Hydraulic Unit ...............................6-53
Battery .................................................6-6 Filter Screen ........................... 6-54
Adding Water ..................................6-9 Pump ...................................... 6-55
Charging .........................................6-8 Relief Valve Adjustment .......... 6-57
Exterior Cleaning ............................6-7 Reservoir ................................ 6-54
Maintenance Free ..........................6-10 Solenoid .................................. 6-53
Specific Gravity ...............................6-9 Suction Tube .......................... 6-54
Storage .........................................6-10
Voltage Check .................................6-9
K
Battery Pack
Swingout .........................................6-6
Brake ..................................................6-35 Key Switch (Optional) ..........................6-28

C L

Circuit Breaker ...................................6-16 Lift Motor ............................................6-55

Contactors ..........................................6-23 Lift-Limit Switch .................................6-27
Control Handle ...................................6-17 Load Wheel
Cover, Tractor .....................................6-11 Pull Rod Adjustment ......................6-49
Load Wheels ........................................6-49
Lubrication
D Drive Housing ...............................6-32

Drive Unit ...........................................6-29

M
Brake, Electromagnetic .................6-35
Drive Housing Lubrication .............6-32
Drive Motor ...................................6-46 Master Control ON/OFF Switch ..........6-25
Drive Wheel ...................................6-33 Motors
Transmission Assembly .................6-29 Brush Spring Tension ....................6-40
Drive Wheel ........................................6-33 Brushes ........................................6-39
Commutator ..................................6-40
Drive .............................................6-46
E General .........................................6-39
Lift ................................................6-55
Electromagnetic Brake ........................6-35 Tests .............................................6-43

F P

Fuses ..................................................6-15 Power Amplifier ...................................6-22

Power Cables ......................................6-12
Pump, Hydraulic .................................6-55

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Alphabetical List of Components procedures

Switches
Arm Angle .................................... 6-26
General ........................................ 6-53
Key Switch (Optional) ................... 6-28
Lift-Limit ...................................... 6-27
Master Control ON/OFF ............... 6-25

Wheels
Load ............................................. 6-49
Wiring Harness .................................. 6-13

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Alphabetical List of Components procedures

6-4 00700-CL340-08, Issued: 06/20/2008

Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Component Locator Photo

Component Locator Photo

Section 6. Component Procedures

Battery
Connector Hydraulic Cylinder
Main page 6-51
Contactor
page 6-23
Power
Amplifier Fill/Vent
page 6-22 Plug

Main
Hydraulic
Relay
Reservoir
page 6-24
page 6-54

Horn
Drive Unit
page 6-21
page 6-29

Handle
Upstop

Figure 6-1. Tractor Interior

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Battery

Battery
Pallet truck may be equipped with a multiple
(swing-out) 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.

Swing-out Battery Pack

Removal (Single Battery)
1. After the truck is stopped and the stem 1790 001.eps

handle is returned to the full up position, Figure 6-2. Multiple Battery Wiring Hookup
press the red OFF (O) key on the keypad.
2. Disconnect the battery connector found at
Installation (Single Battery)
the top of the tractor cover. Remove the 1. Position the fully-charged and tested
battery cover. batteries in the battery pack.
3. Lift up on the top battery frame to get 2. Reconnect the battery cables to the battery
access to the lower two batteries. terminals in accordance with the battery
4. As the frame is lifted, swing the battery wiring hookup shown on the decal in the
toward the center of the forks. battery frame.
5. Cables may now be disconnected from the 3. Reconnect the battery connector, reinstall
battery terminals and the batteries may be the battery cover, press the green ON (I)
serviced or replaced if necessary. See key on the keypad, and test the operation
Figure 6-2. of the pallet truck.

Removal (Entire Battery Pack)

1. Press the red OFF (O) key on the keypad.
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 manufacturer’s designated lift
points.
4. Remove the battery with the lifting device.
5. Put the discharged battery on the charging
stand.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Battery

Installation
1. With a fully charged and tested battery on Cable
the lifting device, position the lifting device
Vent Hole
in accordance with the manufacturer’s
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 Filler Plug
the truck. 09g6s047.tif

Figure 6-3. Battery Filler Plugs and Vent Holes

Maintenance-Free Batteries
2. Keep the top of the battery clean and dry.
The truck may be equipped with a Corrosion, dust, and moisture provide a
maintenance-free battery and charger pack. conducting path to short-circuit cells or
The specific gravity need not be measured on a create grounds.
maintenance-free battery. Please follow
manufacturer’s recommendations for service of
these batteries. Do not clean the top of the battery with
the soda solution while it is installed in
A maintenance-free battery still requires some the truck. Water will seep into the
care. The battery must be kept clean and dry electrical compartments and cause
and may be washed to remove any accumulated serious damage.
foreign matter.
3. Disconnect the battery connector, and
Battery Maintenance remove the battery from the truck before
you clean it.
Exterior Cleaning 4. Tighten the battery filler plugs.

1. Inspect the battery. 5. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
a. Make sure the cables are not frayed or of 1 lb. (0.45 kg) of baking soda added to
loose. 1/2 gal (1.9 liters) of hot water.
b. Make sure there is no foreign material 6. Use a brush with flexible bristles to clean
inside the connector. the entire top of the battery with the soda
c. Make sure the filler plugs are tight and solution. Wait until all foaming stops,
the vent holes in the filler plugs are indicating that the battery exterior is
open. See Figure 6-3. 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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Battery

Charging battery plates. If electrolyte level is below

the plates, add just enough water to cover
To charge a battery, direct current is passed the plates. Do not fill to level yet.
through the battery cells in the direction Electrolyte level will increase during
opposite to that of discharge. Charging time is charging. See “Adding Water” on page 6-9.
5% to 20% longer than discharge time.
8. Using a hydrometer, measure and record
Most important element in battery service and the specific gravity of each cell. See
prolonging battery life is correct charging. Make “Specific Gravity” on page 6-9.
sure you follow the approved method for each 9. Measure and record the voltage of each
application, following the battery and battery cell.
charger manufacturers’ instructions. 10. To get the maximum use out of each
battery, recharge only when effectively
discharged. Routinely recharging batteries
The vent holes in the filler plugs must be when only partially discharged will
open to permit hydrogen gas to escape decrease battery life. At maximum
from the cells. When you charge the recommended discharge, the specific
battery, make sure the polarity gravity must read 1.140 to 1.160 or less.
connections are correct. The positive 11. Make sure that the filler plugs are clean
lead of the charger must be connected to and the vent holes are open. Tighten all
the positive terminal, and the negative filler plugs.
lead must be connected to the negative
terminal.

1. Familiarize yourself with the following: NEVER plug the battery charger into the
truck. This will severely damage the
• Charging rate, starting rate, and finish
truck’s electrical system. Plug the
rate
charger only into the connector from the
• Time available for charge battery.
• Overheating, excessive gassing, or
overcharging 12. Charge the battery, following specific
instructions in your battery and battery
• Variations between cell voltage
charger manufacturer’s manual.
2. Battery performance varies depending on
13. Using a hydrometer, measure the specific
the type of application. If you use more
gravity of each cell. No amount of charging
than one truck, one battery, and one
will increase battery capacity or increase
charger, keep the same batteries and
specific gravity above its fully charged level
charger assigned to each truck. This
(specific gravity 1.280 to 1.300).
makes it easier to diagnose any battery or
charging problem. 14. If after charging, the electrolyte level is
below the fill port, add water to move it to
3. Consult your battery and battery charger
the fill level. Do not overfill the cells or
manufacturer’s manual for specific
permit electrolyte to spill on the battery
charging procedures.
case. See “Adding Water” on page 6-9.
4. Wear personal protective equipment. See
“Battery Safety” on page 2-6. In general, a lead-acid battery may be charged
5. Press the red OFF (O) key on the keypad, at any rate in amperes that does not cause
and disconnect the battery. excessive gassing or produce electrolyte
temperatures above 110° F (43° C).
6. Inspect the battery.
Temperatures of 120° F (49° C) are permitted
7. Examine the electrolyte level in each cell. only for short periods of time.
Electrolyte must cover the top of the

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Battery

Adding Water Procedure

1. Wear personal protective equipment. See
Water must be added to battery cells “Battery Safety” on page 2-6.
periodically. Frequency and quantity depend on
2. Insert the nozzle of the hydrometer into
the water level above the plates and the amount
the battery cell and draw enough
of gassing during charge.
electrolyte into the tube to permit the float
to ride free.
Guidelines:
3. Leave the hydrometer nozzle in the battery
• Wear personal protective equipment. Use
and read the specific gravity of the cell.
only distilled water or water approved by
the battery manufacturer. See “Battery 4. If there is not enough electrolyte in the
Safety” on page 2-6. battery to get a hydrometer reading then:
• Before charging, make sure battery plates • Add just enough water to cover the
are covered with electrolyte. Add water, if battery plates
necessary, only to cover plates. • Charge the battery, then take readings
• Electrolyte level increases during charging. 5. Record the specific gravity reading on the
To prevent overflow, add water to fill port, battery maintenance chart.
if necessary, after charging, and after
hydrometer and voltmeter readings are
Voltage Check
taken.
• Keep the outside of the battery case clean Take a voltage check on each cell after
and dry. performing the specific gravity check. Attach a
voltmeter to the positive and negative terminals
Specific Gravity of each cell. Voltage readings will change with
the state-of-charge.
Specific gravity readings for lead acid batteries
Charge Voltage Reading
with electrolyte temperatures at 80° F (27° C)
change with the state-of-charge as follows: 100% 2.14

Charge Specific Gravity 75% 2.07

100% 1.280 to 1.300 50% 1.95

75% 1.250 to 1.260 25% 1.80

50% 1.200 to 1.210

Record the voltage reading for each cell on the
25% 1.150 to 1.160 battery maintenance chart. There must be a
difference of less than 0.2V between cells.
0% 1.080

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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Battery

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 battery in a clean, cool, dry location away

from radiators and other sources of heat.

Measure electrolyte level and the specific gravity

every 30 days during storage. Whenever specific
gravity is less than 1.230, charge the battery.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Tractor Covers

Tractor Covers
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.

Grasp Top
Cover Here

Bottom Cover

Figure 6-4. Top Cover Removal (decals omitted)

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
original position, and secure by engaging
the captivating clasps located on the top of
cover.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Power Cables

Power Cables
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.

Power Cables

Figure 6-5. Power Cables

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.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures
Click here for Wiring Harness
information on
Wiring Harness replacing Main During troubleshooting and repairs, it is
sometimes necessary to unmate a connector,
Harness Assy move a harness, cut a cable tie, or remove the
The wiring harness is designed to connect the wire from a bracket.
electrical components of the pallet truck.
NOTE: Make note of the location of wires and
all protective or securing attachments
before moving the harness.
Wiring 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
Figure 6-6. Wiring Harness
identification.
All wires in the harness are marked with a wire NOTE: It is normal to find unused connectors
identification number. These numbers for uninstalled options that have had
correspond to wire identification given in the heat shrink applied over them and have
schematic. All connectors are represented by been strapped to the harness.
“J” followed by a number. See “Schematics” on
page A-9.
Main Harness Replacement
Inspection 1. Park the truck on a smooth level surface.
Set the parking brake and block
Whenever working on the truck, use care load-wheels to prevent accidental
around wiring harnesses. movement.
• Do not pull on wires. NOTE: The control handle and drive unit must
• Carefully mate and unmate all connectors. be turned to the left when installing a
new harness.
• Do not pry apart connectors with
unspecified tools. 2. Press the red OFF button (O) on the
keypad, or if truck has a key switch, turn
• Examine and maintain any added
the key to the OFF position. Depress the
materials used to dress or protect the wire.
main ON/OFF switch to the OFF position.
This includes spiral wrap, brackets, cable
ties, fasteners, flexible conduit, and so 3. Disconnect the battery connector.
forth. 4. Remove the truck covers and upstop (See
• Examine harness wires for abrasions, Figure 6-8) to gain access to the wiring
scrapes, nicks in the wire, damage from and cables.
overheating or burns, or other general 5. Disconnect connector J11 and switches
insulation damage. S24 and S25 (wires 24, 50 and 51), located
• Replace terminations with exposed wire inside the control handle mount.
visible at the connectors. Damaged 6. Disconnect all ring terminals (number 3
terminations, exposed wires, or damaged thru 6, 26 and 57) from the drive motor
connectors can cause operational failure of terminal block, see Figure 6-7.
the truck.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Wiring Harness

NOTE: Make sure power wires are vertically

stacked one on top of the other next to
Power Cables Control Wires\ S25 switch, and above the power
on Left Side Wire Guard terminals and wire guard with ring
terminal. See Figure 6-9.
13. When installing the ring terminals, install
ring terminal and secure middle nut,
torque to 79 in. lbs. (8.925 Nm). Install
ring terminal and secure outer nut,
making sure wire is out of the way before
torquing outer nut to 79 in. lbs. (8.925
Nm).
14. Make sure the short wire guard and wire
tie are located inside the transmission.
Figure 6-7. Motor Terminal Block

7. Remove the stem mount and control

handle as an assembly from the drive unit, Wire 51 - S25 Wire 24
remove harness from truck. See
Figure 6-8

Upstop Stem Control Handle Main Harness

Wire 50 - S24

Figure 6-9. Stem Mount with Harness Wiring

Stem Mount
15. Install the stem mount and control handle
assembly.
16. Reconnect connector J11 and switches
S24 and S25 (wires 24, 50 and 51) inside
the stem mount. See Figure 6-9.
17. Install the control handle upstop and
Figure 6-8. Upstop, Stem Mount and Control Handle
truck covers.
8. Lay the new harness into the truck. 18. Reconnect the battery connector.
9. Connect the truck end of the harness. 19. Turn the main ON/OFF switch to the ON
position. Enter the key code and press the
10. Install the harness (long wire guard and
green ON button (l) on the keypad, or turn
power wires) down through the
the key switch ON.
transmission opening.
20. Check all operation functions on the
11. Position power cables and control wires as
steering control handle.
shown in Figure 6-7.
12. Connect power cables and control wires to
the drive motor terminal block.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Fuses

Fuses
Under extreme operating conditions, fuses (F50
and 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 6-10.

