Toyota 7FBEF 15 Service Manual Download Page 44

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4-11

Front brake

■

General

Hydraulic parts such as the master cylinder are discontinued by adoption of mechanical disc brake that
has excellent maintainability.

■

Brake specifocations

Type

Foot brake

Mechanical disc brake

Parking brake

Mechanical disc brake

Brake disc outside diameter mm (in)

203 (8.0)

Brake effective diameter mm (in)

165 (6.5)

Brake pad

Material

Semi-metallic phenol resin

Dimension mm (in)

Outside diameter: R100 (3.94)

Inside diameter:

R65 (2.56)

Thickness: 6(0.24)

Area mm

(in

)

3528 (5.47)

Brake ASSY

Brake disc

Motor & Drive unit

Summary of Contents for 7FBEF 15

Page 1: ...Index Tillbaka till Servicemanual 7FBEF 15 20 ...

Page 2: ...features Please read it carefully for sales and service activities This manual has been edited for the vehicles launched into the market in May 2003 Any later change shall be informed through Toyota Industrial Equipment Parts Service News Please refer to the repair manual and parts catalog for the matters necessary for servicing TOYOTA Material Handling Company A Division of TOYOTA INDUSTRIES CORP...

Page 3: ...VELOPMENT OBJECTIVE 1 ELECTRICAL SYSTEM 2 POWER TRAIN 3 TRAVELING STEERING AND BRAKE SYSTEMS 4 INSTRUMENTS 5 FRAME AND AUXILIARY EQUIPMENT 6 MATERIAL HANDLING AND HYDRAULIC SYSTEM 7 SAS CONTROL SYSTEM 8 OUTLINE OF MAJOR OPTIONS 9 APPENDIX 10 ...

Page 4: ...0 1 GENERAL Page VEHICLE EXTERIOR VIEWS 0 2 MODEL LINEUP 0 3 2 3 0 3 ...

Page 5: ...0 2 VEHICLE EXTERIOR VIEWS Vehicle exterior views Front View Rear View ...

Page 6: ... MODEL LINEUP Vehicle model lineup L C Load center Payload L C 500 mm New model Previous model Voltage 1 5 ton 7FBEF15 5FBE15 48V 1 6 ton 7FBEF16 48V 1 8 ton 7FBEF18 5FBE18 48V 2 0 ton 7FBEF20 48V 2 3 0 3 ...

Page 7: ...0 4 ...

Page 8: ...1 1 DEVELOPMENT OBJECTIVE Page DEVELOPMENT OBJECTIVE 1 2 FEATURES SELLING POINTS 1 3 MAJOR DIFFERENCES BETWEEN NEW AND PREVIOUS MODELS 1 9 2 3 1 ...

Page 9: ...9 ahead of other companies by consolidation of our time tested technologies Its features have fully been utilized not only in performances but also in operating feel We propose these models as three wheel counter battery forklift trucks without an equal in performance and operating feel 1 Optimum material handling operation matching each customer s needs by making the most of the features of AC mo...

Page 10: ...otor voltage motor structure and the controller between the AC system and DC system Comparison between the DC and AC systems Motor voltage Motor structure Controller DC sys tem Conversion from battery DC voltage into the mean volt age by the chopper Need of brush and commu tator maintenance Complicated structure Relatively easy by mean DC voltage control Need of contactor for rotat ing direction c...

Page 11: ...ng working hours P mode Operation hour preference mode featuring the longest operation hours with the performance equivalent to that of previous models S mode To satisfy individual customer requirements a power control select function is provided for setting the traveling mode by selection from six modes including H P and S The operation efficiency is greatly improved by selection of the optimum p...

Page 12: ... 0 12 5 12 5 30 UP 14 0 11 5 FL15 0 H mode P mode S mode 5FBE15 H mode P mode S mode 5FBE15 H mode P mode S mode 5FBE15 STILL R20 H mode P mode S mode 5FBE15 STILL mm sec NL610 540 480 480 600 420 260 FL430 NL No load FL Full load NL No load FL Full load 280 350 65 UP Cycle time TOYOTA 30m operation cycles sec cycle 85 11 UP 91 95 95 min 185 240 270 230 Operation time DIN 4PzS 440L TOYOTA 30m oper...

Page 13: ...y adoption of the power keep function and extension of the operation hours The number of operation cycles without feeling performance degradation is also improved by 40 This new function actually improves the operation efficiency at each customer greatly However note that efficient operation becomes hard when the battery level indicated by the battery charge indicator becomes one bar battery disch...

Page 14: ...e motor brush replacement 5 Drive contactor replacement in controller Since the AC motor has no brush and contactor as explained earlier brush replacements are unnecessary Depending on the operating conditions at each customer the annual maintenance cost can be reduced as much as 80 The newly adopted acceleration off regeneration system regenerates the electrical braking energy upon accelerator pe...

Page 15: ... the same DIN size batteries for the STILL R20 on all series models Safety control Functional outline Mast con trol Active mast front tilt angle control Decreases the front tilt angle at a high fork height or under a heavy load and increases it at a low fork height or under a low load Active mast backward tilt speed control Retards the backward tilting speed at a high fork height and increases it ...

Page 16: ...All models Contactor type All models Traveling sys tem Steering system Steering synchro nizer EHPS system All models FHPS system All models Parking brake lever Parking brake lever ratchet type All models Parking brake lever ratchet type All models Tires Front tire 18 7 8 1 5 to 1 8 ton 18 7 8 14PR 1 5 ton 200 50 10 2 0 ton 18 7 8 16PR 1 8 ton Rear tire 15 4 1 2 8 dual 1 5 to 1 8 ton 16 6 8 10PR du...

Page 17: ...1 10 ...

Page 18: ...2 1 ELECTRICAL SYSTEM Page BATTERY 2 2 MOTORS 2 4 MAIN CONTROLLER 2 10 2 3 2 ...

Page 19: ... shown in the table below Vehicle model Compartment dimensions mm in Minimum required battery weight with case Kg lb Remarks Length X Width Y Height Z STD 7FBEF15 630 24 8 830 32 7 627 24 7 830 1830 7FBEF16 to 20 738 29 1 985 2172 R O 7FBEF15 630 24 8 830 1830 7FBEF16 to 20 738 29 1 985 2172 R O Battery roll out specifications Width Y Height Z Length X ...

Page 20: ...IN 43 531A Vehicle models Voltage Installed battery Battery case Supplier Model Capacity AH 5HR Dimensions mm in length width height 7FBEF15 48 VARTA 5PzS550L 550 630 24 8 830 32 7 627 24 7 5PzS600Hx 600 OLDHAM 24CYQ5 500 24CYH5 550 CHLORIDE 5PzS500 500 627 24 7 5PzS550H 550 7FBEF16 to 20 48 VARTA 6PzS660L 660 738 29 1 830 32 7 627 24 7 6PzS720Hx 720 OLDHAM 24CYQ6 600 24CYH6 660 CHLORIDE 6PzS600 6...

Page 21: ...and power keep A motor temperature sensor is adopted to ensure stabilized output and to prevent burning due to overloaded use Caution Depending on the use at each customer continuous heavy load operation for example the vehicle performance may temporarily be dropped to protect the controller and motor from overheating This is due to restriction of the current to the motor as a result of specified ...

Page 22: ...cy For new models a new AC induction motor best suitable for forklift trucks has been developed and adopted The rotor consists of the core made up of piled thin electromagnetic steel plates through the grooves in which aluminum conductor bars pass Both ends of conductor bars are shorted by end rings on both sides of the core as illustrated in b below When the bars and end rings are taken off the s...

Page 23: ...illustrated direction when the magnetic field is generated as illustrated an emf current is generated in the illustrated direction 3 Fleming s left hand rule Place a linear substance in freely movable state on a fixed material as shown at right If a current flows in the fixed material when the magnetic field is generated as illustrated a force is applied to the linear substance in the illustrated ...

Page 24: ...que is generated by the electromagnetic force as explained above The rotating speed of the rotor is slightly less than that of the filed poles 6 Actually the outer field winding does not move The sine wave of each phase of the three phase alternate current generates a rotational magnetic field to generate a rotating torque of the rotor Rotational direction magnetic of pole Rotational direction mag...

Page 25: ...ree pairs are placed on the outer side of the rotor When the six coils a1a1 a2a2 b1b1 b2 b2 and c1c1 c2c2 are connected in three phases to receive a three phase alternate current the magnetic flux varies as shown in the figure below to generate a four pole rotational magnetic field In this case the rotational magnetic field makes a 1 2 turn in one cycle of the three phase AC In a motor with three ...

