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Toyota 7FBCU 15-55 Manual Download Page 35

2-1

CONTROLLER

2

2

Page

GENERAL

.......................................... 2-2

SPEC

I

F

I

CAT

I

ONS

............................ 2-3

COMPONENTS

................................. 2-4

CONTROLLER

................................ 2-15

TRAVEL

I

NG

/

MATER

I

AL HANDL

I

NG 

CONTROLLER ASSY 
REMOVAL

⋅

I

NSTALLAT

I

ON 

(

15 ~ 32 MODEL

)

........................... 2-15

TRAVEL

I

NG CONTROLLER 

ASSY REMOVAL

⋅

I

NSTALLAT

I

ON 

(

35 ~ 55 MODEL

)

........................... 2-16

MATER

I

AL HANDL

I

NG CONTROLLER 

ASSY REMOVAL

⋅

I

NSTALLAT

I

ON 

(

35 ~ 55 MODEL

)

........................... 2-17

TRAVEL

I

NG AND MATER

I

AL 

HANDL

I

NG CONTROLLER 

I

NSPECT

I

ON ................................. 2-18

CONTACTOR PANEL ASSY 

REMOVAL

⋅

I

NSTALLAT

I

ON 

(

15 ~ 32 MODEL

)

........................... 2-21

CONTACTOR PANEL ASSY 

REMOVAL

⋅

I

NSTALLAT

I

ON 

(

35 ~ 55 MODEL

)

........................... 2-22

CONTACTOR PANEL 

I

NSPECT

I

ON ................................. 2-23

PS CONTROLLER ASSY 

REMOVAL

⋅

I

NSTALLAT

I

ON 

(

15 ~ 32 MODEL

)

........................... 2-24

PS CONTROLLER 

I

NSPECT

I

ON 

(

15 ~ 32 MODEL

)

........................... 2-25

SAS CONTROLLER ASSY 

REMOVAL

⋅

I

NSTALLAT

I

ON........... 2-29

2

Page

BOARD 

I

NSPECT

I

ON ..................... 2-30

D

I

SASSEMBLY................................ 2-67

REASSEMBLY................................. 2-68

D

I

SPLAY 

I

NSPECT

I

ON ................... 2-79

D

I

RECT

I

ON SW

I

TCH

.................... 2-80

REMOVAL

⋅

I

NSTALLAT

I

ON............. 2-80

D

I

SASSEMBLY

⋅

I

NSPECT

I

ON

⋅

REASSEMBLY ............................. 2-81

ACCELERATOR 

POTENT

I

OMETER 

ADJUSTMENT

.............................. 2-83

BRAKE SW

I

TCH 

ADJUSTMENT

.............................. 2-84

FOOT BRAKE.................................. 2-84

PARK

I

NG BRAKE ........................... 2-84

MATER

I

AL HANDL

I

NG LEVER 

SW

I

TCH ADJUSTMENT

............ 2-85

EZ PEDAL 

(

OPT

)

............................ 2-86

COMPONENTS................................ 2-86

I

NSPECT

I

ON ................................... 2-87

Summary of Contents for 7FBCU 15-55

Page 1: ...OLLER MULTI DISPLAY FUNCTIONS TROUBLESHOOTING MOTOR 5 DRIVE UNIT 6 FRONT AXLE 7 REAR AXLE 8 STEERING 9 BRAKE 10 BODY 11 MATERIAL HANDLING SYSTEM 12 MAST 13 CYLINDER 14 OIL PUMP 15 OIL CONTROL VALVE 16...

Page 2: ...0 10 CIRCUIT TESTER 0 11 STANDARD BOLT NUT TIGHTENING TORQUE 0 13 BOLT STRENGTH TYPE IDENTIFICATION METHOD 0 13 TIGHTENING TORQUE TABLE 0 14 PRECOAT BOLTS 0 15 HIGH PRESSURE HOSE FITTING TIGHTENING TO...

Page 3: ...0 2 EXTERIOR VIEWS 0...

Page 4: ...BCU20 30 7FBCU20 Dust proof 25 5000 lbs 7FBCU25 30 7FBCU25 Dust proof 7FBCHU25 High capacity battery compartment 30 7FBCHU25 Dust proof High capacity battery compartment 30 6000 lbs 7FBCU30 30 7FBCU30...