Fuse F50 Fuse F51

1665 031.tif

Figure 6-10. Fuse/Circuit Breaker Location

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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Circuit Breaker

Circuit Breaker
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 6-11.

Circuit Breaker
CB1

Figure 6-11. Circuit Breaker Location

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.
Resistance must be less than 1 ohm.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Control Handle

Control Handle NOTE: For replacement parts information refer

to Parts Catalog.
For SIB CC12-001 Click here for SIB
Moisture Control on CC12-002
20
ETAC Card, click on 19
Preprogramming ETAC
the word "Control 21 18
Card.
Handle" above.
17

15
14
13
22
11
23
24
25

26
10

27

28
16
30

12
32
29
33

31
35
36
31
34 7

6
35
4 5

8 1
9

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Control Handle

Item Description Item Description Item Description

1 Screw 13 Electronic Circuit Board 25 Gasket

2 Keypad 14 Push Button (optional) 26 Signal Button

3 Screw, 2 x M5 x 45 - 15 Top Cover 27 Push Button (optional)

2 x M5 x 60

4 Handle 16 Display Card 28 Wire, Hold Down

5 Cover, Keypad (Optional) 17 Push Button 29 Screw

6 Top Plate 18 Emergency Reverse 30 Control Switch

Button

7 Screw 19 Push Button 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

Control Handle Disassembly Changing Horn Button/Switch [26

and 27]
1. Remove screw [1], then unplug and
remove the keypad [2]. 1. Remove the horn button. See Figure 6-12.
2. Remove the four screws [3] that secure the
top cover assembly to the handle. Hold the
top cover [15] firmly while removing
Do not use excessive force when prying
screws.
on the button or you can damage the
3. Disconnect the cable connected to the locking tabs.
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
Figure 6-12. Horn Button Removal
cover [12] and button [18] to hold the
control switch [30] in place.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Control Handle

2. Disconnect the connection for the switch 3. Unscrew the button’s holder and arm.
on the electronic circuit board [13].
3. Press out the switch from its mounting in Control Handle and Stem
the top cover assembly.
Removal
Changing Lift/Lower Button [22]
1. Press the red OFF (O) key on the keypad.
1. Remove the button by placing a Disconnect the battery connector.
screwdriver in the hole [A]. See
2. Remove the cap screw securing the stem
Figure 6-13.
upstop to stem mount. See Figure 6-15.

Cap Screw

A A Stem Upstop

Stem Mount

Figure 6-13. Lift/Lower Button Removal Figure 6-15. Removing Stem Upstop and Stem Mount

2. Unscrew the holder [21] so that the arm 3. Disconnect the wiring harness connector
[23] comes loose. and arm angle switch connections. See
Figure 6-16.
Changing Push Button [19] Arm Angle
Switch
1. Press the push button sideways.
Connections
2. Insert a screwdriver and carefully pry the
button loose. See Figure 6-14.

Push Button

Keep Wiring
Harness To This
Side

Figure 6-16. Wires Shown With Stem Mount Removed

Figure 6-14. Push Button Removal

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Control Handle

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 three cap screws located at the

base of the control handle and stem. See
Figure 6-17.

Cap Screws

Figure 6-17. Cap Screws Location

5. Carefully remove the control handle, stem

and stem mount.

Reassembly
1. During reassembly, make sure that the
brake release cam assembly and the
harness is in the correct position before
installing. See Figure 6-16.
2. Position the stem handle mounting base
on the pivot assembly.
3. Reinstall the three 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 to stem mount.
8. Connect the battery connector. Press the
green ON (I) key on keypad.
9. Test the operation of the truck.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Horn (H1)

Horn (H1)
Removal
1. Press the red OFF (O) key on keypad.
Disconnect the battery connector.
2. Remove the tractor cover.
3. Disconnect the two wires from the horn.
See Figure 6-18.
4. Remove the horn mounting bolt.

Horn (H1)

Figure 6-18. Horn Location

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.
4. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
5. Install the tractor cover.
6. Reconnect battery connector.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Power Amplifier (A1)

Power Amplifier (A1) 3. Discharge the capacitors in the power

amplifier by connecting a load (such as a
contactor coil or a horn) across the power
The power amplifier is installed in the tractor amplifier’s B+ and B– terminals.
compartment. See Figure 6-19.
4. Push the locking tab and disconnect the
J5 connector from the power amplifier. See
Figure 6-19. 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).
5. Remove the three hex head cap screws
Power securing the power amplifier to the
Amplifier electrical panel. Remove the power
J5 Connector
amplifier.

Installation
1665 031.tif
NOTE: All power amplifiers are preset to factory
Figure 6-19. Power Amplifier Location default specifications.
1. Secure the power amplifier to the electrical
panel with the three previously removed
hex head cap screws.
Do not open the power amplifier. 2. Reconnect the three power cables
Opening the power amplifier could (terminals B+, B– and M–) on the power
damage it and will void the warranty. amplifier. Torque screws to 12 ft. lbs.
(16.3 Nm) maximum. Do not stress the
Cleaning cable connections and put strain on
internal components.
1. Press the red OFF (O) key on the keypad
and disconnect the battery connector. 3. Connect the J5 connector and wiring
harness connectors (terminals F1 and F2)
2. Remove the tractor cover. to the power amplifier.
3. Discharge the capacitors in the power 4. Connect the battery connector and press
amplifier by connecting a load (such as a the green ON (I) key on the keypad.
contactor coil) across the power amplifier’s
B+ and B– terminals. 5. Test operation of the truck.

4. Clean the power amplifier with a moist 6. Press the red OFF (O) key on the keypad.
rag. Let it dry before connecting the 7. Install the tractor cover.
battery.
5. Make sure the power cable connections
are tight. Do not stress the cable
connections or put strain on internal
components.

Removal
1. Press the red OFF (O) key on the keypad
and disconnect the battery connector.
2. Remove the tractor cover.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Contactors

Contactors 4. Install the tractor cover.

5. Connect the battery connector. Press the
NOTE: For replacement parts information refer green ON (I) key on the keypad.
to Parts Catalog. 6. Test the operation of the truck.

Contactors (K10 and K30) control the

transmission of battery power to the drive and
lift motors.
Lift Motor Contactor (K30)
Main Contactor (K10)
Removal Lift Motor
Contactor
1. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
2. Remove the tractor cover.
3. Disconnect the wires from X and Y
terminals on the contactor coils. See
Figure 6-20. Remove the nuts securing the
bus bar and cables to the contactor. Note
the location for assembly later. See
Figure 6-20.
Figure 6-21. Lift Motor Contactor K30
4. Remove the two screws holding the
contactor assembly to the electrical panel. See “Hydraulic Components” on page 6-51.

X and Y
Terminals

Bus Bar

Figure 6-20. Main Contactor K10

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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Main Relay (K4)

Main Relay (K4)

Main relay (K4) should be regularly tested for
correct operation.

Inspection/Test
1. Remove the tractor cover.
2. With the battery connected, press the
green ON (I) key on the keypad.
3. Use a voltmeter to check voltage between
wire #26 (terminal 4) and wire #24
(terminal 2). See Figure 6-22. Voltmeter
should read approximately 24V.

Wire #26 Wire #24

1665 031.tif

Figure 6-22. Main Relay (K4)

4. Move the control handle down into the

operating position. Voltmeter should now
read 0V. If not, replace the main relay.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Switches (General)

Inspection
Switches (General)
Section 6. Component Procedures

1. With the battery plugged in and the Main

Refer to schematic in the Appendix to identify ON/OFF switch in the ON position, battery
the electrical circuit location of the switch. See voltage B+ must be present on the two
“Schematics” on page A-9. terminals of the switch.
2. Test the Main ON/OFF switch with an
Test/Inspection ohmmeter after disconnecting the battery
and removing the wires from the switch
Examine the switch for signs of arcing, terminals.
overheating, discoloration, cracking, or other In the OFF position, the ohmmeter must
physical damage. Replace switch if such read greater than 1 megohm, and in the
damage is shown. ON position, the ohmmeter must read less
than 1 ohm. If not, replace the switch.
To test a switch, isolate it from the electrical
circuit. Do this by removing all connections Removal
from the switch, making sure all wires are
labeled and identified for later reconnection. 1. Disconnect the battery connector.
2. Remove the tractor cover.
Use an ohmmeter set to a low resistance scale
3. Disconnect the wires from the switch.
to measure the resistance across the switch. In
the closed position, the switch must have a 4. Remove the Main ON/OFF switch.
resistance of less than 1 ohm. In an open
position, the switch must show a resistance Installation
greater than 10 megohms.
1. Install the new Main ON/OFF switch.

Main ON/OFF Switch 2. Connect the wires to the new Main

ON/OFF switch terminals.
A Main ON/OFF switch (S21) is provided on the 3. Reconnect the battery connector and verify
truck. In the OFF (O) position, battery power to operation.
all control functions is interrupted. In the ON (I) 4. Install the tractor cover.
position, battery potential is provided to all
control functions via the power amplifier. See
Figure 6-23.

Main ON/OFF
Switch

1581 004.tif

Figure 6-23. Main ON/OFF Switch Location

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual
Click here for
Switches (General)
information on
Arm Angle Switches Arm Angle Switch
Failure
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 B1 and B2 of operating range in order
for the switches to be closed, permitting travel.
See “Arm Angle Switches” on page 5-6.

Adjustment
Nuts
The arm angle switches are found at the base of 1581 008.tif

the control handle stem. See Figure 6-24. Figure 6-25. Arm Angle Switch Nuts
1. Press the red OFF (O) key on keypad.
Disconnect the battery connector. 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 nuts.
6. Make sure that the cam arm makes solid
Use extreme care when the truck is
contact with the switch lever.
jacked up. Keep hands and feet clear
from vehicle while jacking the truck. 7. Verify that the switch “clicks” near the
After the truck is jacked, do not rely on middle of the cam movement.
the jack alone to support the truck. For 8. Switch S25 must operate within B1 and
details, See “Jacking Safety” on B2 of operating range of the full up or
page 2-9. down handle position. Make sure switch
does not bottom out when fully
2. Jack the truck and block the frame. compressed. See “Arm Angle Switches” on
page 5-6.
9. Install the stem mount cover. See
Arm Angle Switches Figure 6-26.

