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<p>FOREWORD This manual covers the service procedures of the TOYOTA ELECTRIC POWERED FORKLIFT 7FBE10 to 20 series. Please use these manuals for providing quick, correct servicing of the corre- sponding forklift models. This manual deals with the above models as of February 2003. Please under- stand that disagreement can take place between the descriptions in the man- ual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. SECTION INDEX NAME SECTION GENERAL 0 BATTERY 1 CHARGER (OPT) 2 CONTROLLER 3 MULTI-DISPLAY FUNCTIONS 4 TROUBLESHOOTING 5 MOTOR 6 DRIVE UNIT & FRONT AXLE 7 REAR AXLE 8 STEERING 9 BRAKE 10 BODY & FRAME 11 MATERIAL HANDLING SYSTEM 12 MAST 13 CYLINDER 14 OIL PUMP 15 OIL CONTROL VALVE 16 SAS FUNCTIONS (OPT) 17 APPENDIX 18 0-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 GENERAL Page Page VEHICLE EXTERIOR VIEW........... 0-2 VEHICLE MODELS.......................... 0-3 FRAME NUMBER............................. 0-3 HOW TO USE THIS MANUAL ...... 0-4 EXPLANATION METHOD ................. 0-4 TERMINOLOGY................................. 0-5 ABBREVIATIONS.............................. 0-5 SI UNITS ............................................ 0-6 OPERATING TIPS............................ 0-7 GENERAL INSTRUCTIONS.............. 0-7 JACK-UP POINT ............................... 0-8 HOISTING THE VEHICLE ................. 0-9 WIRE ROPE SUSPENSION ANGLE LIST .............................................. 0-10 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE................. 0-10 MEMBER WEIGHTS........................ 0-11 TOWING THE VEHICLE.................. 0-11 ELECTRICAL PARTS INSPECTION ................................ 0-12 NOTES ON SAS .............................. 0-14 STANDARD BOLT & NUT TIGHTENING TORQUE............. 0-15 BOLT STRENGTH CLASS IDENTIFICATION METHOD ......... 0-15 TIGHTENING TORQUE TABLE ...... 0-16 PRECOATED BOLTS ...................... 0-17 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE............. 0-17 RECOMMENDED LUBRICANT QUANTITY AND TYPES ........... 0-18 LUBRICATION CHART................. 0-19 PERIODIC MAINTENANCE......... 0-20 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ..... 0-25 0-2 VEHICLE EXTERIOR VIEW 0-3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 VEHICLE MODELS FRAME NUMBER Vehicle model code Payload (ton) Vehicle Model Control method Voltage (V) 10 1.0 7FBE10 AC microcomputer controller 48 13 1.25 7FBE13 15 1.5 7FBE15 18 1.75 7FBE18 20 2.0 7FBE20 Vehicle model Drive motor model Punching format Punching position 7FBE10 AR09 7FBE13-50011 7FBE13 7FBE15 7FBE18-50011 7FBE18 7FBE20 7FBE20-50011 Punching position 0-4 HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operating procedure (1) Operating procedures are described using either pattern A or pattern B. Pattern A: Each step of the operation is explained with its own illustration. Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations. Example of pattern B DISASSEMBLY INSPECTION REASSEMBLY Tightening torque unit T=Nm(kgm)[ftlbf] Disassembly Procedure 1 Remove the cover. [Point 1] 2 Remove the bushing. [Point 2] 3 Remove the gear. Point Operations [POINT 1] Disassembly: Make match marks before removing the pump cover [POINT 2] Inspection: Measure the bushing inside diameter. Limit 19.12 mm Some step numbers may be omitted in some illustrations. T = 46.1 to 48.1 (470 to 490) [34.0 to 35.5] 1 2 3 4 7 6 5 8 5 9 1 Operation to be explained Explanation of operation point with illustration 0-5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1. How to read component figures (1) The component figures use the illustration in the parts catalog for the vehicle model. Please refer to the catalog to check the part name. 2. Matters omitted from this manual (1) This manual omits descriptions of the following jobs, but perform them in actual operation: (a) Cleaning and washing of removed parts as required (b) Visual inspection (partially described) TERMINOLOGY CAUTION: Important matters, negligence of which may cause accidents. Be sure to observe them. NOTE: Important items, negligence of which may cause accidents, or matters in operating procedure which require special attention. Standard: Value showing the allowable range in inspection or adjustment Limit: The maximum or minimum value allowed in inspection or adjustment. ABBREVIATIONS Abbreviation Meaning Abbreviation Meaning ASSY Assembly SAE Society of Automotive Engineers (USA) ATT Attachment SAS System of active stability LH Left Hand SST Special Service Tool L/ Less STD Standard OPT Option T= Tightening Torque O/S Oversize {{T Number of teeth ({{T) PS system Power Steering U/S Undersize RH Right Hand W/ With (Example) 3201 Parts catalog FIG number 0-6 SI UNITS Meaning of SI This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for smoother international