Page 26: ... output is increased by making use of the induction motor to improve the performance both in loaded and unloaded states 3 The motor is maintenance free because of no brush Specifications Vehicle model Voltage V Rated output kW 5 min rating Type Size Diameter Length mm in Mass kg lb 7FBEF15 to 20 48 9 2 3 phase AC φ180 7 1 290 11 4 31 68 Diameter Field core Length Rotor Field winding Rpm sensor bea...

Page 27: ...rmined by the controller output voltage itself The characteristic of the motor itself when the battery voltage is applied chopper duty 100 is the maximum output The performance therefore drops as the battery voltage decreases On the other hand the AC motor drive system maintains the performance by changing the AC current and frequency combination according to the battery discharge level The power ...

Page 28: ...driver Drive motor thermo sensor Drive rpm sensor Drive motor thermo sensor Drive motor rpm sensor Direction switch Traveling accelerator potentiometer Brake switch Tire angle sensor Material handling switch Solenoid valve Display Pump motor thermo sensor Pump motor rpm sensor Battery Material handling AC driver Main controller Traveling material handling controller ...

Page 29: ... and error codes I O Input Output Input output interface CANI O Controller Area Network Input Output interface CAN input output interface Sensors and switches Display Main controller I O I Cooling fan Power supply contactor Battery Traveling AC driver Traveling AC driver Material handling AC driver Lift solenoid valve Tilt solenoid valve Steering synchronizer solenoid valve O CPU RAM ROM EEPROM CA...

Page 30: ...han H P and S are possible by operation on the multi screen display 8 Auto off function If the vehicle is left with the key switch kept at the ON position the controller forcibly turn the key switch off for power saving To use the vehicle again turn the key switch to OFF and ON 9 Deadman Switch Function Traveling is disabled while the operator is not on the seat 10 Anti rollback function The anti ...

Page 31: ...pedal is depressed traveling is disabled unless the direction lever and accelerator pedal are returned to their neutral positions 18 Parking brake ON alarm An alarm tone sounds when traveling is attempted without releasing the parking brake 19 Parking Brake OFF Warning Warning alarm sounds if the operator leaves the seat without applying the parking brake ...

Page 32: ...3 1 POWER TRAIN Page DRIVE UNIT 3 2 2 3 3 ...

Page 33: ...he 2 axis 2 stage reduction mechanism with semi built in traveling motors has reduced the drive unit size 3 Hypoid gear oil API GL 4 SAE 75W 85W is adopted as the common lubricant for all models same as for previous models Structure Gears First stage reduction adopts the helical gear featuring high transmission efficiency Second stage reduction adopts the planetary gear featuring high space effici...

Page 34: ...4 1 TRAVELING STEERING AND BRAKE SYSTEMS Page ACCELERATOR 4 2 REAR AXLE 4 3 TIRES 4 4 STEERING 4 6 BRAKE 4 10 2 3 4 ...

Page 35: ...The pedal effort is decreased from 1 5 kg to 0 7 kg by revising the accelerator structure D2 pedal option The accelerator pedal and the direction switch are integrated This pedal allows quick smooth control of the vehicle speed and changeover between forward and reverse traveling directions The traveling direction can be changed without freeing one hand from the steering wheel ...

Page 36: ...4 3 REAR AXLE General Double tires are installed as the standard feature for rear wheels of all vehicle models for longer tire life 2 3 4 ...

Page 37: ...hen color tires are adopted install tire bands because static electricity is likely to be generated in the vehicle by the use on resin coated floor or roads with high friction Front tire Vehicle model Type Tire size Rim size Tire pressure kPa kgf cm2 psi 7FBEF15 PSC 18 7 8 4 33 SOLID 4 33R 8 7FBEF16 PSC 18 7 8 4 33 SOLID 4 33R 8 7FBEF18 PSC 18 7 8 4 33 SOLID 4 33R 8 7FBEF20 PSC 200 50 10 6 50 SOLI...

Page 38: ...nonmarking white FR U LUG Tire 18 7 8 4 33 Sidering 4 33R 8 F01K F01K F01K WATTS FR U LUG Tire 200 50 10 6 50 Sidering 6 50F 10 F01K WATTS Tire name Model Tire brand Tire specification Tire size Wheel specification Wheel size 7FBEF15 7FBEF16 7FBEF18 7FBEF20 Pneumatic shaped cushion RR U LUG Tire 15 4 1 2 8 3 00 Sidering 3 00D 8 STD STD STD WATTS RR U LUG Tire 16 6 8 4 33 Sidering 4 33R 8 STD WATTS...

Page 39: ...the previous models has used an exclusive motor pump to supply hydraulic oil to the power steering system On the new models the hydraulic oil from the oil pump is shunted by the priority valve to supply hydraulic oil at an appropriate pressure to each power system Solenoid valve Priority valve Oil control valve Steering valve Oil pump Oil tank Rear axle Rear axle cylinder ...

Page 40: ...eering operation is performed Hydraulic oil flows from the pump through the spool to PP and LS pilot line As the CF line in the steering valve is shut and the pilot line is drained internal pressure of CF goes through inside the spool to PP and to the LH chamber pushing the spool to the right side of the figure Spool Control spring P Oil pump ...

Page 41: ...pens the CF line The lower side pressure of the control orifice goes through the LS pilot line to the RH chamber generating the pressure difference with the LH chamber in which the pressure is equal to that of the upper control orifice The pressure difference differs depending on the opening of the control orifice steering speed The spool is operated by this pressure difference to divide some pres...

Page 42: ...ring wheel General 1 The steering wheel outside diameter is changed from 380 mm 15 0 in to 360 mm 14 2 in for easier operation 2 Tilt steering with memory is adopted 3 Since the steering tilt angle is memorized when the steering column is raised and returned to the original position no re setting is necessary 4 The steering wheel adjustable angle is widened from 6 on the previous models to 9 Previ...

Page 43: ... pendant pedal link structure is adopted as on the previous models The regenerative brake The regenerative brake sensor use a limit switch not only to improve the sensor system reliability but also to facilitate maintenance when readjustment of the regenerative brake becomes necessary Sensor for regenerative brake Brake pedal ...

Page 44: ...specifocations Type Foot brake Mechanical disc brake Parking brake Mechanical disc brake Brake disc outside diameter mm in 203 8 0 Brake effective diameter mm in 165 6 5 Brake pad Material Semi metallic phenol resin Dimension mm in Outside diameter R100 3 94 Inside diameter R65 2 56 Thickness 6 0 24 Area mm2 in2 3528 5 47 2 2 Brake ASSY Brake disc Motor Drive unit ...

Page 45: ...h a wire cable Operation method 1 Grip the knob and pull the lever from position A to position B to apply the parking brake 2 For releasing throw the lever from position B to position A while pressing the release button in the illustration Lever operating force The figure above is maximized at the position when the lever is pulled about 35 from position A above Previous model New model Position A ...

Page 46: ...5 1 INSTRUMENTS Page MULTIPLE DISPLAY 5 2 GENERAL FUNCTIONS 5 10 DIAGNOSIS 5 15 MASK FUNCTIONS 5 21 2 3 5 ...

Page 47: ... 7 Multiple display area 3 Diagnosis ON indicator 8 2 speed travel speed control 4 Overheat warning indicator 9 Hour meter selector button 5 Battery charge indicator 10 Power select button 3 0 9 A M 1 1 00 S P H S P H MENU 0 1 1 1 0 0 K m h S P H S P H MENU S P H S P H MENU A 1 1 A 1 2 A 1 3 h O 1 2 3 4 5 During traveling Upon error occurrence 7 6 10 5 1 2 3 4 8 9 S P H S P H MENU O T Y O T A Init...

Page 48: ...warning indicator If the temperature of the main controller traveling AC driver material handling AC driver drive motor or pump motor rises beyond the specified level the overheat warning indicator blinks At the same time a buzzer sounds to warn the operator When the indicator is blinking vehicle operation is restricted and the overheat section indication blinks Display Information Vehicle Operati...

Page 49: ...dication and indicator blink 2 Buzzer continues 3 Change to half throttle S Pump motor STD H 1 Character indication and indicator blink 2 Buzzer continues 3 Restrict material handling output P S Fisherman spec OPT H 1 Character indication and indicator blink 2 Buzzer for 5 seconds 3 Change to P mode 1 Character indication and indicator blink 2 No buzzer 3 Change to S mode 1 Character indication an...

Page 50: ...y pressing the power select button on the GENERAL screen If all symbols are enclosed control is performed in the original mode level set on the POWER CONTROL LEVEL SETTING screen 7 Multiple display area The date and time are normally displayed in this area This area is also used for various function settings and error code displays of the diagnosis function 8 2 speed travel speed control Press thi...