1581 007.tif

Figure 6-24. Arm Angle Switches

3. Remove the stem mount cover. Figure 6-26. Control Handle Cover Installed
4. Loosen the two nuts holding the bracket
on the stem mount. Slide the bracket out 10. Remove the blocks, connect the battery
as far as possible. See Figure 6-25. connector, and press the green ON (I) key
on the keypad.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Switches (General)

11. Test the operation of the truck. Lift-Limit Switch

Removal When the forks are fully raised, the lift-limit
switch (S36) turns the hydraulic pump motor
1. Lower the forks completely. off. This keeps the pump from trying to extend
2. Press the red OFF (O) key on the keypad. the lift cylinder beyond its maximum travel. See
Disconnect the battery connector. Figure 6-27.
3. Remove the stem mount cover.
4. Disconnect the wires on the switch.
5. Remove the mounting bracket from the Lift-Limit Switch
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. 1581 014.tif

2. Connect the wires to the switch. Figure 6-27. Lift-Limit Switch

3. Install the mounting bracket.
4. Reconnect the battery connector. Press the
Adjustment
green ON (I) key on keypad. 1. Raise the forks until they reach their fully
5. Test drive the truck. raised position. If the lift-limit switch does
not shut the pump down when the lift
6. Adjust the switch if necessary.
cylinder reaches its upper limit, the relief
7. Press the red OFF (O) key on keypad. valve on the hydraulic pump will make a
Disconnect the battery connector. high-pitched squeal, indicating that the
8. Install the stem mount cover. relief valve is opening.
9. Reconnect the battery connector. 2. Press the red OFF (O) key on keypad.
Disconnect the battery connector.
3. Loosen bolt and slide 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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Switches (General)

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 Main ON/OFF switch is in the ON
position.

Inspection
1. Remove the tractor cover.
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 key switch to OFF, disconnect the
battery and remove wires from the switch
terminals.
4. Test the key switch for continuity with an
ohmmeter.
In the OFF position, 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.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Drive Unit

Drive Unit 6. Disconnect the cables/wire from the

Section 6. Component Procedures

terminal block on the transmission. See

Figure 6-29.
The drive unit includes the drive motor,
electromagnetic brake assembly, drive wheel,
and transmission assembly.

Transmission Assembly
Removal
1. Lower the forks, press the red OFF (O) key
on the keypad. Disconnect the battery Terminal Block
connector. Connections

Figure 6-29: Terminal Block

Use extreme care whenever the truck is 7. Remove the ten socket head bolts that
jacked up. Keep hands and feet clear secure the transmission and bearing
from vehicle while jacking the truck. assembly to the frame.
After the truck is jacked, put solid blocks
beneath it to support it. do not rely on NOTE: Remove four socket head bolts to
the jack alone to support the truck. For remove only the transmission but not
details, See “Jacking Safety” on the steer bearing.
page 2-9.

2. Jack the truck and block the frame.

3. Remove the tractor cover. Transmission assembly may fall free
4. Remove the stem mount cover. Disconnect from mounting after bolts are removed.
the handle harness and arm angle
sensors. 8. Remove the transmission and steer
bearing assembly by lowering through the
5. Remove the three socket head cap screws
pivot-frame mount.
that secure the control handle assembly to
the drive unit assembly. See Figure 6-28. 9. Feed the control wiring harness and power
cables through the transmission pivot
mount.

Socket Head Disassembly

Cap Screws
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 6-33.
3. Remove the nine hex head cap screws
1665 045.tif
securing the gear case cover. Remove the
Figure 6-28. Control Handle Assembly Removal gear case cover.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Drive Unit

4. Remove the retaining ring that secures the

top (pinion) gear.
5. Remove the top (pinion) gear and Woodruff Make sure that the motor end cap is
key attached to the drive motor armature installed before proceeding to the next
shaft. step.
6. Remove the drive motor if required. See
“Drive Motor” on page 6-46. 8. Install the pinion gear woodruff key, and
the retaining ring on the armature shaft.
7. Remove the drive motor bearing, bearing
shim, and seal from the gear case if 9. Use gasket eliminator (Loctite 515 or GE
required. Weicon Silmate) on the mating surface and
install the gear case cover. Torque the
8. Remove the second stage gear set from the
cover bolts to 30 ft. lbs. (42 Nm).
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 second stage gear set.
See Figure 6-30.
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 second 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 6-46.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Drive Unit

1 9
21
4
20
25
5
18
3

17
16
2 13
12 19

10 13 11

27 7

W08175b.eps
Figure 6-30. Transmission Assembly, Exploded View

Legend:
Item Description Item Description
1 Housing, Gearbox 15 Seal, Motor (Not Shown)
2 Cover, Gearbox 16 Seal
3 Screw 17 Drive Axle
4 Pinion, Drive first Stage 18 Bearing, Sealed
5 Gear Set, second Stage 19 Spacer, Bearing
7 Gear Set, Output 20 Ring, Retaining
9 Bearing, Steering Outer Race 21 Key, Woodruff
10 Plug, Fill/Level 22 Screw, Allen Head, Cap
11 Plug, Drain 23 Hub, Wheel (Not Shown)
12 Bearing, Sealed 25 Axle, second Stage
13 Bearing Set, Cup and Cone 26 Key, Output (Not Shown)
14 Bearing, Motor (Not Shown) 27 Ring, Retaining

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Drive Unit

Installation Transmission Housing

Lubrication

Make sure the Main ON/OFF switch is

Gear Oil Level
OFF and the battery connector is 1. Remove the fill/level plug. See
disconnected before you start. Figure 6-31.

1. Install the steer bearing assembly if

removed previously.
2. Reinstall the drive unit assembly through
the pivot frame while feeding the harness Drain Screw
and cables through the pivot frame mount. Fill/Level Plug

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” 1665 039.tif

on page 6-33. Figure 6-31. Transmission Assembly Fill/Drain Plugs

7. Unblock and lower the truck.
2. Check the oil level. When the truck is level,
8. Install the control handle. the oil must be up to the bottom of the
9. Reconnect the wiring harness. plug opening.
10. Make sure drive unit is filled to the correct 3. If necessary, add the specified oil through
level with gear oil. Install the fill/level the plug opening, but do not overfill.
plug. 4. Install the fill/level plug securely.
11. Install the stem mount cover and tractor
cover. Changing Gear Oil
12. Install the battery, reconnect the battery
connector, and the turn the Main ON/OFF 1. Remove the drain plug from the bottom of
switch ON. Press the green ON (I) key on the gear housing and permit the oil to
the keypad. drain. See Figure 6-31.

13. Check the controls for correct operation. 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.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Drive Unit

Drive Wheel 2. If any stud appears damaged, replace

using installation procedures listed below.
Removal NOTE: Installation procedure of studs, wheel
and lug nuts must be done in less than
1. Press the red OFF (O) key on the keypad 1/2 hour to ensure the thread locking
and disconnect the battery connector. compound don’t start setting up before
installation is complete.

Stud Installation
Use extreme care whenever the truck is
jacked up. Keep hands and feet clear 1. Remove and clean or replace stud.
from vehicle while jacking the truck. 2. Install two lug nuts jammed together to
After the truck is jacked, put solid blocks the end of the stud. This will allow
beneath it to support it. Do not rely on tightening of the stud using a torque
the jack alone to support the truck. For wrench.
details, See “Jacking Safety” on 3. Apply thread accelerator/primer to stud.
page 2-9.
4. Apply thread-locking compound to stud.
2. Jack and block the truck under the tractor 5. Install studs and torque to 23 to 28 ft. lbs.
frame. [41Nm].
3. Remove the drive wheel mounting nuts. NOTE: Do not over-torque studs. If torqued to
See Figure 6-32. more than 30 ft. lbs. (41 Nm), studs will
cut new threads and damage the lip
seal. If the lip seal is damaged, the axle
will have to be replaced.
Drive
Wheel 6. Remove lug nuts from studs making sure
Nuts (5) studs do not rotate in the hub.

Wheel Installation
1. Install drive wheel over mounting studs
and apply lug nuts.
2. Alternately torque lug nuts across Hub.
Initially use low torque (5 ft. lbs. [7 Nm]).
Final torque each lug nut to 55 ft. lbs. (75
1581 007.tif Nm).
Figure 6-32. Drive Wheel Nuts

4. Remove the drive wheel.

Drive Wheel Studs

Visually inspect lug nuts for tightness, damage

or one stud protruding farther than others. If
any of these conditions exist, perform stud
installation procedure.
1. Loosen lug nuts to finger tight. If one or
more studs turn while loosening, perform
stud installation procedure.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Drive Unit

Tire Replacement 3. If the outside edge of the hub is not flush

with the edge of the metal insert in the old
Any misalignment of the tire and hub while the tire, measure how far the hub is recessed
tire is being pressed on the hub can cause inside the tire. The new tire must be
damage to the hub. For this reason, chamfers placed in the same position the old tire
are provided on the outside edge of the hub and was installed on the hub. You can use a
on the end of the inside diameter of the tire’s spacer (slightly smaller in diameter than
metal insert. The chamfers help to center the the inside diameter of the tire insert and
hub and tire during pressing and to reduce the the same thickness as the depth of the
possibility of misalignment. 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
To prevent damage, the hub must be
the wheel is positioned upward. The
installed on the circular ram with the
outside edge of the hub has a chamfer to
chamfered side up.
help guide the new tire on the wheel.
Chamfered edge must always be the
1. Check the inside surface of the metal
leading edge when a tire is pressed on the
insert on the new tire. Remove any scaling
hub.
or rust with sandpaper. Clean the inside of
the metal insert. 5. Center the hub assembly on top of the ram
and make sure they mate squarely.
2. Place a circular ram on the press table.
The length of the ram must be longer than 6. Position the new tire with its chamfered
the width of the old tire to permit complete insert facing the hub. Align the new tire
removal of the old tire. The outside and the hub so they are concentric.
diameter of the ram must be small enough 7. Begin pressing the new tire on the hub
to fit loosely in the insert of the tire but and the old tire off the wheel. Run the
must be large enough to rest squarely on press slowly for the first few inches of
the flat surface on the outer edge of the travel because this is the critical step of
hub. See Figure 6-33. 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).

tire.pcx

Figure 6-33. Tire Replacement

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Electromagnetic Brake

Electromagnetic Brake Air Gap Adjustment

Section 6. Component Procedures

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).
Allow the brake to cool completely 1. Press the red OFF (O) key on the keypad.
before servicing. Disconnect the battery connector.

Brake Disc Location

The electromagnetic brake assembly is Use extreme care whenever the truck is
mounted directly to the drive motor. See jacked up. Keep hands and feet clear
Figure 6-34. from vehicle while jacking the truck.
After the truck is jacked, do not rely on
Please see SIB BR12-001 for a brake boot the jack alone to support the truck. See
kit that will help with frozen brakes on units “Jacking Safety” on page 2-9.
left in the freezer. The SIB is at the end of
Electromagnetic
Brakemanual (book marked).
the repair 2. Jack the truck and block the frame.
3. Remove the drive unit cover.
4. Loosen the three 4 mm socket head brake
assembly mounting bolts. See Figure 6-35.

Air gap Mounting

Adjusting Bolt
Screw 0.008 - 0.010 in.
(0.2 - 0.25 mm)

1581 009.tif

Figure 6-34. Brake Location

Friction Disc Pressure Plate Coil Housing

1665 053.tif

Figure 6-35. Brake Gap Adjustment

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. lbs.
(5.6 Nm). Recheck the gap with the feeler
gauge.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Electromagnetic Brake

Friction Disc Replacement 4. Adjust the air gap and torque mounting
bolts. See “Air Gap Adjustment” on
Replace the friction disc when its total page 6-37.
thickness is reduced to 0.20 in. (5.5 mm). 5. Install the drive unit cover.
1. Loosen and remove the three 4 mm
mounting bolts and remove the brake coil Cold Storage Stainless Steel
assembly. See Figure 6-36. Brake Plate Replacement
2. Replace the friction disc on the hub.
Inspect friction plate for wear. Replace the Removal:
friction plate if the surface is worn
unevenly. 1. Park the truck on a level surface. Apply
the parking brake and block the load
3. Install the brake coil assembly on the
wheels to prevent accidental movement.
motor end. Adjust the air gap and torque
mounting bolts. See “Air Gap Adjustment” 2. Press the red OFF button (O) on the
on page 6-37. keypad, or if the truck has a key switch,
turn it to the OFF position. Depress the
main ON/OFF switch to the “OFF”
Mounting Bolt (x3) position.
3. Remove the upper and lower covers.
Hub Snap Ring 4. Loosen and remove the brake mounting
bolts and brake coil assembly.
5. Remove the friction disc from the hub.
Installation

Installation:
1. Install the stainless steel brake plate over
the top of the existing brake plate. Before
Friction Disc Brake Coil Assy installation of friction disc, inspect for
wear, replace if the surface is worn
Stainless Steel Plate unevenly. See Figure 6-36.
(Cold Storage Option)
2. Install brake coil assembly on the motor
end. Adjust air gap, See “Air Gap
Figure 6-36: Friction Disc Replacement Adjustment” on page 6-37.
3. Install truck cover(s).
Mechanically Releasing the 4. Connect the battery connector to truck.
Brake 5. Remove blocks, turn the main ON/OFF
switch to the “On” position. Enter key code
If the brake cannot be electrically released, and press the green ON button (l) on the
perform the following: keypad or turn key switch ON. Test truck
1. Remove the drive unit cover. for proper operation before returning to
2. Loosen socket head mounting bolts evenly service.
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.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Electromagnetic Brake

Air Gap Adjustment

1. Turn the adjusting screws while checking
the air gap at several points with a 0.008
to 0.014 in. (0.2 to 0.36 mm) feeler gauge.
See Figure 6-37.
2. Tighten the mounting bolts to 50 in. lbs.
(5.6 Nm). Double check the air gap with
feeler gauge.