Page 5: ...5 307FBCU18 60011 307FBCU18 60011 30 7FBCU35 307FBCU45 60011 30 7FBCU18 30 7FBCU45 7FBCU20 7FBCU25 60011 7FBCU25 60011 7FBCU55 7FBCU55 60011 7FBCU25 30 7FBCU55 307FBCU55 60011 30 7FBCU20 307FBCU25 600...

Page 6: ...TION REASSEMBLY Tightening torque unit T N m kgf cm ft lbf Disassembly Procedure 1 Remove the cover Point 1 2 Remove the bushing Point 2 Operation explained later 3 Remove the gear Point Operations Ex...

Page 7: ...nt Limit Maximum or minimum allowable value in inspection or adjustment ABBREVIATIONS Abbreviation code Meaning Abbreviation code Meaning ASSY Assembly SAE Society of Automotive Engineers USA EHPS Ele...

Page 8: ...n to the center of the specified tightening torque range If no tightening torque is specified tighten the bolt or nut according to the standard tightening torque table 3 Protection of functional parts...

Page 9: ...place Use a jack with ample capacity and jack up the vehicle at the specified jack up point Jacking up at any other point will be dangerous Never operate while the vehicle is held with a jack Always...

Page 10: ...h to the neutral position 4 Before towing either remove the fork or take an action to prevent fork contact with the ground due to bounding Cautions for Deadman Brake Spec Model The brake exclusive to...

Page 11: ...s such as to change the original specification If improper change the label See Page 17 27 5 Care should always be exercised for safety operation whenever you operate the truck Make distinction betwee...

Page 12: ...esults with the digital type and analog type The result may be different between measurements with the analog type and digital type Always use a circuit tester according to its operation manual Cautio...

Page 13: ...bes the results of measurement with a circuit tester whose power supply voltage is 3 0 V 3 Difference in measurement result by measurement range analog type In the analog type circuit tester changing...

Page 14: ...entification by bolt shape 2 Identification by part No Shape and class Class Hexagon head bolt Hexagon head bolt 4 4T 5 5T 6 6T 7 7T 8 8T 4T Hexagon flange bolt 4T Hexagon head bolt 5T Hexagon flange...

Page 15: ...24 43 67 101 7 5 18 36 65 100 157 75 175 360 670 1050 1600 65 in lbf 13 26 48 76 116 6T 6 8 10 12 14 16 1 0 1 25 1 25 1 25 1 5 1 5 7 8 19 38 72 110 170 80 195 400 730 1100 1750 69 in lbf 14 29 53 80...

Page 16: ...Also check no dent or other damage on the contact surfaces before installation 2 When connecting a high pressure hose hold the hose to align the fitting with the nipple and tighten the fitting 3 The m...

Page 17: ...0 1 06 2337 8630 0 88 1940 8 mm 0 32 in 31480 3 21 7078 4410 0 45 992 3 8830 0 9 1985 8530 0 87 1918 7650 0 78 1720 6280 0 64 1411 17650 1 8 3969 17060 1 74 3937 15300 1 56 3440 12550 1 28 2322 10 mm...

Page 18: ...565 1246 18 Approx 695 1532 20 Approx 670 1477 25 Approx 1065 2348 30 Approx 1195 2635 32 Approx 1370 3021 35 Approx 1420 3131 45 Approx 2240 4939 55 Approx 2370 5226 V mast ASSY L fork and backrest w...

Page 19: ...35 55 model 4 5 1 18 Planetary gear 35 55 model Proper quantity Hydraulic oil V FV FSV mast lifting height 3300 mm 130 in 15 18 model 17 0 4 49 ISO VG32 Hydraulic oil 20 32 model 22 0 5 81 Hydraulic o...

Page 20: ...14 Rear axle beam rear pin 15 Swing lock cylinder crank and rod pin 1 3 4 5 1 5 4 11 12 13 20 30 model 15 15 15 18 model 7 8 9 10 14 1 2 6 5 4 6 6 1 1 1 6 2 3 1 6 1 6 1 1 1 1 1 1 3 4 5 7 8 9 10 2 6 3...