Page 51: ...set by option setting of mask function Speedometer can not be displayed when wheel indicator is set to be displayed Specifications O L D A M 1 1 00 S P H S P H MENU C C D R Low temperature section Display information Low temperature section Traveling AC driver Material handling AC driver COLD DCR COLD PCR A M 1 1 0 0 S P H S P H MENU 3 0 9 Wheel indicator A M 1 1 0 0 3 0 9 In straight traveling st...

Page 52: ...lever neutral position ATT1 Matching of the ATT1 lever neutral position ATT2 Matching of the ATT2 lever neutral position Matching of the tilt forward restricted angle Matching of the tilt level angle Setting the battery type Setting the specification of 2 way mini lever models Setting the specification of 4 way mini lever models Setting the wheel indicator indication 36V 2 WAY VALVE 4 WAY VALVE US...

Page 53: ...BP Material handling AC driver control board surface temperature KSOL Steering synchronizer solenoid TD Drive motor temperature LOAD Material handling hydraulic pressure TEMP CPU board surface temperature L Lift switch THCD Main drive circuit temperature LSB Brake switch THCP Main pump circuit temperature LSD Seat switch TILTF Forward tilt restriction position MH Lifting height switch TILTL Tilt l...

Page 54: ...ing brake ON indicator Power select indicator Wheel indicator Level setting function Power select Traveling power control level setting Material handling power control level setting 2 speed travel speed level setting Multi hour meter function Key ON hour meter Traveling hour meter Material handling hour meter Traveling or Material handling hour meter Odometer Lap time meter Trip meter Calendar clo...

Page 55: ...1 K m h S P E E D A L A R M P O WE R S E L E C T 3 0 9 S P H S P H MENU S P E E D 1 5 8 L E V E L S P H S P H MENU Press button 3 for 2 seconds or more Button 3 Button 1 Press button 3 Press button 3 Press button 3 Press button 3 To GENERAL screen GENERAL screen 2 SPEED TRAVEL SPEED LEVEL SETTING screen OVERSPEED ALARM SETTING screen OPT POWER CONTROL FUNCTION SELECTION screen CLOCK SET FUNCTION S...

Page 56: ... standard Press button 2 S P H S P H MENU T R I P S W 2 0 5 3 4 2 1 G Trip meter S P H S P H MENU L A P R E S E T S W S E C 2 0 5 3 4 2 1 F Lap time meter S P H S P H MENU O D O 0 0 0 0 h D Traveling or material handling hour meter E Odometer B Traveling hour meter C Material handling hour meter S P H S P H MENU 0 0 h 0 0 h A M 1 1 00 S P H S P H MENU 3 0 9 GENERAL screen A Key ON hour meter S P H...

Page 57: ...ED TRAVEL SPEED LEVEL SETTING screen to display the OVERSPEED ALARM SETTING screen 1 Press button 1 to decrease the traveling speed setting 2 Press button 2 to increase the traveling speed setting 3 Press button 3 to display the next screen Model Easy model All round model Description Function A Key ON hour meter Indicates the total key ON time B Traveling hour meter Traveling operation time C Mat...

Page 58: ...2 MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen 1 Press button 1 to select the lower level 2 Press button 1 to select the higher level 3 Press button 3 to display the next screen 2 To display the next screen press button 2 on the POWER CONTROL FUNCTION SELECTION screen select NO and press button 3 alternatively press button 3 on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING screen S P H...

Page 59: ... selected blinking value 2 Press button 2 to increase the selected blinking value 3 Press button 3 to enter the selected blinking value and proceed to the next item 4 Press button 3 when MINUTES is selected on the CLOCK SET FUNCTION SELECTION screen to display the next screen GENERAL screen 2 Press button 3 when NO is selected on the CLOCK SET FUNCTION SELECTION screen to display the next screen G...

Page 60: ...on on vehicle Detection controller DCR Low temperature Display only DCR_LH DCR_RH PCR Low temperature Restricted material handling output PCR 30 1 30 1 DCR_LH Low voltage Traveling disabled DCR_LH 30 2 30 2 DCR_RH Low voltage DCR_RH 30 3 30 3 PCR Low voltage Material handling and power steering stop PCR 31 1 31 1 DCR_LH Low starting voltage Traveling disabled DCR_LH 31 2 31 2 DCR_RH Low starting v...

Page 61: ...angle sensor Short circuit 72 1 72 1 Steering angle sensor STS1 abnormality No steering knob syn chronizer C R 72 2 72 2 Steering angle sensor STS2 abnormality 72 3 72 3 Steering angle sensor STSC abnormality 72 4 72 4 Steering angle sensor Open 73 1 73 1 Steering knob synchronizer solenoid Open Steering knob synchro nizer solenoid output stop C R 73 2 73 2 Steering knob synchronizer solenoid Shor...

Page 62: ...ormality Restricted material han dling output PCR AC AC Semiconductor switch abnormality Traveling disabled Material handling and power steering disabled MB not turned on C R AD 1 AD 1 Communication abnormality from DCR_L to C R 1 Traveling disabled C R AD 2 AD 2 Communication abnormality from DCR_L to C R 2 Traveling disabled when AD 4 and AD 6 occur at the same time MB not turned on C R AD 3 AD ...

Page 63: ...4 Accelerator potentiometer abnormality 4 Display only C7 C7 Direction switch abnormality Traveling disabled C R C8 1 C8 1 Drive motor 1 rpm sensor abnormality Restricted traveling out put DCR_LH C8 2 C8 2 Drive motor 2 rpm sensor abnormality DCR_RH CB 1 CB 1 MB contactor abnormality Traveling disabled Material handling and power steering disabled solenoid off C R CB 2 CB 2 MB contactor fused Disp...

Page 64: ...eter matching abnormality H3 1 1 H3 1 Attachment 1 potentiometer abnormality 1 Attachment 1 operation stop C R H3 2 1 H3 2 Attachment 1 potentiometer abnormality 2 H3 3 1 H3 3 Attachment 1 potentiometer abnormality 3 H3 4 1 H3 4 Attachment 1 potentiometer neutral abnor mality H3 5 1 H3 5 Attachment 1 potentiometer matching abnormality H4 1 1 H4 1 Attachment 2 potentiometer abnormality 1 Attachment...

Page 65: ...t 1 operation stop H7 4 1 H7 4 Attachment 1 b3 solenoid abnormality 2 Material handling dis abled H7 5 1 H7 5 Attachment 1 solenoid drive circuit abnor mality Material handling dis abled H8 1 1 H8 1 Attachment 2 a4 solenoid abnormality 1 Attachment 2 operation stop C R H8 2 1 H8 2 Attachment 2 a4 solenoid abnormality 2 Material handling dis abled H8 3 1 H8 3 Attachment 2 b4 solenoid abnormality 1 ...

Page 66: ...ntrol board Function Description When used Vehicle delivery Board replace ment Others Analyzer Displays the vehicle s electrical system operating status and reads the error information detected by controllers Upon vehicle abnormality detection Tuning Makes fine adjustment of traveling and material handling functions 2 As requested by customer Option set Specification setting Sets each vehicle opti...

Page 67: ...up the vehicle until the drive wheels front tires leave the ground and support the vehicle with wooden blocks under the front frames Be sure to fully lower the fork 1 Check that the battery plug is connected securely and turn the key switch to ON 2 Operate mask functions according to Password Input Procedure See page 5 23 ...

Page 68: ... short beep sounds 4 Press buttons 2 and 3 at the same time and hold for 2 seconds or more in 10 seconds after pressing button 2 End of password input A short beep sounds 5 The VERSION screen is displayed automatically 6 After displaying the VERSION screen for 3 seconds the MASK MENU screen appears auto matically A M 1 1 00 S P H S P H MENU 9 3 0 1 Press buttons 1 and 2 at the same time A M 1 1 00...

Page 69: ... voltage stored in the controller output voltage values from the SAS function and mini lever function sensors in the standard vehicle condition 5 WHEEL DIA screen Updates the tire information in the controller to correct the speed and trip meter display 6 END screen GENERAL screen can displayed from this screen Press button 3 on this screen to display the GENERAL screen As an alternative method tu...

Page 70: ...TOR This function displays the analog input values from individual sensors in the traveling material handling EHPS and SAS systems The circuit or sensor quality can be judged by monitoring the displayed value a I O MONITOR1 Displays the temperature of each electrical functional part and the analog input voltage detected by each controller b I O MONITOR2 Displays the ON OFF states of traveling rela...

Page 71: ...terial handling AC driver board tempera ture C I O 1 7 TEMP 25 0 CPU board temperature C I O 1 8 VB48 50 0 Battery voltage V I O 1 9 VBKS 50 0 Key start voltage V I O 1 10 VBSOL 50 Solenoid voltage V I O 1 11 VBMB 50 Voltage after MB contactor V I O 1 12 VBBD 50 50 Traveling AC driver 1 DC_BUS voltage V Traveling AC driver 2 DC_BUS voltage V I O 1 13 VBBP 50 Material handling AC driver DC_BUS volt...