Adjusting Air Gap

Screw 0.008 - 0.014 in.
(0.2 - 0.36 mm)
Optional
Stainless Mounting Bolt
Steel Brake
Plate

Friction Disc Pressure Plate Coil Housing

1581 004.tif

Figure 6-37. Air Gap Adjustment

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Electromagnetic Brake

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Motors, General

Motors, General you must take this into account when

Section 6. Component Procedures

considering brush replacement.

2. Check brush spring tension. See “Drive
Drive Motor Brush Inspection Motor Brush Spring Tension” on
page 6-40.
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
MTRBRUSH.tif
passage around the motor to permit heat
Figure 6-38. Drive Motor Brush/Spring Location
radiation.
Conduct a partial inspection of the drive motor
after every 1,000 hours of truck operation. If Replacement
you work in an abnormally severe or caustic
environment or if you have a rigorous duty If one brush needs replacement, always replace
cycle, inspect the motor more frequently. the entire set of brushes.

Set up and rigidly adhere to a strict inspection Use only genuine Toyota brushes. Using
schedule to obtain the maximum efficiency another type of brush could damage the
from the electrical equipment. commutator or cause excessive brush wear.

Each partial inspection of the motor must If the end of the brush is not already contoured
include the following: to fit the commutator, use the following
procedure to seat the brush to the commutator:
1. Inspect the brushes for wear and for
correct contact with the commutator. See NOTE: If the motor commutator is not
Figure 6-38. Record the level of wear on accessible, form the brush contour
the brushes. This history will give you an using a brush seating stone.
indication of whether a brush must be
1. Move the motor brush springs out of your
changed or if it can wait until the next
way.
inspection. Refer to page 6-40 for
acceptable brush length and general motor 2. Wrap a piece of 00 sandpaper around the
information. commutator. Do not use emery cloth to
seat brushes.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore, 3. Move the brushes back down in their
holders so that the face of the brushes
matches the curve of the commutator.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Motors, General

4. Remove the sandpaper. 7. While gently pulling the scale outward,

5. Blow any dust out of the motor with clean, slowly pull the paper strip in the direction
compressed air at a maximum of 30 psi that the commutator normally rotates.
(207 kPa). 8. When the paper strip starts to move freely,
the spring scale will read the spring brush
tension.
Drive Motor Brush Spring
Tension 9. Refer to the table below for correct spring
tension.

Inspection Minimum Spring

Motor
Brush Length Tension
1. Press the red OFF (O) key on the keypad.
Disconnect the battery connector. Drive 0.59 in. 20 oz. min.
Motor (15 mm) (568 grams)
2. Remove the drive motor cover.
3. Slide the brush up slightly in its holder.
10. Repeat steps 3 thru 9 for the remaining
4. Insert a paper strip between the brush brushes.
face and the commutator. See Figure 6-39.
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 6-40.

Leather Loop
Mica Segments
Coil Spring

Normal
Paper Undercut
High Mica

TENSION.tif

Figure 6-39. Motor Brush Spring Tension Inspection

High Mica
5. Place a small leather loop around the coil 1881 003.tif
spring for the brush. If the brush spring Figure 6-40. Mica Inspection
has a loop at the brush, hook the spring
scale directly to the spring. The commutator must be smooth and clean to
6. Attach a 5 lb. (2.27 kg) spring scale to the provide maximum brush wear. When
leather loop. commutators are not correctly maintained,
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Motors, General

Good commutation is indicated by a dark If the commutator appears rough, pitted, or has
brown polished commutator and an evenly signs of burning or heavy arcing between the
polished brush wearing surface. See Table 6-1, commutator bars, remove the motor for
“Commutator Surfaces.” servicing.
Table 6-1: Commutator Surfaces

Condition Probable Cause Commutator Surface

Good Condition-Light Uniform coloring indicates satisfactory

Film operation of machine and brushes. Film
color is largely an effect of thickness;
therefore, provided the film is uniform, it is
perfectly acceptable.

Satisfactory This is not a good condition, but in our

Condition-Light and experience it is known that machines
Dark Pattern 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 Frequently due to under-loaded operation,

Condition-Streaky Film machine grossly over-brushed or brush
With No Commutator grade incorrect for particular machine
Wear application. Atmosphere and
environmental conditions can contribute.

Unsatisfactory Patchy colors of varying densities and

Condition-Uneven Film shape. Due to unclean operating
conditions or incorrect physical condition
of commutator.

Unsatisfactory These areas can be isolated or regular.

Condition- Film With Commutator out of round. This can be
Dark Areas caused by vibration or mechanical
deficiencies in equipment operation,
bearings, couplings, and so forth.

Unsatisfactory Bars are low on entry and leaving edges

Condition-Example of giving rise to the brushes riding on the
Poor Commutator middle of the bars.
Machining

Unsatisfactory Bars are low in the middle giving rise to the

Condition-Example of brushes riding on entry and leaving bar
Poor Commutator edges. This and the previous illustration
Machining indicate the need for better maintenance.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Motors, General
Table 6-1: Commutator Surfaces

Condition Probable Cause Commutator Surface

Unsatisfactory This is a further development of the third

Condition-Streaky Film example. Brush grade, machine
With Commutator Wear applications, and working environment are
all suspect. Earlier corrective action
should have been taken.

Unsatisfactory Darkening of commutator in sequences two

Condition-Double Pole pole pitches apart is due to armature fault,
Pitch bad coil, riser bars, or equalizer
connections.

Unsatisfactory Storage of machines, for lengthy periods,

Condition-Brush with brushes in position. This can also
Contact Mark result from operation of machine in
prolonged stall conditions.

Unsatisfactory Illustration shows high mica in every slot.

Condition-Bar Edge Same effect can occur on one bar only.
Burning-Cause High Similar conditions can be caused by a high
Mica or low bar.

Unsatisfactory Related to over-loaded machines and low

Condition-Small Bright brush pressure. Due to sparking under
Spots brush that gives rise to spots being of a
random distribution. If not corrected, will
result in scored commutator.

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.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Motors, General

Terminal Nuts Electric Motor Tests

Motor Types
Whenever you disconnect and reconnect any
power leads to a motor, always tighten the • A shunt-wound motor, such as the drive
motor cable securing nuts with a torque wrench motor, has four external connections: two
to prevent over-tightening them and damaging armature (A) and two field (E). See
the motor. Use a second wrench on the stud Figure 6-42.
terminal securing nut to avoid twisting the • A compound motor, such as the lift motor,
stud. See Figure 6-41. has only two external connections because
the armature and field windings are
Terminal connected internally.
Stud

Motor Shunt-Wound Motor

Cable Flat A2 S2/E2/D2
Securing Washer
Nut
Fiber MD
Washer
Stud
Terminal Motor A1 S1/E1/D1
Securing Housing
Nut
Compound Motor
CABLENUT.eps
A
Figure 6-41. Motor Terminal Nuts

Check these torques each time you check motor

MX
brushes.

Stud
Motor Cable
Stud Size Terminal
Securing Nut
Securing Nut
S/D
3/8 in. 100-120 in. lb. 140-160 in. lb. Dschem.eps

(M10) (11.2-13.6 Nm) (15.8-18.1 Nm) Figure 6-42. Motor Circuits

5/16 in. 90-110 in. lb. 110-140 in. lb.

(M8) (10.2-12.4 Nm) (12.4-15.8 Nm) Open Circuit Motor Test
1/4 in. 40-50 in. lb. 50-60 in. lb. An open circuit is one where the electrical
(M6) (4.5-5.6 Nm) (5.6-6.8 Nm) 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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Motors, General

2. With the motor at room temperature, 4. If the meter indicates high resistance in
connect the leads of a digital ohmmeter the armature, check the condition of the
between the individual circuits in the brushes before replacing the motor.
motor. 5. If an open circuit is found in a compound
3. Observe the measurements given in motor, the motor must be disassembled by
Table 6-2. a motor rebuilding facility to isolate the
problem to the field or armature circuit.
Table 6-2: Motor Resistance Readings

Acceptable Resistance Unacceptable

Motor Terminals
Readings Resistance Readings

Traction Armature A1 to A2 0.01 to 0.10 ohms Greater than

(Drive) 0.10 ohms

Field E1 to E2 0.8 to 1.7 ohms Less than 0.5 ohms or

(S1 to S2) 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 6-42 on page 6-43.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Motors, General

Grounded Motor Test • severe burning or discoloring on one or

two commutator segments every 90° of
In a grounded motor, an electrical circuit exists rotation.
between the current-carrying conductors and
the motor housing. This can be caused either by These symptoms can also be caused by
direct contact or through conductive foreign problems other than the motor itself, such as:
material. • brake too tight or dragging
• wheel bearings too tight
The ground may be caused by:
• faulty transmission
• insulation breakdown
• binding in an attached pump
• brush leads touching the motor housing
build-up of carbon dust or other materials
Testing a motor for short-circuited windings
requires special equipment at a motor
To test a motor for grounds:
rebuilding facility.

1. Isolate the motor from the truck circuit by Short-Circuited Armature

removing the power cables. Use two
wrenches to avoid twisting the terminal A short circuit in the armature will cause
studs. heating, and will probably result in burning of:
2. Attach one lead of a digital ohmmeter to a • armature coil
motor terminal and the other lead to an • brush wires
unpainted surface of the motor housing.
• commutator segments
Set the ohmmeter to the highest scale.
3. If the ohmmeter reads resistance of less Visual inspection may reveal these conditions.
than 100,000 ohms, the motor is
grounded. Clean, repair, or replace the Positive determination of a short-circuited
motor as necessary. armature requires special equipment at a motor
rebuilding facility.
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

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Drive Motor

Drive Motor 6. Remove the brake disc from the brake

hub.
7. Remove the retaining ring that secures the
Brush Replacement brake hub. Remove the hub and woodruff
1. Press the red OFF (O) key on the keypad. key.
Disconnect the battery connector. 8. Remove the four screws and lock washers
holding the brush end bell to the housing.
2. Remove the tractor covers.
3. Remove any shields around the motor end 9. Separate the end bell from the motor
cover to expose the brushes. See housing. The armature will come out with
Figure 6-43. 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.
Brush
Shield
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
Figure 6-43: Drive Motor Brush Shield motor bearing, bearing shim, and seal in
the gear case.
4. Lift the spring off the brush, pull the
NOTE: The seal must be replaced any time the
brush out of the holder.
motor is removed from the housing.
5. Follow the brush replacement
instructions. See “Drive Motor Brush The seal must be installed correctly with
Inspection” on page 6-39. its open side and seal ring positioned
towards the bearing.
6. Replace the shields around the motor end
that were removed in step 3. 3. Reinstall the end bell cover, with the brush
plate attached, on the motor armature
Motor Disassembly shaft.
1. Press the red OFF (O) key on the keypad. 4. Carefully slide the drive motor armature in
Disconnect the battery connector. the motor housing.
2. Remove the tractor covers. 5. Attach the end bell cover to the motor
housing with the four screws.
3. Disconnect the power cables from the
terminal block on the drive motor, note 6. Install the pinion gear, Woodruff key, and
their correct position. the retaining ring on the armature shaft.
4. Follow steps 1 thru 5 in ("Disassembly" on 7. Use Permatex gasket eliminator on the
page 6-29) to remove the top (pinion) gear mating surface and install the gear case
attached to the motor armature shaft. cover.
5. Remove the electromagnetic brake 8. Make sure the drive unit is filled to the
assembly by removing the three mounting correct level with gear oil. Install the
bolts that secure the assembly to the fill/level plug. See “Transmission Housing
motor end bell cover. Lubrication” on page 6-32.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Drive Motor

9. Install brake hub and Woodruff key then

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 Main ON/OFF
switch ON. Enter your PIN-key code then
press the green ON (I) key on the keypad.
15. Test the operation of the truck.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Drive Motor

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Pallet Forks and Load Wheels

Pallet Forks and Load 8. Align the wheel with the holes in the load
Section 6. Component Procedures

arm casting.
Wheels 9. Drive the axle through the load arm
casting and wheel. Align the “dimple” in
the axle with the set screw hole.
Load Wheels 10. Install and tighten the set screw.