Page 21: ...nuckle king pin 9 Rear wheel bearing 10 Tie rod end pin 11 Rear axle cylinder end pin 12 Oil tank 13 Rear axle beam front pin 14 Rear axle beam rear pin 15 Swing lock cylinder crank and rod pin Inspec...

Page 22: ...ear For pump motor and PS motor only M Battery Charging level I Electrolyte level I Electrolyte specific gravity M Terminal looseness I Abnormality in the upper portion of the battery case I Insulatio...

Page 23: ...E SYSTEM Wheels Tire cuts damage and uneven wearing I Loose rim and hub nuts T Tire groove depth M Metal chips pebbles and other foreign matter trapped in tire grooves I Rim side bearing and disc whee...

Page 24: ...I Anchor pin rusting I Return spring fatigue M Automatic adjuster function I Backing plate Deformation cracks and damage I Loose mounting T MATERIAL HANDLING SYSTEM Forks Abnormality of fork and stopp...

Page 25: ...tion I Tank and oil strainer C Oil leak I Control lever Loose linkage I Operation I Oil control valve Oil leak I Relief pressure measurement M Relief valve and tilt lock valve functions I Hydraulic pi...

Page 26: ...age and cracks of frame cross members etc I Bolts and nuts looseness T SAS Functions I Loosening and damage at sensor mounting portion I Damage deformation oil leakage and loosen ing of the mounting o...

Page 27: ...ours Drive unit oil z Differential oil 35 55 model z Planetary gear oil 35 55 model z Hydraulic oil z Hydraulic oil filter z New vehicle initial replacement z Wheel bearing grease z Brake fluid 15 32...

Page 28: ...1 1 1 BATTERY 1 Page BATTERY COMPARTMENT AND REQUIRED WEIGHT 1 2 SERVICE STANDARD 1 3 DISPLAY 1 3 TROUBLESHOOTING 1 4 BATTERY ASSY 1 5 REMOVAL INSTALLATION 1 5 INSPECTION 1 6...

Page 29: ...mendation Compartment dimensions mm in Minimum required battery weight with case kg lb Remarks Depth X Width Y Height Z 7FBCU15 18 680 26 8 878 34 6 585 23 0 830 1840 7FBCU20 25 775 30 5 992 39 1 585...

Page 30: ...e warning any attempt at traveling or material handling operation will cause all charge indicator segments to blink and the alarm to sound to warn the operator Specific gravity upon full charge 1 280...

Page 31: ...1 4 TROUBLESHOOTING...

Page 32: ...1 Disconnect the battery plug 2 Open the battery hood 3 Remove the rear toe board 4 Loosen battery stoppers RH and LH and the fixing bolts 5 Remove the battery ASSY Point 1 Installation Procedure The...

Page 33: ...uation for conversion S20 St 0 0007 t 20 S20 Specific gravity at 20 C St Specific gravity measured at t C t Electrolyte temperature upon measurement C How to use the hydrometer 1 Insert the nozzle of...

Page 34: ...hen the insulation resistance is less than 1 M wash the battery with water after removing it from the vehicle Fully dry the washed battery and measure the insulation resistance again Install the batte...

Page 35: ...2 21 CONTACTOR PANEL ASSY REMOVAL INSTALLATION 35 55 MODEL 2 22 CONTACTOR PANEL INSPECTION 2 23 PS CONTROLLER ASSY REMOVAL INSTALLATION 15 32 MODEL 2 24 PS CONTROLLER INSPECTION 15 32 MODEL 2 25 SAS C...

Page 36: ...the accelerator PS circuit SAS function or any other sensor and displays the corresponding error code together with the warning buzzer tone At the same time an action such as stopping traveling stopp...

Page 37: ...or drive 100V 800A 100V 880A 100V 800A 100V 880A 100V 880A TMD2 For drive 100V 880A TMP For pump 100V 800A 100V 880A 100V 880A TMPS For PS 1MI100H 025 Current sensor CSBATT For power supply S3CM7 800...

Page 38: ...2 4 COMPONENTS Traveling Material Handling Controller 15 32 Model 2401 Chopper less...

Page 39: ...2 5 2 Chopper less 2401 Chopper...

Page 40: ...2 6 Chopper 2401...

Page 41: ...2 7 Traveling Controller 35 55 Model 2401...

Page 42: ...2 8 2401...

Page 43: ...2 9 Material Handling Controller 35 55 Model 2402...