Page 72: ...0 90 3 50 01 Attachment 1 lever angle 1 sensor voltage V Attachment 1 lever angle 2 sensor voltage V Attachment 1 raise switch 0 OFF 1 ON Attachment 1 lower switch 0 OFF 1 ON I O 3 6 A1 SOL Unused 2 A1 SOL 0 35 Attachment 1 proportional valve current A I O 3 7 A2 Unused 3 A2 0 90 3 50 01 Attachment 2 lever angle 1 sensor voltage V Attachment 2 lever angle 2 sensor voltage V Attachment 2 raise swit...

Page 73: ...n of steering angle knob position Steering knob synchronizer solenoid 0 OFF 1 ON I O 4 4 TIRE 2 40 Tire angle sensor voltage V 6 ACTIVE TEST operation test ACT 1 FAN ON OFF 48 Fan output Fan voltage V ACT 2 KSOL ON OFF 0 Steering knob synchronizer solenoid output Steering knob synchronizer solenoid check signal 0 normal 1 error ACT 3 PSOL Unused 1 PSOL ON OFF 0 Unload valve output Unload valve che...

Page 74: ...1 or 2 to switch screen Press button 1 or 2 to switch screen Press button 1 or 2 to switch screen Press button 1 or 2 to switch screen S P H S P H MENU 1 A N A L Y Z E R M E N U MASK MENU screen S P H S P H MENU A N L M E N U 1 D I A G M E M O R Y 1 DIAG MEMORYscreen S P H S P H MENU A N L M E N U 2 I O M N O I T O R 1 2 I O MONITORI screen S P H S P H MENU A N L M E N U I O M N O I T O R 2 3 3 I ...

Page 75: ...Button 3 Displays past diagnosis codes Press button 3 on the DIAG 10 screen to display the ANALYZER MENU screen When no error codes are displayed on the screen and the hour meter time is 0 0h it indicates that no error codes are stored in the memory Other screen cannot be displayed from DIAG MEMORY screen Display ANALYZER MENU screen to display other screen For the details of diagnosis error codes...

Page 76: ...ile traveling is disabled Indication Battery charge indica tor blinks Beep Short beeps 4 Return to neutral warning Warns if the key switch is turned to ON when the direction switch is in the forward or reverse posi tion Beep Short beeps No display 5 Material handling lock OPT When the operator leaves the seat while operat ing the mini lever and then sits down again a buzzer sounds to warn the oper...

Page 77: ... O 1 13 screen to display the ANALYZER MENU screen Other screen cannot be displayed from I O MONITOR1 screen Display ANALYZER MENU screen to display other screen 1 I O 1 1 screen THCD Main drive circuit 1 2 temperature C Temperatures of the main drive circuit element 1 2 are displayed Checks if the temperature measurement function is functioning properly The temperatures at the time of measurement...

Page 78: ...urface temperature of the material handling AC driver board is displayed Checks if the temperature measurement function is functioning properly The temperatures at the time of measurement are displayed 7 I O 1 7 screen TEMP CPU board temperature C The surface temperature of the main controller CPU board is displayed Checks if the temperature measurement function is functioning properly The tempera...

Page 79: ... 2 voltage V Voltages of the main drive motor circuit 1 2 are displayed Standard 48 V 13 I O 1 13 screen VBBP Main pump motor circuit voltage V Voltage of the main pump motor circuit is displayed Standard 48 V S P H S P H MENU I O 1 9 V B K S 5 0 0 9 I O 1 9 screen S P H S P H MENU I O 1 0 1 V B S O L 5 0 10 I O 1 10 screen I O 1 8 screen S P H S P H MENU I O 1 1 1 V B M B 5 0 11 I O 1 11 screen S...

Page 80: ...ENU screen Other screen cannot be displayed from I O MONITOR2 screen Display ANALYZER MENU screen to display other screen 1 I O 2 1 screen POTA Accelerator potentiometer voltage V A When the accelerator pedal is released SWAC OFF Standard 0 3 to 2 4 V B Standard voltage when the accelerator pedal is depressed to its stroke end Standard 1 7 to 4 7 V B A 1 4 V or above SWAC Accelerator switch When t...

Page 81: ...ect the rpm sensor while the vehicle is traveling The rpm of the drive motor increases according to the speed increase 6 I O 2 6 screen SPD Traveling speed km h Check the traveling speed while the vehicle is jacked up Gradually depress the accelerator pedal Check that the traveling speed increase is almost at the same rate of the depression of the accelerator pedal to judge the quality Operation I...

Page 82: ... neutral or DOWN position L 0 OFF Operate the lift lever to judge ON OFF quality Mini lever models OPT L Lift lever angle 1 sensor voltage V Lift lever angle 2 sensor voltage V Lift raise switch 0 OFF 1 ON Lift lower switch 0 OFF 1 ON Judge the raise and lower input quality by lift lever operation 2 I O 3 2 screen Standard models L SOL Unused Mini lever models OPT L SOL Lift proportional valve sol...

Page 83: ...ttachment 1 lever angle 2 sensor voltage V Attachment 1 raise switch 0 OFF 1 ON Attachment 1 lower switch 0 OFF 1 ON Judge the input quality by attachment 1 lever operation Operation Display Forward tilt switch Backward tilt switch Forward tilt T 10 1 ON 0 OFF Neutral T 00 0 OFF 0 OFF Backward tilt T 01 0 OFF 1 ON Tilt lever angle 1 sensor voltage Tilt lever angle 2 sensor voltage Forward tilt 1 1...

Page 84: ...A2 SOL Attachment 2 proportional valve solenoid current A Judge the output quality to attachment 2 proportional valve solenoid by attachment 2 lever operation Standard 0 3 to 0 85 A Lever operated Attachment 2 lever angle 2 sensor voltage Attachment 2 lever angle 2 sensor voltage Raising 1 1 to 2 3 V 2 2 to 3 5 V Lowering 0 4 to 1 6 V 2 9 to 4 2 V S P H MENU S P H MENU S P H MENU S P H MENU S P H ...

Page 85: ...st forward from the vertical position Input voltage decrease When operating the mast backward from the vertical position Input voltage increase 13 I O 3 13 screen SPL Load sensor voltage V MPa display Check the input voltage of load sensor controller Standard without load Approx 0 8 V Input voltage increases according to the load increase Lifting height Indication MH1 switch MH2 1 switch Low lifti...

Page 86: ...screens sequentially Press button 3 on the I O 4 4 screen to display the ANALYZER MENU screen Other screen cannot be displayed from I O MONITOR4 screen Display ANALYZER MENU screen to display other screen 1 I O 4 1 screen STS Steering angle sensor inspection 0 OFF 1 ON Turning the steering wheel one round will turn STS1 and STS2 ON OFF and then ON STSC turns on only when the steering wheel is in t...

Page 87: ...ce between target and actual values at I O 4 2 SOL Steering synchronizer solenoid 0 OFF 1 ON Operate the steering wheel to check that the steering synchronizer solenoid turns on when there is deviation of steering angle knob position 4 I O 4 4 screen TIRE Tire angle sensor voltage V Operate the steering wheel to check the variation in voltage Standard at tire straight travel position Approx 2 40 V...

Page 88: ...ther screen 1 ACT 1 screen FAN Fan Fan voltage V Forcibly output the ON OFF signal to check the fan operation and display visually v Press button 1 to select ON Fan rotates and fan voltage is displayed Press button 2 to select OFF Fan stops rotating and fan voltage is displayed Note Be sure to open the battery hood and remove the side cover to check the fan operation 2 ACT 2 screen KSOL Steering k...

Page 89: ...sible If the unload valve stays off material handling operation is disabled Turn the key switch to OFF and operate the material handling lever If the unload valve turns off normally material handling operation is disabled If the unload valve stays on material handling operation is possible S P H MENU S P H MENU 3 ACT 3 screen Press button 3 ANALYZER MENU screen ACT 2 screen S P H A C T 3 P S O L O...

Page 90: ...Auto off function activation time Sets the time for activating auto off function Attachment power control No 1 Changes the pump motor output for when attachment switch No 1 is ON Traveling speed limiter Adjust the maximum traveling speed Battery charge indicator correction Corrects decreasing rate of battery charge indicator Battery warning setting level Changes the activation timings of low remai...

Page 91: ...g lift raising operation Slow Fast 27 Lift raising adjustment 3 Adjusts the maximum solenoid output current during lift raising operation Small Large 28 Lift raising adjustment 4 Adjusts acceleration during lift raising operation Weak Strong 29 Lift raising adjustment 5 Adjusts deceleration during lift raising operation Weak Strong 30 Forward tilt adjustment 1 Adjusts solenoid output current at th...