Load wheels are installed on each pallet fork

and are designed to support the rated load at Load Wheel Pull Rod
the forks fully raised height.
Load wheel pull rods are installed on each fork,
and are designed to transfer the hydraulic
Removal and Replacement
cylinder lifting action at the tractor end to the
1. Lift the forks to maximum height and load wheel fork.
block them. See “Jacking Safety” on
page 2-9. Removal and Replacement
2. Remove the axle set screw. See
NOTE: It may be easier to work with the truck
Figure 6-44.
upside down. Remove the battery before
turning the truck over. Some oil may
leak from the hydraulic reservoir.
Load Wheel
1. Extend the load wheel forks. Remove the
Fork
set screw and shaft connecting the wheel
fork to the pallet fork. See Figure 6-45.

Axle Set
Screw

27y7s173.tif

Figure 6-44. Removing Set Screw

Wheel Fork
Set Screw
3. Drive the axle out of the load arm casting
with a hammer and brass drift pin.
4. Push the wheel out. Figure 6-45. Wheel Fork Set Screw Location (top view)
5. If the bearings are to be reused, insert a
brass drift pin into each end of the load 2. Remove the pivot pin locking bolt and
wheel and knock the bearings out. drive the pivot pin out with a brass drift
pin.
6. Install the bearings in the new load wheel
with the shields facing out. 3. With the lower links out of the lift frame
channels, the links can be separated and
7. Place the new load wheel upright on a flat
the pull rod removed from the link pin.
surface. Position the bearing over the load
Each link has one set screw at opposite
wheel. Put a flat metal plate over the
ends. The link can be pulled apart without
bearing, and hammer the bearing in
removing any other set screws.
position with a plastic mallet. Make sure
the bearing is fully seated in the load 4. Press new bushings in the pull rods, if
wheel. necessary.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Pallet Forks and Load Wheels

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 pin and the locking 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

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 upper and lower linkages then lift
the lift frame off the carrier frame. See
Figure 6-46.

Figure 6-46: Lower Links

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Hydraulic Components

Hydraulic Components 3. Press the green ON (I) key on the keypad.

Section 6. Component Procedures

Leave the control handle in the neutral

(vertical) position.
General Guidelines 4. Press the lift button, raise the forks to
maximum height and block them. See
To prolong the life of your Pallet Truck, follow Figure 6-48.
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 Hydraulic Hydraulic
thread, use a sealing compound on the Hose Cylinder
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 1665 033.tif

are tightened. Always use two wrenches on Figure 6-48. Hydraulic Cylinder (shown extended with
a swivel-type fitting, one to hold the fitting retaining clip removed)
and the other to tighten the hose.
5. Lower the forks on the blocking to release
pressure on the hydraulic cylinder. See
Hydraulic Cylinder “Jacking Safety” on page 2-9. Manually
press down on the cylinder after the forks
come to rest on the blocking to disengage
Fluid leakage indicates that the seal is worn.
the cylinder from the tractor frame.
Replace the seal, wiper, and retaining ring when
fluid leakage becomes excessive. 6. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
Cylinder Removal
1. Remove the tractor cover.
2. Remove retaining clip. See Figure 6-47.
Hot oil under pressure is present. Make
sure truck is safely blocked and
Retaining
pressure is released.
Clip
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
1665 041.tif
hydraulic cylinder in a suitable
Figure 6-47. Remove Retaining Clip container.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Hydraulic Components

8. Lift the cylinder up and out of the tractor 2. Install new seal in the barrel. Install new
frame. Some spillage of hydraulic oil may wiper in the barrel with lips facing inward.
occur. 3. Install new retaining ring in deep groove of
the piston rod end.
Cylinder Disassembly 4. Oil the outside of piston rod and carefully
insert rod into barrel.
1. Thoroughly clean the outside of the
5. Push rod into barrel until the retaining
cylinder.
ring is seen thru the inlet port.
2. Pull the rod out until the end of the rod
6. Insert a screwdriver into the inlet port and
and the retaining ring are visible thru the
slide the retaining ring into the lock
inlet port. See Figure 6-49.
position.
3. Insert a screwdriver into the inlet port and
7. Extend rod to full out position to make
slide the retaining ring into the deep
sure the retaining ring is locked in place.
groove in the piston rod assembly.
4. Remove the rod assembly from the barrel.
Cylinder Installation
5. Remove the retaining ring from the piston
rod. 1. Place the new cylinder into position in the
tractor frame. Install retaining clip. See
6. Remove the wiper and seal from inside the
Figure 6-47.
barrel assembly.
NOTE: To prevent air from filling the cylinder,
install the cylinder with the rod
Inlet Port retracted.
2. Connect the hydraulic hose.
3. Reconnect the battery connector and press
the green ON (I) key on the keypad.
4. Press the lift button to extend the cylinder.
Barrel
5. Check the hydraulic reservoir fluid level. If
Wiper necessary, add fluid. See “Lubrication
Equivalency Chart” on page A-2.
Seal
6. Remove the blocking. Lift and lower the
Retaining Ring Rod
forks several times. Look for leakage
around the fittings and cylinder seal.
Figure 6-49. Hydraulic Cylinder Disassembly
7. Recheck the hydraulic reservoir fluid level.
Cylinder Inspection If necessary, add fluid.
8. Install the tractor cover.
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.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Hydraulic Components

Hydraulic Solenoid 5. Reconnect the battery connector and press

the green ON (I) key on the keypad. Test
Hydraulic solenoid activates the hydraulic the functions of the truck.
solenoid release valve that releases pressure on 6. Press the red OFF (O) key on the keypad.
the lift cylinder, lowering the forks. See Disconnect the battery connector.
Figure 6-50. 7. Install the tractor cover.

Hydraulic Unit
Draining and cleaning the hydraulic reservoir is
Hydraulic Solenoid
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.

1665 033.tif Removal

Figure 6-50. Hydraulic Solenoid
Remove the hydraulic unit from the truck in
Removal order to separate the pump from the motor.
1. Lower the forks completely.
1. Make sure that the forks are fully lowered.
2. Press the red OFF (O) key on the keypad.
2. Press the red OFF (O) key on the keypad.
Disconnect the battery connector. Remove
Disconnect the battery connector.
the tractor cover.
3. Remove the two wires from the terminals
3. Remove and tag all wires and cables
on the solenoid.
connected to the pump motor. See
4. Remove the nut holding the solenoid coil Figure 6-51.
to the solenoid valve.
4. Remove and cap the hydraulic line from
5. Lift the solenoid coil off the solenoid valve the hydraulic unit. Disconnect the
stem. solenoid control wires.
6. Remove the solenoid valve stem from the 5. Remove the bolts that attach the hydraulic
manifold. unit mounting bracket to the tractor
frame.
Installation 6. Remove the hydraulic unit from the truck.
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 nut, torque
the nut to 48 to 60 in. lbs. (5 to 7 Nm).
4. Connect the wires to the terminals.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Hydraulic Components

9. Check the hydraulic fluid level in the

reservoir.

Pump Motor
Hydraulic Reservoir

Lift Motor Removal

Solenoid
1. Remove the hydraulic unit from the truck.
See “Removal” on page 6-53.
Adapter Body 2. Remove the hose clamp that secures the
(Pump) hydraulic reservoir to the adapter housing.
3. Tap the reservoir lightly to loosen. Wiggle
the reservoir sideways while pulling up on
Hydraulic the pump and motor at the same time to
Solenoid remove.
4. Remove the reservoir and correctly dispose
Fill/Vent of the old hydraulic fluid.
Plug
5. After the fluid has drained, flush the
inside of the reservoir with a suitable
Hydraulic cleaning solvent.
Reservoir
6. Dry the inside of the reservoir with clean,
dry compressed air.
1665 040.tif

Figure 6-51. Hydraulic Unit Installation

Installation 1. Inspect the reservoir O-ring and the inside
leading edge for damage. Replace if
1. Install the hydraulic unit on the tractor necessary.
frame and attach with the previously
2. Lubricate the O-ring (with applicable
removed bolts.
hydraulic fluid) and install the O-ring.
2. Install the hydraulic line on the hydraulic
3. Carefully install the reservoir on the
unit.
adapter housing and attach with hose
3. Fill the reservoir with the specified clamp. Torque clamp to 48 to 60 in. lbs.
hydraulic fluid. See “Lubrication (5.5 to 7 Nm).
Equivalency Chart” on page A-2. Use a
4. Install hydraulic unit in the truck. See
funnel with a flexible neck. Fill the
“Installation” on page 6-54.
reservoir to within 1 in. (25.4 mm) below
the filler plug elbow. Use up to 0.8 qt.
(0.75 liters). Filter Screen and Inlet Tube
4. Install the vent plug. See Figure 6-51. 1. Remove the reservoir. See “Hydraulic
5. Connect all wires and cables to the pump Reservoir” on page 6-54.
motor switch and hydraulic solenoid. 2. With the pump assembly inverted,
6. Connect the battery connector and press unthread and remove the inlet tube fitting
the green ON (I) key on the keypad. and sealing washer from the pump
7. Raise and lower the forks. Check all hoses housing.
and fittings for leaks. 3. Clean the filter screen at the bottom of the
8. Lower the forks. inlet tube with a suitable solvent. See
Figure 6-52.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Hydraulic Components

4. From the pump side, blow dry with clean, Installation

dry compressed air.
1. Stand the motor assembly on end, with
the adapter body facing up.
2. Lubricate the O-ring and install on the
Filter Screen
adapter body facing up.
3. Insert the pump drive coupling on the end
of the motor armature shaft. Fill the cavity
with lubricant (Molybdenum anti-seize
compound).
4. Align the splines on the motor drive and
Inlet Tube pump shaft. Gently push the pump pilot
on the adapter.
5. Secure the pump with the two pump
27y7s158.tif mounting bolts. Torque to 40 to 45 in. lbs.
Figure 6-52. Cleaning Filter Screen (4.5 to 5 Nm).
6. Check the inlet screen for clogging. Clean
Installation with a suitable solvent. Install the inlet
1. Inspect the filter screen and inlet tube for tube fitting into the pump. Torque fitting
damage. Replace if necessary. to 245 to 275 in. lbs. (27 to 31 Nm).

2. Install the inlet tube sealing washer and 7. Install the reservoir. See “Hydraulic
fitting in the pump housing. Torque to 245 Reservoir” on page 6-54.
to 275 in. lbs. (27 to 31 Nm).
3. Install the hydraulic reservoir. See Lift Motor
“Hydraulic Reservoir” on page 6-54.
Removal
Hydraulic Pump 1. Remove the hydraulic unit from the truck.
See “Hydraulic Unit” on page 6-53.
Removal 2. Remove the two bolts from the end plate
1. Remove the hydraulic unit from the truck that attach the motor to the adapter body.
and put on a clean bench for disassembly. 3. Separate the motor and the adapter body.
See “Hydraulic Unit” on page 5-33. 4. Remove the start solenoid from the side of
2. Remove the reservoir to gain access to the the motor housing for later reuse.
pump. See “Hydraulic Reservoir” on
page 6-54.
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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Hydraulic Components

Installation 4. Remove brush assembly then remove each

brush and replace with a new one.
1. Stand the pump assembly on end, with
the adapter body facing up.
Hydraulic Fluid
2. Set aside the pump drive coupling for later
reuse.
Proper Level
NOTE: The coupling is the mechanical
connection between the pump shaft and To prevent air from entering the lines, fill fluid
the electric motor armature shaft. It level (with forks fully lowered) to within 1 in.
may have been removed with the motor. (25.4 mm) below the fill port elbow. See
3. Insert the pump drive coupling on the end “Installation” on page 6-54. The usable
of the pump shaft and fill coupling cavity reservoir capacity is 0.8 qt. (0.75 Liter). Add the
with lubricant (Molybdenum anti-seize specified fluid if necessary. See “Lubrication
compound). Equivalency Chart” on page A-2.
4. Rotate the pump or the motor shaft to
align the motor shaft correctly with the Changing Fluid
coupling.
Store and handle the hydraulic fluid with
5. Install the new motor on the adapter body. extreme care to prevent moisture and foreign
Rotate the pump or the motor shaft if matter from entering the hydraulic system.
necessary to allow the motor to contact the
adapter body. Contaminated hydraulic fluid is the major
6. Insert the bolts into the motor end plate, cause of hydraulic system failures. Keep any
thru the motor, and into the adapter body. service equipment, such as containers, funnels,
7. Make sure the motor is mating flush with and hand pumps, clean at all times. Cover them
the adapter body. Torque screws to 36 to when not in use.
45 in. lbs. (4 to 5 Nm) maximum. 1. Lower the forks.
8. Install the start solenoid. 2. Press the red OFF (O) key on the keypad.
9. Install the hydraulic unit. See “Hydraulic Disconnect the battery connector.
Unit” on page 6-53. 3. Remove the upper tractor cover.
4. Disconnect the lift cylinder hose at the
Brush Replacement hydraulic cylinder. See Figure 6-53.
5. Insert the hose in a waste fluid container.
Brush Replace brushes when they have
Replacement worn to the minimum length of
0.35 in. (9 mm).
Lift Cylinder
Spring Adjust the spring tension of new
Hose
Tension brushes to 32 to 40 oz. (908.8 to
1136 gm).