technical communication. New Units Adopted in SI <Reference> * 1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the rate for conversion between conventional and SI units. * 2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which should be used as the unit of force. Conversion between Conventional and SI Units Equation for conversion When converting, change the unit of the value in conventional or SI units to the one in the conversion rate column in the table above before calculation. For example, when converting 100 W to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499. Item New unit Conventional unit Conversion rate*1 (1 [conventional unit] = X [SI unit]) Force*2 N (newton) kgf 1 kgf = 9.80665 N Torque*2 (Moment) Nm kgfcm 1 kgfcm = 9.80665 Nm Pressure*2 Pa (pascal) kgf/cm2 1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa mmHg 1 mmHg = 0.133322 kPa Revolving speed rpm rpm 1 rpm = 1 r/min Spring con- N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm Volume l cc 1 cc = 1 ml Power W PS system 1 PS = 0.735499 kW Heat quantity Wh cal 1 kcal = 1.16279 Wh Specific fuel g/Wh g/PSh 1 g/PSh = 1.3596 g/kWh Value in SI unit = Conversion rate Value in conventional unit Conversion rate: Figure corresponding to X in the conversion rate column in the table above Value in conventional unit = Value in SI unit Conversion rate 0-7 OPERATING TIPS GENERAL INSTRUCTIONS 1. Skillful operation (1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation. (2) Check the cable color and wiring state before disconnecting any wiring. (3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting a precision part such as the control valve, use clean tools and operate in a clean location. (5) Follow the specified procedures for disassembly, inspection and reassembly. (6) Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new ones each time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the "standard tightening torque table". 2. Protection of functional parts (battery operated vehicles) (1) Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection. Failure or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers. 3. Defect status check Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect. 4. Waste fluid disposal Always use a proper container when draining waste fluid from the vehicle. Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposal. 0-8 JACK-UP POINT Always observe the following instructions when jacking up the vehicle: When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface. Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous. Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the vehicle with the jack only is very dangerous. Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle. Jack-up point Wooden block or stand setting points 0-9 HOISTING THE VEHICLE When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist by any other attachment section as it is very dangerous. 0-10 WIRE ROPE SUSPENSION ANGLE LIST SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (tf) [lbf] Suspension Angle Tension Compression Suspension method Suspension Angle Tension Compression Suspension method 0 1.00 time 0 time 90 1.41 time 1.00 time 30 1.04 time 0.27 time 120 2.00 time 1.73 time 60 1.16 time 0.58 time Rope diameter Cutting load Single- rope Two-rope suspension four-rope suspension 0 0 30 60 90 0 30 60 90 6 mm (0.24 in) 21380 (2.18) [4807] 3040 (0.31) [683.6] 6080 (0.62) [1367] 5880 (0.6) [1323] 5200 (0.53) [1169] 4310 (0.44) [970] 12160 (1.24) [2734] 11770 (1.2) [2646] 10400 (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 (0.4 in) 49230 (5.02) [11690] 6960 (0.71) [1565.6] 14020 (1.43) [3153] 13440 (1.37) [3021] 11770 (1.2) [2646] 9810 (1.0) [2205] 27460 (2.8) [6174] 26480 (2.7) [5954] 23540 (2.4) [5292] 19610 (2.0) [4410] 12.5 mm (0.5 in) 76880 (7.84) [17387] 10980 (1.12) [2469.5] 21570 (2.2) [4851] 21280 (2.1) [4631] 18630 (1.9) [4190] 14710 (1.5) [3308] 43150 (4.4) [9702] 41190 (4.2) [9261] 37270 (3.8) [8379] 29420 (3.0) [6615] 14 mm (0.56 in) 96400 (9.83) [21675] 13730 (1.4) [3087] 27460 (2.8) [6174] 26480 (2.7) [5954] 23540 (2.4) [5292] 18630 (1.9) [4190] 54920 (5.6) [12348] 52960 (5.4) [11907] 47070 (4.8) [10584] 37270 (3.8) [8379] 1tf2t 2t 1.41tf90 2t 1.04tf30 2t 2tf120 2t 1.16tf60 0-11 MEMBER WEIGHTS Unit: kg (lbs) TOWING THE VEHICLE Note the cautions below when towing the vehicle. 1. Lift the rear wheels for towing 2. The traveling speed when towing must not exceed the maximum traveling speed of the forklift. 3. Before starting towing, always set the key switch to OFF and the direction switch to the neutral position. 4. Before towing, either remove the fork or take action to prevent the fork from coming into contact with the ground due to bouncing. Member Vehicle model Weight BATTERY ASSY See P1-2 Drive motor ASSY All Models Approx. 37 (82) Pump motor ASSY All Models Approx. 