Page 92: ...g adjustment 4 Adjusts acceleration during lowering operation of attachment 1 Small Large 44 Attachment 1 lowering adjustment 5 Adjusts deceleration during lowering operation of attachment 1 Weak Strong 45 Attachment 1 raising adjustment 1 Adjusts solenoid output current at the beginning of raising operation of attachment 1 Weak Strong 46 Attachment 1 raising adjustment 2 Adjusts inching speed dur...

Page 93: ...ng adjustment 1 Adjusts solenoid output current at the beginning of raising operation of attachment 2 Weak Strong Small Large 56 Attachment 2 raising adjustment 2 Adjusts inching speed during raising operation of attachment 2 Weak Strong 57 Attachment 2 raising adjustment 3 Adjusts the maximum solenoid output current during raising operation of attachment 2 Small Large 58 Attachment 2 raising adju...

Page 94: ...2 TUNING2 LIFTV to 5 TUNING5 ATT2V tuning No 20 to 59 are not used on the standard models They are only used on the mini lever models OPT S P H S P H MENU M E N U 2 T U N I N G S P H S P H MENU T U N M E N U 1 T U N I N G 1 S P H S P H MENU T U N M E N U 2 T U N I N G 2 L I F T V S P H S P H MENU T U N M E N U 3 T U N I N G 3 T I L T V S P H S P H MENU T U N M E N U 6 E N D S P H S P H MENU T U N ...

Page 95: ...nnot be displayed from each level setting screen of TUNING1 Display TUNING MENU screen to display other screen Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels TUNING No 3 The default is level 7 Press button 3 Press button 3 Press button 3 S P H T U N M E N U 1 T U N I N G 1 S P H T U N 1 5 8 N O 1 S P H T U N 1 5 8 N O 2 S P H T U N 1 5 8 N O 1 2 Press button 3 Button 3 B...

Page 96: ...uning level down Button 2 Tuning level up Button 3 Enter to the next item screen Press button 3 on the TUNING No 29 setting screen to display the TUNING MENU screen Other screen cannot be displayed from each level setting screen of TUNING2 LIFTV Display TUNING MENU screen to display other screen S P H MENU S P H MENU S P H MENU S P H MENU Press button 3 Press button 3 Press button 3 Press button 3...

Page 97: ...uning level down Button 2 Tuning level up Button 3 Enter to the next item screen Press button 3 on the TUNING No 39 setting screen to display the TUNING MENU screen Other screen cannot be displayed from each level setting screen of TUNING3 TILTV Display TUNING MENU screen to display other screen S P H MENU S P H MENU S P H MENU S P H MENU Press button 3 Press button 3 Press button 3 Press button 3...

Page 98: ... 1 Tuning level down Button 2 Tuning level up Button 3 Enter to the next item screen Press button 3 on the TUNING No 49 setting screen to display the TUNING MENU screen Other screen cannot be displayed from each level setting screen of TUNING4 ATT1V Display TUNING MENU screen to display other screen S P H MENU S P H MENU S P H MENU S P H MENU Press button 3 Press button 3 Press button 3 Press butt...

Page 99: ... 1 Tuning level down Button 2 Tuning level up Button 3 Enter to the next item screen Press button 3 on the TUNING No 59 setting screen to display the TUNING MENU screen Other screen cannot be displayed from each level setting screen of TUNING5 ATT2V Display TUNING MENU screen to display other screen S P H MENU S P H MENU S P H MENU S P H MENU Press button 3 Press button 3 Press button 3 Press butt...

Page 100: ...ERY Adjust the charge indicator calculation constant A Feature A B Feature B OPT 9 Not used OPT 10 SEAT P OFF Enables disables operation of the auto power off function in relation to the seat switch Y Enable N Disable OPT 11 PARKING ERR Enables disables parking brake OFF warning Y Enable N Disable OPT 12 TILT CONT Enables disables the active mast front tilt angle limit Y Enable N Disable OPT 13 No...

Page 101: ...screen 2 Press button 2 twice to display 3 OPTION SET and press button 3 enter to display the OPTION SET MENU screen 3 Press button 3 to display the desired option item to be set on the screen 4 Functions of buttons on the OPTION SET screen are as follows Button 1 N Y Button 2 Y N Button 3 Enter to the next item screen Press button 3 on OPT 22 OPTION SET screen to display the MASK MENU screen A T ...

Page 102: ...L T F L I M P T 4 1 Y N S P H S P H MENU O K N O B C O N T P T 3 1 Y N S P H S P H MENU O T I L T C O N T P T 2 1 Y N S P H S P H MENU O P A R K I G N E R R P T 1 1 Y N S P H S P H MENU O S E A T O F F P P T 0 1 Y N P H S P H MENU O B A T T E Y R P T 8 A B S Press button 3 Press button 3 Press button 3 Press button 3 Press button 3 Press button 3 Press button 3 Press button 3 Press button 3 Press ...

Page 103: ...een Not used Not used Not used S P H S P H MENU O 2 WA Y V L V E A P T 7 1 Y N Press button 3 Press button 3 S P H S P H MENU O 4 W A Y V A L V E P T 8 1 Y N Press button 3 S P H S P H MENU O U S A P T 9 1 Y N Press button 3 Press button 3 S P H S P H MENU O S A S P T 2 1 Y N MASK MENU screen Press button 3 Press button 3 Button 3 Button 1 Button 2 ...

Page 104: ... 3 When the tilt angle sensor rod is replaced or its length is changed 4 When the load sensor is replaced 5 When the tire angle sensor and sensor cover is removed installed replaced 6 When an attachment is changed 7 When the mast is replaced 8 When the tilt cylinder is replaced 9 When the lift lever angle sensor is replaced 10 When the tilt lever angle sensor is replaced 11 When the attachment 1 l...

Page 105: ...hat the mast is in the vertical position by checking with an angle gauge Tilt the mast from backward tilt position to forward until it becomes vertical 4 Tire straight travel position check Signal voltage of the tire angle sensor in tire straight travel position is stored Tire straight travel position is the condition in which driving the vehicle 5 meters 16 ft with the steering wheel fixed causes...

Page 106: ...n S P H S P H MENU 4 M A T C H I N G M E N U S P H S P H MENU M A T C H I N G O K T I L T L 2 2 0 0 0 0 S P H S P H MENU M A T C H I N G O K T I L T F 2 2 0 0 0 0 S P H S P H MENU M A T C H I N G O K L O A D 0 0 7 7 0 0 S P H S P H MENU M A T C H I N G O K T I R E 2 2 4 4 0 0 S P H S P H MENU M A T C H I N G A T T 2 S P H S P H MENU M A T C H I N G A T T S P H S P H MENU M A T C H I N G T I L T S ...

Page 107: ...n 3 enter to display the tire constant setting screen 3 Press button 1 or 2 to set the desired tire constant and press button 3 enter to display the MASK MENU screen 4 Functions of buttons on the tire constant setting screen are as follows Button 1 Decreases the tire constant Button 2 Increases the tire constant Button 3 Enter and display MASK MENU screen Tire constant list S P H S P H MENU 5 W H ...

Page 108: ...6 1 FRAME AND AUXILIARY EQUIPMENT Page BODY FRAME 6 2 INSTRUMENT PANEL AND ADJACENT PORTION 6 8 AUXILIARY EQUIPMENT 6 10 FUSES 6 13 2 3 6 ...

Page 109: ... facilitates ingress egress 2 Elimination of side covers Side covers on previous vehicles are eliminated and replaced with structural members to strengthen the lower portion of the frame 1 Round type front stay 3 Cautions for jacking up 2 Side cover 4 Cautions for hoisting the vehicle 1 4 2 3 ...

Page 110: ...ce work when the vehicle is jacked up Always place wood blocks etc under the vehicle before starting the work For jacking up the rear side see the WEIGHT section 4 Cautions for hoisting the vehicle Hoist the front of the vehicle at the mast and the rear at the head guard similarly as for previous models Weight General 1 Compared with previous models each new model vehicle has a weight of novel des...

Page 111: ...e notch of the head guard to replace the battery from the right hand side of the vehicle Battery hood opening closing procedure Caution When opening closing the battery hood hold the handle on the right hand side of the hood 1 Set the mast in vertical position 2 Pull the lock release lever 3 Tilt the steering post forward 4 Open the battery hood 2 1 3 4 Lock release lever ...

Page 112: ...er stay is adopted as a standard part to reduce the hood opening closing force 2 When fully open the stay is automatically locked To close the hood release the lock with a finger Side hoods 1 Stamped side hoods are adopted to create a simple and clean product image 2 Simply open the battery hood only for daily inspection and battery fluid addition 3 For battery replacement the side hoods on both s...