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. 1665 040.tif

Figure 6-53. Hydraulic Connections

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Hydraulic Components

Relief Valve Settings

Pressure Settings
Fluid is under pressure and may spray Truck Capacity
or splash. Point hose away from your PSI kPa
body and hold firmly in waste fluid
4,500 lb. (2,041 kg) 3,000 20,684
container.

6. Connect the battery connector and press Table 6-3: Truck Pressure Levels
the green ON (I) key on the keypad.
Check Setting
7. Run the hydraulic pump by pressing the
lift button until all the hydraulic fluid is 1. Attach a jumper wire across the terminals
pumped from the system. of the lift-limit switch so the switch will
8. Press the red OFF (O) key on the keypad. not shut the pump down when the forks
Disconnect the battery connector. reach their upper limit.
9. Reconnect the lift cylinder hose. 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
Mixing different types of cold storage 0 to 3,500 psi (0 to 24,131 kPa) pressure
fluids can cause “gelling” of the fluid gauge. See Figure 6-54.
and lead to premature pump failure.

10. Remove the vent plug and fill the reservoir

to within 1 in. (25.4 mm) below the filler
port elbow with the recommended
hydraulic fluid. See “Lubrication
Equivalency Chart” on page A-2.
11. Replace the vent plug.
12. Connect the battery connector and press
the green ON (I) key on the keypad.
13. Raise and lower the forks several times to
purge air from the system.
14. Install the upper tractor cover.
15. Dispose of the waste fluid correctly.

Adjusting Hydraulic Pump

Pressure Relief Valve
Hydmtrpm.tif

Figure 6-54. Checking Relief Valve Pressure

The hydraulic system is protected by a relief 3. Press the green ON (I) key on the keypad.
valve installed in the adapter body. The relief Leave the control handle in the neutral
valve is set by the manufacturer to open at a (vertical) position.
specified pressure. See Table 6-3 on page 6-57.
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.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Hydraulic Components

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
pressure setting or outward to decrease
the pressure setting.
3. Check the indicator on the pressure
gauge. After the relief valve is correctly set,
release the lift button.
4. Reinstall the hex cap. Torque to 144 to
180 in. lbs. (16 to 20 Nm).
5. Recheck the relief valve setting.
6. Lower the forks completely. Press the red
OFF (O) key on the keypad.
7. Remove the pressure gauge. Replace the
elbow.
8. Press the green ON (I) key on the keypad.
Raise the forks. Inspect all hoses and
fittings for leaks.
9. Adjust the lift-limit switch to shut down
the pump when the forks reach their
upper limit. See “Lift-Limit Switch” on
page 6-27.

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Toyota Model 7HBW23 Service Manual Section 6. Component Procedures

Cold Storage Conditioning

Cold Storage
Conditioning

Mixing different types of cold storage

fluids can cause “gelling” of the fluid
and lead to premature pump failure.

Pallet Trucks supplied with a standard

conditioning package are designed to operate in
an environment where temperatures range from
32° to 104°F (0° to 40°C) in a continuous duty
cycle.

Trucks supplied with a cold storage

conditioning package (New cold storage trucks
have a decal on the hydraulic unit for correct
fluid.) are designed to operate in temperatures
to 5°F (–15°C) in a continuous duty cycle or to
–13°F (–25°C) for in and out operation.

When a truck is installed in a cold storage

environment, change the fluid in the hydraulic
reservoir according to the recommended fluids
listed in the Appendix. See “Lubrication
Equivalency Chart” on page A-2.

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Section 6. Component Procedures Toyota Model 7HBW23 Service Manual

Cold Storage Conditioning

6-60 00700-CL340-08, Issued: 06/20/2008

Appendix
Toyota Model 7HBW23 Service Manual Appendix

Appendix

00700-CL340-08, Issued: 06/20/2008 A-1

 Appendix Toyota Model 7HBW23 Service Manual

Lubrication Equivalency Chart

Lubrication Equivalency
Chart
s

Approved Toyota Lubricants

Where Used Type Specification Toyota Part Number

Drive Unit Gear Case Synthetic 80W - 90 Gear Oil 00590-04835-71

–25° to +110°F Gear API Service GL-5 (1 quart/0.9 liter)
(–31.5° to +43.3°C) Lubricant 00590-04837-71
(5 gal./18.9 liters)

Hydraulic Reservoir Hydraulic ISO 46 00590-04934-71

(non-cold storage trucks) Fluid (1 quart/0.9 liter)
+35° to +120°F 00590-04840-71
(+1.6° to +48.8°C) (5 gal./18.9 liters)

Hydraulic Reservoir Hydraulic MIL-DTL-17111C 00590-47588-71

(cold storage trucks) Fluid (1 gal./3.785 liters)
(–20°F to +70°F)
(–29°C to +21°C)

Hydraulic Reservoir Hydraulic 10W-30 Motor Oil 00590-04837-71

(for high Fluid (5 gal./18.9 liters)
performance/high API Service CE,CD,CC,SG,SF 00590-04835-71
temperature applications) (1 quart/0.9 liter)

Bearings and Bushings Grease Mystic JT-6 00590-04844-71

(10 cartridges per case)
NLGI Grade 2 00590-04845-71
(5 gal./18.9 liters)

A-2 00700-CL340-08, Issued: 06/20/2008

Toyota Model 7HBW23 Service Manual Appendix

Torque Chart - Standard

Torque Chart - Standard

Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
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-1. Torque Chart - Standard
*NOTE: Use “oiled” values for bolts with thread-locking compound.

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Appendix Toyota Model 7HBW23 Service Manual

Torque Chart - Metric

Torque Chart - Metric

Ferrous Metric Bolts
(The grade rating is stamped on the head of the bolt.)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled*) Torque (with bolts oiled*)
(in millimeters)
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

Metric Bolts, Coarse Thread

Diameter Torque (with bolts oiled*)
(in millimeters) 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

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Toyota Model 7HBW23 Service Manual Appendix

Decimal Equivalent Chart

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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-2. Decimal Equivalent Chart

00700-CL340-08, Issued: 06/20/2008 A-5

Appendix Toyota Model 7HBW23 Service Manual

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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
Table A-2. Decimal Equivalent Chart

A-6 00700-CL340-08, Issued: 06/20/2008

Toyota Model 7HBW23 Service Manual Appendix

Standard/Metric Conversions

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
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85

00700-CL340-08, Issued: 06/20/2008 A-7

Appendix Toyota Model 7HBW23 Service Manual

Standard/Metric Conversions

To Convert... Multiply...
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

A-8 00700-CL340-08, Issued: 06/20/2008

Schematics
Toyota Model 7HBW23 Service Manual Schematics

Schematics

00700-CL340-08, Issued: 06/20/2008 A-9

A-10
Schematics

10A
F50
1 20
10A MAIN ON/OFF
F51 S21
TRUCKS
2 21 21 24
WITH KEYPAD
A1: CURTIS 1243C
110A 24
K10 CB1 IN: +24VDC J5-16
3 K10
2 3
B+ ARM ANGLE A
3 64
OUT: MAIN CONTACTOR J5-4
5 64 24 S24
PTC F1 24 24
DRIVE S17
R1 1 4
MOTOR K4 50 24 20 22

Figure A-1. Electrical Schematic - Sheet 1 of 2

1 2
M1 MCR 0 2
3
64
K30 6 26
F2 K30 ARM ANGLE B
7 4 OUT: PUMP CONTACTOR J5-6 45
4 S25
45 26
M- S20 51 20 TRUCKS WITH
Y1 1 26
1 40 26A 7 KEYSWITCH
57
B- IN/OUT: BRAKE J5-5 2 K5 E.R.B.
B+ 57 26A 58
3 NC
S.S. RELAY
40 8 51
4 57 2 CTRL+
P6KE33A 40
LIFT MOTOR ERB SW 1 CTRL-
24V 58
4 LOAD-
20
Y10 3 LOAD+
38 J11: E.T.A.C. A2
IN/OUT: LOWER VALVE J5-2
B- 38 26
40 M3
26 LIFT LIMIT
J5-7 54 54 + S36
OUT: HORN s H1
-
40 52 24 J11-1 22 RED
IN: ARM ANGLE A J5-12 50 A2-2 IN: +24V
J11-2 119 GRN
IN: ARM ANGLE B J5-14 51 A2-3 CAN HIGH
J11-4 120WHT
IN: LIFT LIMIT J5-15 52 A2-7 CAN LOW
J11-3 40 BLK
A2-6 0VDC
CAN HIGH J5-1 119
CAN LOW J5-8 120
40 1 2 3 4 J41: SERVICE KEY CONNECTOR

40
1881 002.eps

00700-CL340-08, Issued: 06/20/2008

Toyota Model 7HBW23 Service Manual
 DESIGNATION DESCRIPTION DESIGNATION DESCRIPTION
A1 POWER AMPLIFIER M1 DRIVE MOTOR
A2 ELECTRONIC TILLER ARM CARD, M3 LIFT PUMP MOTOR
E.T.A.C. IN HANDLE HEAD
DISPLAY A2 KEYPAD R1 PRE-CHARGE PTC RESISTOR
A17 A6 OPERATOR DISPLAY INTERFACE
A6
A17 KEYPAD (TRUCKS WITH KEYPAD) S17 KEYSWITCH

Figure A-2. Electrical Schematic - Sheet 2 of 2

1 2 3 (TRUCKS WITH KEYSWITCH)
Toyota Model 7HBW23 Service Manual

00700-CL340-08, Issued: 06/20/2008

- + 4 5 6 B+ BATTERY CONNECTOR
% S18 HORN SWITCHES
7 8 9 B- BATTERY CONNECTOR
O 0 |
S20 BRAKE RELEASE SWITCH WITH
P6KE33A TRANSIENT VOLTAGE SUPPRESSOR.
CB1 POWER CIRCUIT BREAKER
S21 MAIN ON/OFF SWITCH
HORN SWITCH F50 CONTROL CIRCUIT FUSE, E.T.A.C.
TRUCKS WITH S24 ARM ANGLE A SWITCH, CHERRY # DC2C-L1RB
S18-1 F51 CONTROL CIRCUIT FUSE,
EMERGENCY KEYPAD S25 ARM ANGLE B SWITCH, CHERRY # DC2C-L1RB
REVERSER INPUTS/OUTPUTS
S36 LIFT LIMIT SWITCH

HORN SWITCH H1 HORN

Y1 BRAKE
S18-2 Y10 LOWER VALVE
J11 HANDLE STEM BASE CONNECTOR
J41 SERVICE KEY CONNECTOR

K4 MAIN RELAY
K5 E.R.B. SOLID STATE RELAY
HANDLE HEAD (ALL TRUCKS)
K10 MAIN CONTACTOR
K30 LIFT PUMP CONTACTOR
1881 002.eps