31 (68) Front axle ASSY W/ drive motor ASSY All Models Approx. 122 (269) Rear axle ASSY W/ rear axle cylinder ASSY All Models Approx. 45 (99) Counterweight 7FBE10 Approx. 405 (893) 7FBE13 Approx. 598 (1319) 7FBE15 Approx. 697 (1537) 7FBE18 Approx. 853 (1881) 7FBE20 Approx. 1040 (2293) Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork, Lifting height 3000mm, V mast) 7FBE10 to 7FBE18 330 (730) 7FBE20 400 (880) Vehicle weight 7FBE10 2225 (4906) 7FBE13 2425 (5347) 7FBE15 2685 (5920) 7FBE18 2840 (6262) 7FBE20 3155 (6957) 0-12 ELECTRICAL PARTS INSPECTION 1. Always disconnect the battery plug before inspecting or servicing electrical parts. 2. Pay sufficient attention when handling electronic parts. (1) Never subject electronic parts, such as computers and relays, to impact. (2) Never expose electronic parts to high temperature or moisture. (3) Do not touch connector terminals, as they may be deformed or damaged due to static electricity. 3. Use a circuit tester that matches the object and purpose of measurement. Analog type: This type is convenient for observing movement during operation and the operating condition. Measured value is only a reference Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or movement. (1) Difference between results of measurement with analog and digital types The results of measurements using the analog type and the digital type may be different. Differences between the polarities of the analog type and the digital type are described below. 1) Analog circuit tester Example of measurement result Tester range: k range 2) Digital circuit tester Example of measurement result Tester range: 2 M range Forward Reverse Analog type Forward Continuity 11 k Reverse No continuity Forward Reverse Digital type Forward No continuity 1 Reverse Continuity 2 M 0-13 (2) Difference in result of measurement with a circuit tester The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used. The resistance of a semiconductor, such as a diode, varies with the circuit tester power supply voltage. The diode characteristics are shown in the figure below. The resistance values of the same semiconductor measured with two types of circuit testers having different power supply voltages are different. This manual describes 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 the measurement range switches over the internal circuit to vary the circuit resistance. Even when the same diode is measured, the measurement result varies with the measurement range. Always use the range described in the repair manual for measurement. 0 1 2 3 4 5 6 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 (V) Forward voltage Germanium diode (mA) Forward currentSilicon diode Resistor Meter 0 Variable resistor Resistor Resistor Range:10 Range:1 Power source: 1.5V Red Black (SW1) Current flow 0-14 NOTES ON SAS 1. For the explanations of SAS functions and operation, also see "New Model Feature 7FBE10 to 20 Pub. No.PE314". 2. See page 17-6 FOR REPAIR WORK of this repair manual before servicing. 3. If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform necessary matching to ensure proper SAS function (see page 4-47). 4. always be sure to operate the vehicle carefully. Be aware of the difference in control features between with and without SAS. 5. Many precision valves are used in the SAS oil control valves. When disassembling or replacing hydraulic parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of the hydraulic oil is also very important. 6. As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may cause vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the electrical parts (auxiliary equipment, optional parts, etc.). 0-15 STANDARD BOLT & NUT TIGHTENING TORQUE Tightening torque of standard bolts and nuts are not indicated throughout the manual. Use the charts and table below to judge the standard tightening torque. 1. Find the class of the bolt strength on the table below and then find the bolt tightening torque on the tightening torque table. 2. The nut tightening torque can be judged from its corresponding bolt type. BOLT STRENGTH CLASS IDENTIFICATION METHOD Identification by bolt shape Identification by part No. Shape and class Class Hexagon head bolt Hexagon bolt (standard) Bolt with raised or etched numeral on head 4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T No mark 4T Hexagon flange bolt No mark 4T Hexagon head bolt (standard) Bolt with two raised lines on head 5T Hexagon flange bolt Bolt with two raised lines on head 6T Hexagon head bolt (standard) Bolt with three raised lines on head 7T Hexagon head bolt (standard) Bolt with four raised lines on head 8T Welded bolt 4T Stud bolt No mark 4T 2 mm groove(s) on one/both edge(s) 6T Hexagon head bolt Part No. 91611-40625 Length (mm) Nominal diameter (mm) Class Stud bolt Part No. 92132-40614 Length (mm) Nominal