Page 113: ...board 1 Toe board is divided into the front and rear sections 2 The front toe board is attached with the accelerator pedal and fixed onto the frame with bolts 3 The rear toe board allows one touch installation removal using a positioning pin 4 For hydraulic oil and other daily inspection simply remove the rear toe board H1 H2 H1 H2 Previous model 545 21 5 New model 430 16 9 545 21 5 mm in RR Toe b...

Page 114: ...o the upper body of the operator in case of unexpected rollover of the vehicle 2 Side wings with holes Restrain the operator in an emergency Assist grip function for ingress 3 Seatbelt installation as standard equipment ELR emergency lock retractor type 4 Reclining function Tilting range 5 each in the forward and backward directions 5 Dial type operator s weight adjustment mechanism Knob position ...

Page 115: ...trol lever for attachment optional 4 Turn signal SW 13 Brake pedal 5 Key SW 14 Accelerator pedal 6 Lamp SW 15 D2 pedal optional 7 Steering wheel 16 Tilt steering lock lever 8 Seat 17 Rear work light SW optional 9 Control lever for lifting 18 Tilt steering lock release lever 1 2 7 8 9 10 11 12 13 14 16 15 5 3 4 6 17 18 F N R Pattern of shift Center of steering Center of vehicle Layout of Pedal D2 P...

Page 116: ...alized with resin molding 2 The instrument panel consists of 2 halves using sturdy and environmentally friendly polypropylene as the material 3 The downsized instrument panel improves the ease of ingress egress RH Instrument panel LH Instrument panel ...

Page 117: ...5 series 2 Direction lever 1 The direction switch is of the lever type easily operable with fingers as on the 7FGF25 series 2 The direction switch is positioned on the left hand side as a standard component 3 Since the D2 pedal OPT has a built in switch no direction lever is provided F N R Fr N Rr Direction switch Neutral Forward Backward ...

Page 118: ... OPT Same as on the previous model 10W Clearance upper 25W Flasher lower 3 Rear combination light OPT High mount transverse rear combi nation lights are installed as stan dard components for improved visibility damage prevention and design 25W Flasher outer 25W 10W Stop tail center 25W Reverse RH only inside 4 Rear working light OPT The rear working light is of a large square type red pilot lamp p...

Page 119: ...ge light switch turns the side clearance lights and taillights ON and OFF in the first stage and the headlights side clearance lights and tail lights ON and OFF in the second stage OFF OFF T H R Turn signal switch W auto return function Light switch N L Neutral Light switch Turn signal switch Switch for rear working light OPT ...

Page 120: ...material handling are integrated as F1 fuse for traveling and material handling Name Applicable function and capacity Cautions for fuse replacement When replacing any fuse always be sure to disconnect the battery plugs and discharge overall capacitor by applying a resistance of approx 100Ω to between P3 and N2 7FBEF15 to 20 F1 For traveling material handling 500A F4 For lights 10A F5 For control c...

Page 121: ...6 14 ...

Page 122: ...AST 7 2 FV MAST 7 3 FSV MAST 7 4 MATERIAL HANDLING SPEED 7 5 LOAD BACKREST FORK 7 6 TILT CYLINDER 7 7 OIL PUMP 7 8 OIL TANK 7 9 OIL CONTROL VALVE 7 10 MATERIAL HANDLING LEVER 7 19 HYDRAULIC CIRCUIT 7 20 MAST INTERCHANGEABILITY 7 21 A4 PIPING 7 22 2 3 7 ...

Page 123: ...ged The size for the 2 0 t mast is the same BL634 as on the 7FBMF 20 and 25 models 4 Lift cylinder The lift cylinder for the 1 5 to 1 8 t masts is the same as that for the 7FBMF16 and 18 The lift cylinder for the 2 0 t mast is the same as that for the 7FBMF20 and 25 5 Lift cylinder piping The basic structure of the piping for the 1 5 to 1 8 t masts remains unchanged The safety down valve is of the...

Page 124: ...rly as on previous models 3 Chain Same as that for the V mast 4 Lift cylinder The lift cylinder remains unchanged from that for the 7FBMF16 and 18 5 Lift cylinder piping The basic lift cylinder piping is the same as that for previous models The same in line type safety down valve as that for the previous models is used except for an addition of the fitting for a pressure sensor 6 Lift roller Same ...

Page 125: ...t lift cylinder for the 1 5 to 1 8 t models remains unchanged from that for the 7FBMF16 and 18 The mast lift cylinder for the 7FBEF20 is the same as that for the 7FBMF20 25 5 Lift cylinder piping The basic piping structure remains unchanged for the 1 5 to 1 8 t models The flow regulator position has been changed to shorten the lost load center distance between the center of the front axle to the f...

Page 126: ...7FBEF16 Lift H 610 120 420 83 560 110 390 77 560 110 390 77 P 540 106 340 67 490 96 320 63 490 96 320 63 S 480 94 260 51 430 85 250 49 430 85 260 51 Lower ALL 550 108 500 98 450 89 480 94 420 83 480 94 7FBEF18 Lift H 610 120 390 77 560 110 380 75 560 110 380 75 P 540 106 320 63 490 96 310 61 490 96 310 61 S 480 94 250 49 430 85 240 47 430 85 240 47 Lower ALL 550 108 500 98 450 89 480 94 420 83 480...

Page 127: ... 3 The forkless option is provided for all masts as on the Previous models STD Standard Available as option Not available Outside width of load backrest mm in 970 42 1 1070 42 1 1220 48 0 1520 59 8 Forkbar width mm in 920 36 2 1020 40 2 1170 46 1 1470 57 9 Height of load backrest mm in 1220 48 0 STD Outside width of load backrest mm in 970 42 1 1070 42 1 1220 48 0 1520 59 8 Forkbar width mm in 920...

Page 128: ...t is changed to a welded rod type 3 The front pin for fixing the mast to the tilt cylinder is changed to an eccentric pin It allows fine adjustment of the backward tilt angle and uneven lifting 4 FR and RR installation points use clevis structure 5 The internal structure is the same as that for the 7FBMF25 series ...

Page 129: ...ced with a single gear pump for noise reduction 3 To improve the lifting speed the pump capacity has been increased Vehicle model 7FBEF15 to 20 Oil pump name Single gear pump Oil pump type TMG1A21A3H5 L Shimadzu Drive system Direct motor drive Delivery at a pumping rate of 1 500 rpm l US gal min 30 8 8 14 Theoretical delivery cm3 in3 rev 21 9 1 34 ...

Page 130: ...r is located under the front toe board Other hydraulic parts 1 Oil tank cap A rubber male female type cap is adopted A separate breather is adopted for downsizing Check the oil level by holding the cap end in contact with the retainer opening as illustrated 2 Breather To ensure prevention of oil leakage from the breather an off cap structure is adopted 40 µ mesh Breather Level gauge cap Return fil...

Page 131: ...ile the key is in the OFF position The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt Appearance The newly installed check valve for locking the lift circuit enables lowering when unlocked at key ON The tilt circuit locking check valve is unlocked to enable tilting only when the tilt lever is operated in the forward tilt direction with the key switc...

Page 132: ...series no solenoid valve is provided on the control valve side Lift circuit 1 During lifting lift solenoid valve ON 1 When the lift lever is operated in the lifting direction the lift spool moves to the left in the figure Then the pump pressure compresses the spring at the lift load check valve to open the valve 2 The pump pressure is led to the lift logic valve The pressure compresses the spring ...

Page 133: ...h ON will be as follows C1 pressure Logic valve upper side pressure Logic valve lower side pressure 3 Then operating the lift lever to the lowering side pushes the lift spool to the right in the figure and opens the circuit between the C1 and tank ports Since part A of the logic valve has an orifice the hydraulic oil between the lower side of the logic valve and the spool flows to the tank port Me...

Page 134: ...t pressure acts on the logic valve to move it downward in the figure because of the difference in area between a and b of logic valve part A The pressure opens the logic valve and the main circuit of the C1 port and the tank port to cause the fork to be lowered C1 a b Part A Logic valve upper side Check valve Solenoid valve Lift spool Logic valve Tank port Lift cylinder Pump port Lift load check v...

Page 135: ... to the tank port because of the check valve in the solenoid valve Thus no pressure difference is generated between the C1 port and the lower part of the logic valve Consequently the logic valve remains closed Since the C1 port and the tank port circuits are cut off the fork does not go down even when the lift lever is operated in the downward direction when the key switch is turned OFF C1 Lift sp...

Page 136: ...roximately the same rate as for normal lowering 4 When the lowering is completed tighten the bolt and the nut according to the instructions given in the repair manual 3 When the lift is manually lowered hydraulic oil in the lower part of the cylinder which is led to the lower side of the lift logic valve is also led to the needle valve on the emergency circuit When the lowering is manually operate...