A-11
Schematics
Schematics Toyota Model 7HBW23 Service Manual

1881 002.eps

Lift
Cylinder

Solenoid
Valve

Check Flow Control

Valve

Pressure
Relief
Valve
Motor
Pump

Filter

Reservoir

Figure A-3. Hydraulic Schematic

A-12 00700-CL340-08, Issued: 06/20/2008

Index
Toyota Model 7HBW23 Service Manual Index

Index
A Display and Programming
Error Codes . . . . . . . . . . . . . . . . . . 5-9
Acceleration . . . . . . . . . . . . . . . . . . . . 5-6 Hourmeter . . . . . . . . . . . . . . . . . . . 5-9
Anti-Static Kit . . . . . . . . . . . . . . . . . . 2-12 Part Numbers . . . . . . . . . . . . . . . . 5-22
Arm Angle Switches . . . . . . . . . . . . . . 6-26 Drive Housing Lubrication . . . . . . . . . 6-32
Drive Motor
Brush Inspection/Replacement . . . 6-39
B Brush Spring Tension . . . . . . . . . . 6-40
Commutator . . . . . . . . . . . . . . . . . 6-40
Battery Drive Unit
Adding Water . . . . . . . . . . . . . . . . . 6-9 Brake, Electromagnetic . . . . . . . . . 6-35
Charging . . . . . . . . . . . . . . . . . . . . 6-8 Drive Motor
Maintenance . . . . . . . . . . . . . . . . . 6-7 Brush Replacement . . . . . . . . . 6-46
Safety . . . . . . . . . . . . . . . . . . . . . . 2-6 Drive Wheel . . . . . . . . . . . . . . . . . 6-33
Specific Gravity . . . . . . . . . . . . . . . 6-9 Lubrication . . . . . . . . . . . . . . . . . . 6-32
Storage . . . . . . . . . . . . . . . . . . . . 6-10 Transmission Assembly . . . . . . . . 6-29
Voltage Check . . . . . . . . . . . . . . . . 6-9 Drive Wheel . . . . . . . . . . . . . . . . . . . . 6-33
Brake . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Disc Location . . . . . . . . . . . . . . . . 6-35
E
Friction Disc Replacement . . . . . . 6-36
Gap Adjustment . . . . . . . . . . . . . 6-35
Electrical Schematic . . . . . . . . . . . . . . A-10
Electrical Symbols, List of . . . . . . . . . . . 5-8
C Electrical Troubleshooting . . . . . . . . . . 5-3
Electromagnetic Brake . . . . . . . . . . . . 6-35
Cables, Power . . . . . . . . . . . . . . . . . . 6-12 Electrostatic Discharge . . . . . . . . . . . . 2-12
Carrier Frame Linkage . . . . . . . . . . . 6-50 Emergency Reverse . . . . . . . . . . . . . . . . 5-6
Caution and Error Codes . . . . . . . . . . 5-10 Equivalent Chart, Decimal . . . . . . . . . . A-5
Circuit Breaker . . . . . . . . . . . . . . . . . 6-16 Error and Caution Codes . . . . . . . . . . 5-10
Codes, Caution and Error . . . . . . . . . 5-10 Error Codes . . . . . . . . . . . . . . . . . . . . . 5-9
Cold Storage Conditioning . . . . . . . . . 6-59 History . . . . . . . . . . . . . . . . . . . . . . 5-9
Contactors . . . . . . . . . . . . . . . . . . . . 6-23 ESD, See Electrostatic Discharge
Control Handle
Changing Horn Button/Switch . . 6-18
F
Changing Lift/Lower Button . . . . 6-19
Changing Push Button . . . . . . . . 6-19
Disassembly . . . . . . . . . . . . . . . . 6-18 Fault Codes . . . . . . . . . . . . . . . . 5-7, 5-26
Display and Programming . . . . . . . 5-9 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Stem . . . . . . . . . . . . . . . . . . . . . . 6-19
Conversions, Standard/Metric . . . . . . . A-7 G
Cover, Tractor . . . . . . . . . . . . . . . . . . 6-11
Creep Speed . . . . . . . . . . . . . . . . . . . . 5-6 Grease Fittings . . . . . . . . . . . . . . . . . . . 4-4
Current Limiting . . . . . . . . . . . . . . . . . 5-6
H
D
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Decimal Equivalent Chart . . . . . . . . . . A-5
Definitions . . . . . . . . . . . . . . . . . . . . . 5-6

00700-CL340-08, Issued: 06/20/2008 I-1

Index Toyota Model 7HBW23 Service Manual

Hydraulic Components M
Cylinder
Assembly . . . . . . . . . . . . . . . . . 6-52 Maintenance
Disassembly . . . . . . . . . . . . . . 6-52 Annually/Every 1500 Hours . . . . . . 4-4
Inspection . . . . . . . . . . . . . . . . 6-52 Every Two Months/250 Hours . . . . 4-3
Installation . . . . . . . . . . . . . . . 6-52 Maintenance-Free Batteries . . . . . . . . . 6-7
Removal . . . . . . . . . . . . . . . . . 6-51 Map, Navigating the Manual . . . . . . . . . 1-2
Fluid Master Control ON/OFF Switch . . . . . 6-25
Changing . . . . . . . . . . . . . . . . . 6-56 Master Control Relay . . . . . . . . . . . . . 6-24
Level . . . . . . . . . . . . . . . . . . . . 6-56 Metric Conversions . . . . . . . . . . . . . . . A-7
Hydraulic Pump Model Identification . . . . . . . . . . . . . . . 3-2
Removal/Installation . . . . . . . . 6-55 Motor Controller . . . . . . . . . . . . . . . . . . 3-6
Hydraulic Reservoir Undertemperature . . . . . . . . . . . . . 5-7
Installation . . . . . . . . . . . . . . . 6-54 Motors
Removal . . . . . . . . . . . . . . . . . 6-54 Drive . . . . . . . . . . . . . . . . . .6-39, 6-46
Hydraulic Unit General . . . . . . . . . . . . . . . . . . . . 6-39
Installation . . . . . . . . . . . . . . . 6-54 Lift . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Relief Valve Adjustment . . . . . . 6-57
Removal . . . . . . . . . . . . . . . . . 6-53
Solenoid N
Installation . . . . . . . . . . . . . . . 6-53
Removal . . . . . . . . . . . . . . . . . 6-53 Neutral Braking . . . . . . . . . . . . . . . . . . 5-6
Hydraulic Schematic . . . . . . . . . . . . . .A-12
Hydraulic Troubleshooting . . . . . . . . . .5-5 O

I Operation
Directional/Speed Control . . . . . . . 3-5
Identification, Model . . . . . . . . . . . . . . .3-2 Lift/Lower . . . . . . . . . . . . . . . . . . . 3-5
Motor Controller . . . . . . . . . . . . . . . 3-6
Truck Starting . . . . . . . . . . . . . . . . 3-5
J
Overvoltage Cutoff . . . . . . . . . . . . . . . . 5-7

Jacking Safety . . . . . . . . . . . . . . . . . . .2-9

P
K
Pallet Forks . . . . . . . . . . . . . . . . . . . . 6-49
PIN-key code . . . . . . . 5-7, 5-9, 5-20, 5-21
key code . . . . . . . . . . . 5-7, 5-9, 5-20, 5-21 Plugging . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Key Switch (Optional) . . . . . . . . . . . . . 6-28 Power Amplifier
Thermal Cutback . . . . . . . . . . . . . . 5-7
L Programmable Maintenance Tool .3-4, 5-28
Pump, Hydraulic . . . . . . . . . . . . . . . . 6-55
Lift Motor . . . . . . . . . . . . . . . . . . . . . . 6-55
Lift-Limit Switch . . . . . . . . . . . . . . . . . 6-27 R
Adjustment . . . . . . . . . . . . . . . . . . 6-27
List of Electrical Symbols . . . . . . . . . . .5-8 Ramp Shape . . . . . . . . . . . . . . . . . . . . 5-7
Load Wheels . . . . . . . . . . . . . . . . . . . . 6-49 Relay, Master Control . . . . . . . . . . . . . 6-24
Carrier Frame Linkage . . . . . . . . . 6-50
Pull Rod Removal/Replacement . . . 6-49
Removal/Replacement . . . . . . . . . . 6-49
Lubrication Equivalency Chart . . . . . . .A-2
Lubrication, Drive Housing . . . . . . . . . 6-32

I-2 00700-CL340-08, Issued: 06/20/2008

Toyota Model 7HBW23 Service Manual Index

S Troubleshooting
Electrical . . . . . . . . . . . . . . . . . . . . 5-3
Safety Hydraulic . . . . . . . . . . . . . . . . . . . . 5-5
Battery . . . . . . . . . . . . . . . . . . . . . 2-6 List of Charts/Tables . . . . . . . . . . 5-31
Definitions . . . . . . . . . . . . . . . . . . . 2-2 Symptom Tables . . . . . . . . . 5-37, 5-42
General . . . . . . . . . . . . . . . . . . . . . 2-3 Truck Model Identification . . . . . . . . . . 3-2
Jacking . . . . . . . . . . . . . . . . . . . . . 2-9 Truck Specifications . . . . . . . . . . . . . . . 3-2
Static . . . . . . . . . . . . . . . . . . . . . . 2-12
Towing . . . . . . . . . . . . . . . . . . . . . 2-10 U
Welding . . . . . . . . . . . . . . . . . . . . 2-11
Schematics Undervoltage Cutback . . . . . . . . . . . . . 5-7
Electrical . . . . . . . . . . . . . . . . . . . A-10
Hydraulic . . . . . . . . . . . . . . . . . . A-12
V
Sequencing Delay . . . . . . . . . . . . . . . . 5-7
Service Key . . . 3-4, 5-18, 5-19, 5-22, 5-23
Solenoid, Hydraulic . . . . . . . . . . . . . . 6-53 Vehicle Specifications . . . . . . . . . . . . . . 3-2
Special Tools . . . . . . . . . . . . . . . . . . . . 3-4
Programmable Maintenance Tool . . 3-4 W
Service Key . . . . . . . . . . . . . . . . . . 3-4
Specifications, Vehicle . . . . . . . . . . . . . 3-2 Welding Safety . . . . . . . . . . . . . . . . . . 2-11
Speed Limiting . . . . . . . . . . . . . . . . . . 5-7 Wheels
Static Discharge . . . . . . . . . . . . . . . . 2-12 Load . . . . . . . . . . . . . . . . . . . . . . . 6-49
Static Wrist Strap . . . . . . . . . . . . . . . 2-12 Wiring Harness . . . . . . . . . . . . . . . . . . 6-13
Static-Sensitive Components . . . . . . . 2-12 Inspection . . . . . . . . . . . . . . . . . . . 6-13
Strap, Static . . . . . . . . . . . . . . . . . . . 2-12
Switches
Arm Angle . . . . . . . . . . . . . . . . . . 6-26
General . . . . . . . . . . . . . . . . . . . . 6-25
Key Switch (Optional) . . . . . . . . . 6-28
Lift-Limit . . . . . . . . . . . . . . . . . . . 6-27
Master Control ON/OFF . . . . . . . 6-25
Test/Inspection . . . . . . . . . . . . . . 6-25
Symptom Tables
Lift/Lower System . . . . . . . . . . . . 5-37
Travel (Forward/Reverse) System . 5-42

Tests
Electric Motor . . . . . . . . . . . . . . . 6-43
Theory of Operation . . . . . . . . . . . . . . . 3-5
Torque Chart
Metric . . . . . . . . . . . . . . . . . . . . . . A-4
Standard . . . . . . . . . . . . . . . . . . . . A-3
Towing Safety . . . . . . . . . . . . . . . . . . 2-10
Tractor Cover . . . . . . . . . . . . . . . . . . 6-11
Installation . . . . . . . . . . . . . . . . . 6-11
Removal . . . . . . . . . . . . . . . . . . . 6-11

00700-CL340-08, Issued: 06/20/2008 I-3

Index Toyota Model 7HBW23 Service Manual

I-4 00700-CL340-08, Issued: 06/20/2008

 Brakes
BR12-001
February 29, 2012
7HBW23 Brake Boot
SERVICE INFORMATION BULLETIN 7HBW23
Subject: 7HBW23 Brake Boot Page 1 of 1

MODEL APPLICATION:
7HBW23

GENERAL INFORMATION:
Some users report frozen brakes after extended freezer storage. After overnight storage in a
freezer truck, then a short use in a warm humid environment and then a return to the freezer,
subsequent use may present a frozen brake.

REPAIR INFORMATION:
In special applications where the 7HBW23 is subjected to extended freezer storage, the brake
may not release and the 7HBW23 is rendered inoperable. This may occur when the 7HBW23 is
stored overnight in an over-the-road truck freezer and is briefly used in a warm humid
environment and then again used in the freezer environment. A brake boot, P/N 00590-50168-71,
may be installed to reduce moisture and contamination accumulation on the brake disc.