Page 44: ...2 10 Contactor Panel 15 32 Model Chopper less 2402 Chopper...

Page 45: ...2 11 Chopper less 2402 Dust proof Chopper Dust proof...

Page 46: ...2 12 Contactor Panel 35 55 Model 2402...

Page 47: ...2 13 PS Controller FHPS 2402 EHPS...

Page 48: ...2 14 SAS Controller 2401...

Page 49: ...tor T N m kgf cm ft lbf Removal Procedure 1 Disconnect the battery plug 2 Remove the side cover LH 3 Remove the contactor panel ASSY See page 2 21 4 Disconnect the connectors and terminals from the tr...

Page 50: ...he capacitor T N m kgf cm ft lbf Removal Procedure 1 Disconnect the battery plug 2 Remove the side cover RH 3 Remove the duct 4 Disconnect the connectors and terminals from the traveling controller AS...

Page 51: ...pacitor T N m kgf cm ft lbf Removal Procedure 1 Disconnect the battery plug 2 Remove the side cover LH 3 Remove the controller cover 4 Disconnect the connectors and terminals from the material handlin...

Page 52: ...explanation here is mainly for inspection of the traveling material handling controller as removed from the vehicle 1 Insulation resistance measurement Always measure before inspecting the traveling m...

Page 53: ...terminals on the rear side of C O 1k Portion to be inspected Measurement terminals Standard Tester range TMD TMP D1 D2 S1 S2 Approx 2 k 1k D1 D2 G Approx 12 k S1 S2 D1 D2 S1 S2 G Approx 10 k G D1 2 G...

Page 54: ...ange 15 32 FAN NO 1 CN132 1 17 CN132 2 N2 1 FAN NO 2 CN133 1 7 CN133 2 8 FAN NO 3 20 32 model CN139 1 18 CN139 2 N2 35 55 FAN NO 1 CN132 1 7 CN132 2 8 FAN NO 2 CN133 1 9 CN133 2 10 FAN NO 3 CN160 1 17...

Page 55: ...Remove the contactor cover Dust proof model 4 Disconnect the connectors and terminals from the contactor panel ASSY 5 Remove the contactor panel ASSY Installation Procedure The installation procedure...

Page 56: ...Remove the contactor cover Dust proof model 4 Disconnect the connectors and terminals from the contactor panel ASSY 5 Remove the contactor panel ASSY Installation Procedure The installation procedure...

Page 57: ...the resistance Model Portion to be inspected Measurement terminals Standard Tester range 15 32 Chopper less MD MP Coil Both terminals of contactor connector Approx 20 at 20 C 68 F 1 15 32 Chopper MB M...

Page 58: ...5 32 MODEL Removal Procedure 1 Disconnect the battery plug 2 Remove the toe board rear 3 Remove the control panel ASSY 4 Disconnect the electrical wiring Installation Procedure The installation proced...

Page 59: ...urement Battery plug connected key switch ON 2 Mps contactor coil conduction measurement Battery plug disconnected key switch O F F Measurement terminals P22 N1 Circuit tester range DC200 V Standard 3...

Page 60: ...2 26 3 F3 PS circuit fuse inspection Battery plug disconnected F3 removal Measurement terminals Both terminals of F3 Circuit tester range 1 Standard 0 F3...

Page 61: ...tate after removal from the vehicle 1 TMPS transistor for PS 1 Inspection method Disconnect the TMPS wiring Caution When shifting to check C2E1 E2 from G2 E2 short connect G2 E2 to avoid the possibili...

Page 62: ...SH wiring 3 F3 PS circuit fuse inspection F3 removal Portion to be inspected Measurement to be inspected Standard Tester range SH Both terminals of SH Continuity shall exist 1 Measurement terminals Bo...

Page 63: ...ont and rear 3 Remove the lower panel 4 Remove the instrument panel RH 5 Remove the front piller cover RH 6 Disconnect the tilt lever rod and the attachment lever rod 7 Remove the oil control valve co...

Page 64: ...e material handling controller on models 35 to 55 is between P12 and N2 Always disconnect the battery plug before installing or removing the controller ASSY or each board Since incorrect SST connectio...