Page 137: ... to the RH chamber of the tilt cylinder the pump pressure is applied to contract the tilt cylinder 4 On the other hand when the tilt spool moves to the left side in the figure the circuit connecting the C2 port and the tank port opens C2 port is jointed to the LH chamber of the tilt cylinder 5 The action in step 3 applies the pump pressure to the RH chamber of the tilt cylinder Consequently the hy...

Page 138: ...o the right side in the figure to open the check valve Then the hydraulic oil in the RH chamber of the tilt cylinder flows through the C3 port right side of the logic valve the solenoid valve the left side of the logic valve and the tilt spool to the tank port 4 Then part A of the logic valve forms an orifice Therefore the hydraulic oil is led from the right side of the logic valve to the spool an...

Page 139: ...e tilt lever to the forward tilting side when the key switch is turned OFF the tilt spool moves to the right in the figure The hydraulic oil at the C3 port is led to the right side of the tilt logic valve but it is cut off by the check valve in the solenoid valve ahead because the tilt solenoid valve is OFF Therefore no pressure difference is generated between the C3 port and the right side of the...

Page 140: ... To improve serviceability cotter pins are replaced with β pins for installing the control valve lever rods control levers and the control valve spool 2 Tilt knob switch is arranged on the knob of the tilt lever Automatic fork leveling switch pin Lift Tilt 3rd 4th ...

Page 141: ...ank is adopted to reduce contamination and the standard adoption of the return filter promotes protection of hydraulic devices 2 The return filter is arranged under the front toe board 3 The following figure shows the function of the hydraulic circuit ...

Page 142: ...geability within new model series Mast interchangeable between respective model groups Not available 2 Interchangeability with previous models No interchangeability 3 Interchangeability with 7FBMF25 series No interchangeability Vehicle model Mast type V FSV FV 7FBEF15 to 18 7FBEF20 ...

Page 143: ... and piping at the lift bracket are the same as on the 7FBMF25 series CTR center termination RH SIDE right hand side termination CTR LH SIDE center and left hand termination RH LH SIDE right hand and left hand side termination nonavailable Type of piping Oil control valve Piping number Mast 7FBEF15 to 18 7FBEF20 V FSV FV V FSV A405 Four valves 0 A410 Three valves 2 A430 Four valves 2 A450 Four val...

Page 144: ...8 1 SAS CONTROL SYSTEM Page SAS CONFIGURATION 8 2 MAST CONTROL 8 5 STEERING SYNCHRONIZER FHPS 8 8 2 3 8 ...

Page 145: ...Synchronizer with FHPS 1 Longitudinal stability is improved by adopting the mast forward tilt angle control 2 Mast backward tilt angle speed control is adopted to prevent load from falling 3 Automatic fork leveling control is adopted to improve operating efficiency 4 Key lift interlock is adopted Characteristics of turning and straight traveling is improved by developing FHPS FHPS Full Hydraulic P...

Page 146: ...sensor 2 Tilt angle sensor 9 Integral control valve 3 Forward tilt switch 10 LCD display diagnosis 4 Backward tilt switch 11 Steering angle sensor 5 Tilt knob switch 12 Steering synchronizing solenoid valve 6 Load sensor 13 Main controller 7 Traveling speed sensor 8 13 1 5 2 10 11 12 9 6 3 4 7 2 3 8 ...

Page 147: ... the motor revolution with a sensor provided to the drive motor 8 Tire angle sensor Detects the tire angle based on the center shaft turning angle with the sensor at the top of the rear axle center shaft 11 Steering angle sensor Detects the steering wheel position with the sensor provided under the steering wheel Name Functions 9 Integral control valve Two solenoids are provided to the integral co...

Page 148: ...uced by tilting the mast backward while keeping the tilt lever knob switch pressed 3 Automatic fork leveling control When operated for forward tilting with the tilt lever knob switch pressed the fork automatically stops in level position with the mast in vertical position This function is convenient for connecting disconnecting fork during cargo loading unloading 4 Key off lift lock The fork does ...

Page 149: ...er tilt the mast forward from the vertical position with the cargo raised same as previous model Or the longitudinal stability will be degraded to cause the hazard of falling even under allowable load Never use the forward tilt control for any work Backward tilting speed control 1 Controls delays backward tilting speed for high lifting irrespective of the load In addition controlled speed continue...

Page 150: ...control and the lift hydraulic circuit is modified accordingly 2 Lowering is disabled if the lever is operated for lowering when the key switch is turned OFF 3 Since the lift lock solenoid valve is provided to the lift hydraulic circuit the solenoid valve remains closed while the key switch is turned OFF preventing the lowering if the lift lever is operated for lowering To lower the fork turn the ...

Page 151: ...to return part of hydraulic oil to be supplied to the PS cylinder to the tank This system retains relation between the steering knob position and the tire angle at a prescribed level 3 Correction may not be made for safety reason depending on the traveling speed and other conditions 4 If the knob position should be offset after maintenance service etc the steering position will be automatically co...

Page 152: ...9 1 OUTLINE OF MAJOR OPTIONS Page FISHERMAN SPECIFICATION 9 2 MASTLESS 9 3 ATTACHMENT LIST 9 4 DRIVE IN RACK SPECIFICATION 9 8 MINI LEVERS 9 9 BATTERY ROLL OUT SPECIFICATION 9 23 2 3 9 ...

Page 153: ... pump motors the rate of operation should be kept at about 60 compared to standard vehicles Depending on the type of operation such as continuous heavily loaded operation the vehicle performances may be temporarily reduced for protecting the controllers and motors from overheating The motor current limiting function that is activated upon detection of the specified temperature by the sensor built ...

Page 154: ...ame No manufacturing year front tread tire size tire pressure voltage battery weight and rated load is riveted in the same position as on the standard model A spare nameplate punched with the model frame No manufacturing year voltage battery weight and rated load is supplied with the vehicle Note Always install the 7FBEF series mast for SAS manufactured by Toyota as described on the repair manual ...

Page 155: ...at for previous models It can be installed on the V FSV and FV 1 t series masts The shifter fork bar width is the same as the fork bar width on the vehicle Front view of detachable sideshifter SIDESHIFTER ATT NAME E811 E811A E811B E911 E911A E911B OPT CODE D910 D911 D912 D900 D902 D903 MODEL INTEGRATED INTEGRATED A430 INTEGRATED A450 HOOKED ON HOOKED ON A430 HOOKED ON A450 7FBEF15 7FBEF16 7FBEF18 ...

Page 156: ...e same 7FBEF15 to 18 STD Standard Available as option Fork bar width mm in 920 36 2 Catalog No 55F SS A890 Assembly weight kg lb 50 3 111 Effective thickness mm in 59 0 2 32 Max sideshift mm in 200 7 87 Series STD 7FBEF20 STD Standard Available as option Fork bar width mm in 1020 40 2 1170 46 1 1470 57 9 Catalog No 55F SS A891 55F SS A930 55F SS A932 Assembly weight kg lb 53 5 2 11 59 0 2 32 88 3 ...

Page 157: ... t series masts The allowable load and load center are the same as those on standard vehicles Rear view of integral sideshifter Specifications 7FBEF15 to 18 STD Standard Fork bar width mm in 920 36 2 Max sideshift mm in 200 7 87 Series STD 7FBEF20 STD Standard Available as option Fork bar width mm in 1020 40 2 1170 46 1 1470 57 9 Max sideshift mm in 200 7 87 Series STD Stroke Stroke Fork bar width...

Page 158: ... they are 2 A4 Piping The E8 attachment includes the A4 piping as shown in the table below 3 Tire chain installation There is no optional tire chain installation structure 4 Control lever layout The control lever layout and operating directions are the same as on previous models E8 code A4 type E811 A410 E811A A430 E811B A450 ...

Page 159: ...t and the seat position is moved by 36 mm toward the center of the vehicle Unallowable Optional Attachments Lights FR RR combination lamps etc 4 way control valve piping etc Others The assist grip and headlamps are not installed The mast backward tilting angle is up to 5 mm in A B C D 780 30 7 1156 45 5 1883 74 1 780 30 7 LOAD D B C A ...

Page 160: ...ever is touched erroneously while the key is OFF The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt Appearance Connection with actual machine components Pressure detection port Specifications Port P Hydraulic pump hydraulic fluid supply source Port C2 Tilt cylinder bottom side Port T1 Tank Port C3 Tilt cylinder rod side Port T2 Tank Port C4 Actuator...

Page 161: ... valve is operated by the equilibrium of chamber c chamber d and spring 2 This controls the oil pressure of chamber d at a fixed pressure higher than the oil pressure in chamber e Chamber d and chamber c are connected by orifice C so they have the same oil pressure and the pressure differential between chamber a and chamber f is kept constant by operation of the unload valve and the pressure compe...