Note: Do not disassemble the brake.

1. Disconnect the harness brake wires at the terminal block.
2. Disconnect the brake wires.
3. Remove the cable tie holding the brake wires (if present).
4. Slide the boot over the brake (but not harness) wires and onto the brake. The ribs in the boot fit
into the groove in the brake body (as shown in Figure 1) and over the stainless brake plate (not
shown).
5. Reinstall the brake and harness wires.
6. Cable tie the brake wires into position as before. (If not previously present, cables tie the brake
wires to A1 - the upper armature wire.)
7. Test the brake function before returning the truck to service

Brake Boot

Figure 1
SERVICE INFORMATION BULLETIN

Subject: Moisture Protection for the Vehicle Manager (ETAC) Card Page 1 of 1

MODEL APPLICATION:
6HBW23, 7HBW23, 7HBW30, 7HBC30, 7HBW40,
7HBE40, 7HBC30, 7HBC40, 7TB50, 8HBW30,
8HBC30, 8HBW40, 8HBE40, 8HBC30, 8HBC40,
8TB50

GENERAL INFORMATION:
Applying a coating of DOW 111 (P/N 00590-47774-71) dielectric silicone to the Vehicle
Manager (VM) card can help prevent failures due to moisture from wet applications.

REPAIR INFORMATION:
In applications where the truck encounters excessive moisture, coat both sides of the VM card
with Dow 111 (P/N 00590-47774-71).
SERVICE INFORMATION BULLETIN

Subject: Preprogrammed Vehicle Manager (ETAC) Card Page 1 of 1

MODEL APPLICATION:
6HBW23, 6BWS10, 6BWS13, 7BWS10, 7BWS13
7HBW23, 7HBW30, 7HBC30, 7HBW40, 7HBE40,
7HBC30, 7HBC40, 7TB50, 8HBW30, 8HBC30,
8HBW40, 8HBE40, 8HBC30, 8HBC40, 8TB50

GENERAL INFORMATION:
The Vehicle manager (ETAC) cards ordered from service parts are no longer preprogramed and will
need to be programmed before installation. Programming can be completed by using Flashware 4.9
that is downloadable from the Toyota Information System (TIS) on the Dealer Portal. With this change
only one Vehicle Manager (ETAC) card will be available (part number 00590-48976-71) to fit all of the
models listed above.
 Chassis Electrical
CE13-002
May 15, 2013
7HBW23 Tiller Switch Arm Failures
SERVICE INFORMATION BULLETIN

Subject: 7HBW23 Tiller Switch Arm Failures Page 1 of 3

MODEL APPLICATION:
7HBW23

GENERAL INFORMATION:
If operating in applications that are subject to sticky substances, such as soda, fruit juices
and syrups, the following may be observed:

1. The switch arm may become stuck in the open or closed position, by contamination.

2. The arm may remain free, but switch button actuation may be blocked by contamination.

3. The roller may fail to roll/slide on the cam and actuating slopes damaging the arm.

4. Corrosion may interfere with the connection between the switch and the harness.

Any of these circumstances may lead to the logging of error code C14 and/or E112, or possibly
only allow slow travel speed without any error code being logged.

Please add this information to chapter 6 in Service Manual 00700-CL340-08.

SERVICE INFORMATION:
For any truck operating in the application described, follow the steps below.

1. On serial numbers between 7HBW23-29531 and 7HBW23-41492: Follow CE11-005

installation instructions for the plastic switch bridge replacement.
On serial numbers below 7HBW23-29531: If the steps below do not correct the issue(s), a
new tiller must be installed prior to performing the update in CE11-005. See page 3 to identify
which tiller arm the truck has.

2. To help with switch arm and button protection, apply Dow Corning Electrical Compound
(P/N 00590-43064-71) around the switch arm as shown in Figure 1 on Page 2.

3. For further protection, apply electrical compound to the surface that the switch arm roller
rides on.
Subject: 7HBW23 Tiller Switch Arm Failures Page 2 of 3

4. For terminal protection, apply a generous coating of Electrical Compound, enough so some
squeezes out when the harness is connected, to the switch terminals before installing the
harness connectors. Make sure the connectors are well seated, as this material is an insulator
rather than a conductor.

CAUTION: Do not use the Dow Corning Electrical Compound in dusty environments. The
compound may retain powder contamination and interfere with switch actuation.

Apply
Grease here
as shown.

Figure 1: Switch with Electrical Compound Applied

PARTS AVAILABILITY: Now available
00590-43064-71 – Dow Corning Electrical Insulating Compound - 5.3 OZ tube
Subject: 7HBW23 Tiller Switch Arm Failures Page 3 of 3

TILLER IDENTIFICATION AID

Just Look for the Extra Visible Machining on the Top of the Right hand Cam
 Hydraulics
HS13-001
March 29, 2013
Diagnosis of Lift Pump and Contactor
8HBE30-40, 8HBW30, 8HBC30-40,
SERVICE INFORMATION BULLETIN 7HBW23

Subject: Diagnosis of Lift Pump and Contactor Page 1 of 3

MODEL APPLICATION: 8HBE30-40, 8HBW30, 8HBC30-40, 7HBW23

GENERAL INFORMATION: Proper Diagnosis of Lift Pump Contactor and Lift Pump

REPAIR INFORMATION: The first step for electrical diagnosis is to measure the battery voltage. If
the battery voltage does not measure at least 24.5 volts, charge or replace the battery and retest. If
there are any error codes showing on the display, diagnose for those codes. After testing the battery
and diagnosing the error codes, then use the following symptom charts to diagnose the root cause.
SYMPTOM: The pump motor runs whenever the battery is plugged in. The contact tips are
welded together. This is usually caused by low battery voltage. Replace the lift pump contactor and check
the battery while lifting. The battery voltage must remain above 23 volts.

SYMPTOM: The pump motor runs whenever the battery is plugged in and the key or
keypad is on. Most likely a lift switch is stuck. Check the lift switches on the handle and see if the
switches are stuck. Repair or replace the lift switches as necessary.

SYMPTOM: The Lift Pump Contactor does not make a “clunk” noise when requesting lift,
with the key or keypad on.
1) Check for battery voltage, with respect to battery negative, at the positive input wire on the
contactor coil. If there is no battery voltage at the positive wire on the contactor, test the wiring
from the motor controller to the pump contactor. See figure 1.
2) If there is battery voltage at positive wire on the pump contactor, check for battery voltage at the
other wire on the contactor. There should be battery voltage when not requesting lift. See figure 2.
If there is no battery voltage at that wire, remove both wires from the contactor and measure the
resistance of the contactor coil. It should be 56 ohms for 8 Series and 16 ohms for the 7HBW23.
This wire should be “0” volts when requesting lift. See Figure 3.
3) Measure the voltage at the contactor output at the motor controller. It should have battery voltage
and then be “0” volts when requesting lift. If it does not go to “0” when requesting lift, use the
display on the control arm to monitor input from the lift limit switch and the output to lift pump
contactor. See page 3 of this bulletin.
8 Series Contactor Shown

Figure 1 Figure 2 Figure 3

Positive Input on Contactor Negative Input: No Lift Negative Input: Lift Requested
SIB: Diagnosis of Lift Pump and Contactor Page 2 of 3

SYMPTOM: The Lift pump Contactor makes a “clunk” noise when requesting lift but the lift
motor does not run.
1) If the lift pump contactor makes a “clunk” noise when requesting lift, but the lift motor does not run,
check for battery voltage with respect to battery negative at the positive cable at the lift pump
contactor. If there is no battery voltage, check the fuse and replace if blown. See Figure 6.
2) If there is battery voltage at the positive cable, check for battery voltage at the cable going to the
motor when requesting lift. If there is no battery voltage, replace the lift pump contactor. See Figure
7.
3) If you do have battery voltage at cable 7 when requesting lift, remove the top of the lift pump motor
and inspect the brushes. Replace the brushes if they are worn. See Figures 4 and 5.

Figure 4 Figure 5

Figure 6 Figure 7

SYMPTOM: The Lift Pump runs when requesting lift but the forks do not raise or the forks
lower immediately when the lift request stops.
1) If the lift motor runs but the forks do not raise or the forks lower immediately when the request
stops, remove the lower solenoid coil from the lower valve with the wires still attached. If the forks
will now lift, either a lower button is stuck, or there is a short in the wire harness. Monitor the inputs
from the lower switches and the output to the lower solenoid using the procedure shown on page 3.
It shows how to use the display segment to monitor inputs and outputs.
2) If the lower solenoid is not electrically activated, there is a hydraulic problem. Turn the lift relief
pressure adjustment all the way in and try lifting again. If the forks lift, return the relief adjustment to
its original position and check the pressure with a gauge as described in the Service Manual.
3) If it still will not lift, replace the pump assembly.
SIB: Diagnosis of Lift Pump and Contactor Page 3 of 3

Below is a reprint from the Service Manual on how to read the Digital Inputs/Outputs on the
display.
 Chassis Electrical
CE14-004
July 31, 2014
7HBW23 Main Wire Harness
SERVICE INFORMATION BULLETIN Installation
Subject: 7HBW23 Main Wire Harness Installation Page 1 of 2

MODEL APPLICATION:
7HBW23

GENERAL INFORMATION:
A new main wire harness is now available, part number 00590-51603-71. See figure 1. Use the
following instructions to install the new harness.

REPAIR INFORMATION:
1) Park the truck on a smooth level surface and make sure the parking brake is applied. Block
the load wheels to prevent movement.
2) Press the red OFF button ( O ) on the keypad, or if the truck has a key switch, turn the key to
the off position. Press the main ON/OFF switch to the OFF position.
3) Disconnect the battery connector.
4) Turn the tiller arm all the way to the left side of the truck for easier access to wire harness
connections.
5) Remove all covers and the tiller arm up stop to gain access to the wiring and cables.
6) Disconnect connector J11 and switches S24 and S25 located inside the tiller arm mount. See
figure 2.
7) Remove tiller arm and mount as an assembly from the transmission. There are three bolts
holding the mount to the transmission.
8) Disconnect all ring terminals from the drive motor terminal block. Use figure 3 to identify ring
terminal locations.
9) Remove the old harness from the truck. Note cable tie locations so new cable ties can be re-
installed with the new harness.
10) Lay the new harness into the truck. Connect the truck end of the harness. For the correct
harness locations, see figure 4.
11) Install the harness (with the long wire guard and power cables) down through the larger of the
two transmission openings.
NOTE: Make sure the power cables are vertically stacked one on top of the other on the LEFT
side of the transmission opening above the power terminals. See figures 5 and 6.
12) Before installing ring terminals, check all terminal inner nuts by torquing them to 79 in. lbs.
(8.925Nm). Install ring terminals by using figure 3 for terminal locations. Torque outer ring
terminal nuts to 79 in. lbs. (8.925 Nm).
13) Make sure the wire harness through the opening is in the correct orientation. See figure 6.
14) Install tiller arm and tiller arm mount assembly.
15) Reconnect connector J11 and switches S24 and S25 inside the tiller arm. See figure 2.
16) Install the tiller arm up stop and truck covers.
Subject: 7HBW23 Main Wire Harness Installation Page 2 of 2

17) Reconnect the battery.

18) Turn the main ON/OFF switch to the ON position. Enter the key code and press the green ON
button ( 1 ) on the keypad, or turn the key switch ON.
19) Test operate all functions on the truck.

S24 Wire 50

S25 Wire 51

Figure 1 Figure 2

Be careful routing
wires over the block

3 Armature
5 Field 26 Brake

4 Armature
6 Field 57 Brake

Figure 3 Figure 4

Figure 5 Figure 6
 Control Circuit
CC16-009
October 31, 2016
Parameter Settings for Nexsys
Battery Pack
7HBW23, 7BWS10-13, 8HBW23,
SERVICE INFORMATION BULLETIN 8BWS10-13

Subject: Parameter Settings for Nexsys Battery Pack Page 1 of 1

MODEL APPLICATION:
7HBW23, 7BWS10, 7BWS13, 8HBW23, 8BWS10 and 8BWS13

GENERAL INFORMATION:
The correct parameter settings when using the Nexsys battery pack has changed with the
introduction of the 8HBW23 and the 8BWS10/13 model trucks.

REPAIR INFORMATION:
Use the parameter settings below when using the Nexsys battery pack.

Model Parameter 21 Parameter 46

7HBW23 2 NA
7BWS10-13 2 NA
8HBW23 3 0
7BWS10-13 3 0