Page 65: ...12 51 LS Key switch O F F LSPB O F F Key switch O F F LSPB ON Approx 0 V Approx 5 V CN101 5 67 LSD CN101 12 51 LS Key switch O F F LSD O F F Key switch O F F LSD ON Approx 5 V Approx 0 V CN101 6 63 L...

Page 66: ...pedal ON Key switch O F F accelerator pedal O F F Approx 0 V Approx 5 V CN102 2 52 POTA CN102 8 50 POT Key switch O F F accelerator pedal depressed 0 4 V Varies with the degree of operation CN102 3 8...

Page 67: ...CN103 13 346 ERR Immeasurable CN103 14 Unused CN103 15 Unused CN103 16 Unused Connector No Connector No Conditions Standard Remarks CN104 1 44 VBMB CN104 17 N2 N2 Key switch O F F Key switch ON Appro...

Page 68: ...N104 18 43 VBKY CN104 17 N2 N2 Approx 36 V 48 V CN104 19 78 THCD CN104 17 N2 N2 Key switch O F F 1 4 V CN104 20 Unused Connector No Connector No Conditions Standard Remarks CN105 1 38 FAN CN104 17 N2...

Page 69: ...CHOPS Immeasurable CN106 5 31 O CL Immeasurable CN106 6 Unused CN106 7 32 TMPAD Immeasurable CN106 8 33 TMPD CN104 17 N2 N2 Approx 5 V CN106 9 35 CKPV CN104 17 N2 N2 Approx 10 V CN106 10 Unused CN106...

Page 70: ...111 5 16 D15V CN111 13 14 GNDD 14 15 V CN111 6 43 VBKY CN112 18 N2 N2 Approx 36 V 48 V CN111 7 Unused CN111 8 9 MPS CN111 2 Battery plug disconnected Resistance measurement Approx 20 PS controller STD...

Page 71: ...on Approx 24 V Approx 0 V CN112 13 8 FAND Immeasurable CN112 14 14 GNDC Immeasurable CN112 15 5 MP Unused CN112 16 6 MP Unused CN112 17 N2 N2 Immeasurable CN112 18 N2 N2 Immeasurable Connector No Conn...

Page 72: ...6 TMDBU SD Immeasurable CN113 17 150 TMDAU2 CN113 14 P3 TMDAU SD 13 15 V CN113 18 152 TMDAD2 CN113 15 N2 TMDAD SD 13 15 V CN113 19 154 TMDBU2 CN113 16 P5 TMDBU SD 13 15 V CN113 20 156 TMDBD2 CN113 24...

Page 73: ...137 1 2 MD CN137 3 1 MD Battery plug disconnected Resistance measurement Approx 20 CN137 2 N2 N2 Immeasurable CN137 3 1 MD CN137 1 2 MD Measurement with probe in con tact with CN137 1 Approx 11 V CN13...

Page 74: ...Approx 15 V CN141 5 309 SSTMA Immeasurable CN141 6 307 SMTSA Immeasurable CN141 7 310 SSTMK Immeasurable CN141 8 308 SMTSK Immeasurable CN141 9 51 OLSD Immeasurable CN141 10 138 SL L CN141 11 320 STPO...

Page 75: ...ON SWMH1 O F F Approx 5 V Approx 0 V CN142 4 70 SWTK CN141 11 12 S20V SWTK O F F SWTK ON Approx 5 V Approx 0 V CN142 5 11 S20V CN141 11 12 S20V Approx 20 V CN142 6 N2 N2 Unused CN142 7 N2 N2 Immeasur...

Page 76: ...prox 12 V CN143 3 334 SOLD CN143 8 331 SOLLD Battery plug disconnected Resistance measurement Approx 10 LSD ON Approx 12 V CN143 4 Unused CN143 5 332 SOLL CN143 8 331 SOLLD Battery plug disconnected R...

Page 77: ...CONNECTING DIAGRAM 15 32 MODEL 18 61...

Page 78: ...CONNECTING DIAGRAM 35 55 MODEL 18 62...

Page 79: ...sec18E_B3 fm Page 20 Wednesday April 27 2005 9 10 PM 18 63 WIRING DIAGRAM 15 32 MODEL...

Page 80: ...WIRING DIAGRAM 35 55 MODEL sec18E_B3 fm Page 21 Wednesday April 27 2005 9 10 PM 18 64...

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