Page 162: ...flows through orifice Q then returns to the tank via chamber g Now chamber c has the same pressure as the tank so all the pressure oil from port P returns to the tank via part E When the pressure compensating mechanism is inactive sectional view of inlet section Port P Port T1 Non leak valve Solenoid c1 Q c E g Main flow excess flow Pilot flow ...

Page 163: ...essure is applied from the port P The pressure compensating mechanism is inactive because solenoid c1 is not activated When the pressure compensating mechanism is inactive sectional view of inlet section Port P Port T1 Non leak valve Solenoid c1 Q c E g Main flow excess flow Pilot flow ...

Page 164: ...controlled by H and I on the seat Leakage of pressure oil that flowed to the lift lock check valve and pressure oil that flowed to the tilt lock check valve is controlled by land part J and land part K respectively This reduces natural drop and natural forward tilt Backpressure leak reduction mechanism sectional view of lift section Backpressure leak reduction mechanism sectional view of tilt sect...

Page 165: ...hen flows through passage 4 and the filter to become the pilot pressure to each solenoid The pressure of the oil is determined by the set load on spring 4 Hydraulic pressure mechanism for solenoid proportional valve 4 Spring 4 h Pilot flow Electromagnetic proportional valve Electromagnetic proportional valve Tilt section Inlet section Lift section Filter Reducing valve ...

Page 166: ...amber c becomes the pressure of spring 2 The pressure of chamber d and chamber c is applied to the unload valve then the unload valve moves to the equilibrium position when pressure of chamber e and chamber c pressure of spring 1 P port pressure The pressure differential between chamber d and chamber c and P port pressure becomes the pressure of spring 1 The force of spring 1 and spring 2 is now c...

Page 167: ...k check valve and then flows to the port C1 and the bottom of the lift cylinder The select valve does not operate at this time so the select valve becomes simply a check valve The pressure differential between chamber a and chamber 7 is kept constant by the pressure compensation mechanism and the load sensing mechanism so the volume of pressure oil supplied to port C1 is determined by the opening ...

Page 168: ...he circuit is configured with the select valve and chamber u connected so the pressure oil of the select valve flows through part M and then flows from chamber g to the tank Accordingly C1 holding pressure opens the lift lock check valve and the oil flows from C1 to the tank Lift DOWN operation lift section If due to a malfunction you want to lower the mast without moving the lift spool opening th...

Page 169: ...der Pressure oil flowing to chamber p enters chamber n and shifts the select valve to the left The circuit is configured so that oil from the tilt cylinder rod side flows from port C3 through the tilt lock check valve and chamber y to chamber g This generates a pressure differential before and after orifice G and the shifting of the tilt lock valve to the right causes the oil on the tilt cylinder ...

Page 170: ...en flows from port C3 to the tilt cylinder rod side The select valve does not operate at this time so the select valve becomes simply a check valve The pressure differential between chamber a and chamber 7 is kept constant by the pressure compensation mechanism and the load sensing mechanism so the volume of pressure oil supplied to port C3 is determined by the opening aperture of part O irrespect...

Page 171: ...he spool moves to the right side Now the oil from chamber s drains out from 10 via the solenoid proportional valve The flow of the pressure oil after this is the same as for tilt operation Attachment operation attachment section a V V 10 s r Main flow excess flow Pilot flow Tilt section Load check Outlet Section V V Port C4 Port C5 Attachment spool Solenoid b3 Electromagnetic proportional valve El...

Page 172: ...switch is installed behind the tilt lever When the button is pressed once the operated state is stored mechanically by the lock mechanism in the switch for automatic leveling of the fork at the time of stopping Pressing it again releases locking to return to the original state without automatic leveling See the mast control section for further details of the function The lever box position can be ...

Page 173: ...liding operation A tall operator with long arms and legs can obtain the best operating position by sliding the seat backward and an operator with short arms and legs by sliding the seat forward The armrest height can be adjusted Loosen the armrest fixing knob set the armrest at the desired height and tighten the knob again Every operator can select the best position for lever operation Driver s po...

Page 174: ...e standard vehicle as they replace battery from the RH side The batteries are the same as those for standard vehicles The following indicate main structure Part A Metal roller guide and rollers can be installed under the battery They enable battery replacement with ease without using the tool Battery stopper A Roller guide steel Rollers FR RH ...

Page 175: ...e battery 1 Open the battery hood 2 Raise the battery stopper to unlock 3 Turn the battery stopper Slide the battery to remove it Installation procedure is the reverse of the removal procedure Open close the battery hood following the same steps as the standard vehicle 1 3 2 ...

Page 176: ... APPENDIX Page CAUTIONS FOR RECEIVING ORDERS 10 2 MAJOR SPECIFICATIONS 10 3 FRAME NUMBER 10 5 TWO PLANE DRAWING OF THE VEHICLE 10 6 ELECTRIC WIRING DIAGRAM VEHICLE INSTALLED WITH OPTIONAL PARTS 10 9 2 3 10 ...

Page 177: ...ent of other than the specified manufacturers for installation on your forklift check for abnormal surge or noise generation beforehand and also pay attention to the installation method If it is unknown whether the auxiliary equipment generates any surge please consult with the auxiliary equipment manufacturer Surge refers to local application of a high voltage instantaneously in a part of an elec...

Page 178: ...d kg 1500 1600 Load center mm in 500 24 500 24 Traveling speed No load km h mph 16 5 10 2 16 0 9 9 forward Load km h mph 15 0 9 3 15 0 9 3 Traveling speed No load km h mph 16 5 10 2 16 0 9 9 reverse Load km h mph 15 0 9 3 15 0 9 3 Raising speed No load mm s fpm 610 120 610 120 Load mm s fpm 430 85 420 83 Lowering speed No load mm s fpm 550 108 550 108 Load mm s fpm 500 98 500 98 Travel device Tire...

Page 179: ...bs 1750 2000 Load center mm in 500 24 500 24 Traveling speed No load km h mph 16 0 9 9 15 5 9 6 forward Load km h mph 14 5 9 0 14 0 8 7 Traveling speed No load km h mph 16 0 9 9 15 5 9 6 reverse Load km h mph 14 5 9 0 14 0 8 7 Raising speed No load mm s fpm 610 120 500 98 Load mm s fpm 390 77 340 67 Lowering speed No load mm s fpm 550 108 500 98 Load mm s fpm 500 98 500 98 Travel device Tire size ...

Page 180: ... NUMBER Frame number punching location Frame number punching format Vehicle Model Punching format Vehicle Model Punching format 7FBEF15 7FBEF15 10011 7FBEF16 to 20 7FBEF20 10011 Frame No punching position 2 3 10 ...

Page 181: ...10 6 TWO PLANE DRAWING OF THE VEHICLE Fr Rr A B C D E I J K R L M N P Q S T O F G H ...

Page 182: ...9 G 1540 60 1 1640 64 6 1645 64 8 1710 67 3 H 175 6 9 175 6 9 175 6 9 205 8 1 I 3920 154 3 3920 154 3 3920 154 3 3920 154 3 J 3000 118 3000 118 3000 118 3000 118 K 1970 77 6 1970 77 6 1970 77 6 1970 77 6 L 150 5 9 150 5 9 150 5 9 125 4 9 M 40 1 6 40 1 6 40 1 6 40 1 6 N 800 31 5 800 31 5 800 31 5 1000 39 4 O 1895 74 6 1995 78 5 2000 78 7 2080 81 9 P 355 14 0 355 14 0 355 14 0 370 14 6 Q 1400 55 1 1...

Page 183: ...10 8 ...

Page 184: ...MINI LEVER LESS P2 G CPR SOL T 7 B G 6 R G SOL L 4 B R 3 W R PBCPU LS LSAT1 LSTR LSTF LSL LSL LSTF LSTR LSAT1 POTL2 POTL POTT2 POTT POTAT12 POTAT1 POTAT21 POTAT22 POTAT2 LSAT2 SOLP SOLP SOLb4 SOLa4 SOL4 SOLb3 SOLa3 SOL3 SOLb2 SOLa1 SOLL SOLL SOLT SOLT D15V SDTMA GNDD SMTDA SDTMK SMTDK 14 B W 16 R 144 G R 143 R G 142 R B 141 W R FANR FANR FANR FANR 48V N1 SMTDA SDTMA SDTMK SMTDK 15V GNDD STMD2 AMD2...

Page 185: ...Published by 1st Printing May 2003 Pub No CE335 CD Printed in JAPAN TOYOTA Material Handling Company A Division of TOYOTA INDUSTRIES CORPORATION I ...

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