![]() ![]() Therefore the body itself would be immune to melting and sagging. ![]() That ignition switch might be an anomaly in our fleet. If it blows the fuse again I will revisit this thread with that story. Time will tell if there is still a problem. Truck ran in intermittent duty for about 5 hours with several different operators and the fuse has not blown yet.īefore I drove the truck back to the dock to release it to service I personally drove it across some rather rough areas of pavement to kinda simulate the conditions of entering and exiting trailers that are mismatched to the dock plates. The final test was done on Friday by putting the truck back together completely and letting shop personnel use it (instead of our designated shop lift) do normal tasks. So I am unable to prove anything about what was taking place at the beginning but I can't stop wondering if the initial finding of the wiring harness pinched between that bolt head and the steel hydraulic pipe might have somehow resulted in current sort of "bleeding" through the thinned out insulation and heating up the fuse after a few minutes of operation. I took the old switch off and once again measured the resistance and it still shows around 9.3 Ohm.īut not wanting to give this old switch any benefit of doubt, I consigned it to my toolbox (for future reference and possible use in a DIFFERENT truck to see if that truck blows a fuse) and put the new switch back in. Just to make sure that the new ignition switch had "cured" the problem, I then put the old ignition switch back in and ran the engine at 1,500 for more than an hour and it never blew a fuse! !! And the old switch never got hot or even warm. System voltage remained at 14.3 to 14.1 the entire time. With a NEW ignition switch in place, I ran the engine for 45 minutes at 1,500 RPM with a volt meter connected across the battery. I taped the harness back up and reassembled the truck to a point that the engine could be started and run. On Monday I cut open the last section of harness and found nothing wrong in any of the wiring. OK, here's where I am on this as of Friday 7/27. If the short was between the White-blue wire it would blow the fuse just sitting turned off, but that is not the case.Īnybody ever in their life time run into this? I think this is now bleeding through enough to cause the 40 amp fuse to heat up gradually when the ignition switch is in the Run position. I am suspicious that the front harness has been "pinched" by something up under the dash panels, resulting in the Black-yellow wire being compressed against a ground wire inside the taped harness hard enough to cause thinning of the insulation. Those wires are a White-blue tracer that feeds the ignition switch from the 40 amp fuse, and a Black-yellow tracer that leads back to the fuse box to power all the "Ignition hot" fuse positions. My opinion of why it is inside the harness mentioned is because there are only 2 wires in the Front Harness large enough to require a 40 amp fuse. I am surmising that there is a problem (short to ground) in the Front Harness, Toyota part # 56213-UN0RP-71. Seems to require about 10 minutes of operation for this to happen. It will blow after the engine has started and is running. This manual will be emailed to you shortly after purchase! If you would like the manual mailed to you on a DVD or print and bound, please select this option at checkout.I have a 7FGCU25 in our shop because it blows the 40 amp fuse in the AM1 fuse box position. Please see the video below for a quick overview of our business. You will be able to use the search function to browse the manual and print out your needed pages. ![]() There are many illustrations to aid you during your job and easy to read text throughout the manual. With hundreds of pages, it will show you how to distinguish any problem and how to fix it on your own. This PDF service manual will show you every nut and bolt on your machine. By applying the knowledge in this service repair manual, any owner will be able to make the right decisions about what they need to do to maintain and repair their machine. This Toyota 7FGCU25 Forklift Service/Shop & Repair Manual PDF Download will guide you through fundamentals of maintaining and repairing, step-by-step, to teach you what the factory trained technicians already know by heart.
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