diameter (mm) Class Nominal diameter Length Nominal diameter Length 0-16 TIGHTENING TORQUE TABLE Class Nominal diameter mm Pitch mm Standard tightening torque Nm kgfcm ftlbf Nm kgfcm ftlbf 4T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 5.4 13 25 47 75 113 55 130 260 480 760 1150 48inlbf 9 19 35 55 83 5.9 14 28 53 83 60 145 290 540 850 52inlbf 10 21 39 61 5T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 6.4 16 32 59 91 137 65 160 330 600 930 1400 56inlbf 12 24 43 67 101 7.5 18 36 65 100 157 75 175 360 670 1050 1600 65inlbf 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 69inlbf 14 29 53 80 127 8.8 21 43 79 123 191 90 215 440 810 1250 1950 78inlbf 16 32 59 90 141 7T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 11 25 52 95 147 226 110 260 530 970 1500 2300 8 19 38 70 108 166 12 28 58 103 167 120 290 590 1050 1700 9 21 43 76 123 8T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 12 29 61 108 172 265 125 300 620 1100 1750 2700 9 22 45 80 127 195 14 32 68 123 196 299 145 330 690 1250 2000 3050 9 24 50 90 145 221 Hexagon head bolt Hexagon flange bolt 0-17 PRECOATED BOLTS 1. Do not replace or restore a precoated bolt as it is in the following cases: (1) After it has been removed. (2) When it has been moved by tightness check, etc. (loosened or tightened) NOTE: For torque check, tighten the bolt at the lower limit of the allowable tightening torque range; if the bolt moves, retighten it according to the steps below. 2. How to reuse precoated bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even when replacing the bolt with a new one) (2) Completely dry the washed parts by blowing with air. (3) Apply a specified seal lock agent to the threaded portion of the bolt. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1. When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or other damage on the contact surfaces before installation. 2. When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting. 3. The maximum tightening torque must not exceed twice the standard tightening torque. Seal lock agent Nominal diameter of screw Tightening torque standard Nm (kgfcm) [ftlbf] Inside diameter of hose mm (in) Standard Tightening range 7/16-20UNF 25 (50) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24) 9/16-18UNF 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35) 3/4-16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47) 7/8-14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47) 7/8-14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15 (0.59) 11/16-12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75) 15/16-12UNF 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98) PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24) PF3/8 49 (500) [36.2] 47 to 52 (480 to 530) [34.7 to 38.3] 9 (0.35) PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47) PF3/4 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75) PF1 137 (1400) [101.3] 130 to 144 (1330 to 1470) [96.2 to 106.4] 25 (0.98) 0-18 RECOMMENDED LUBRICANT QUANTITY AND TYPES Hydraulic oil level by lifting height Unit:l (US gal) Application Type Capacity Drive unit Castle hypoid gear oil W (API GL-4, SAE 75W-80) Approx. 0.4 l (0.11 US gal) (Until purring out from the filler port) Hydraulic oil STD: Castle hydraulic oil (ISO VG32) Cold storage vehicle: Mobil Aero HFE See "Hydraulic oil level by lifting height" below Chassis parts MP grease Chassis grease special Esso beacon 325 Appropriate amount Battery Distilled water Appropriate amount Lifting height V mast SV mast FV Mast FSV Mast To 3000mm (118 in) Capacity 14 (3.70) 14 (3.70) 17 (4.49) Hydraulic oil level in the tank 12.4 (3.27) To 4000mm (157.5 in) Capacity 15 (3.96) 15 (3.96) 19 (5.01) 16 (4.22) Hydraulic oil level in the tank 14.2 (3.75) To 6000mm (236 in) Capacity 18 (4.75) 19 (5.01) Hydraulic oil level in the tank 17.2 (4.54) 0-19 LUBRICATION CHART {: Inspection and addition I. Inspection every 8 hours (daily) z: Replacement II. Inspection every 40 hours (weekly) A: MP grease III. Inspection every 170 hours (monthly) B: Motor oil IV. Inspection every 1000 hours (6 monthly) C: Gear oil (SAE 75W-80) V. Inspection 2000 hours (annual) D: Hydraulic oil (ISO VG32) E: Chassis grease special 1. Mast strip 8. Steering rack and pinion gear 2. Tilt cylinder front pin 9. Accelerator link 3. Mast support bushing 10. Oil tank 4. Lift chain 11. Tilt steering lock device 5. Drive unit 12. Rear wheel bearing 6. Brake link 13. Rear axle bearing 7. Oil control valve lever pin I II III IV V 0-20 PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection Repair or Replacement if required M: Measurement Repair or Adjustment if required T: Retightening C: Cleaning L: Lubrication *: For new vehicle *1: Flaw detector Inspection timing Every month Every 3 months Every 6 months Every 12 months Item Every 170 hours Every 500 hours Every 1000 hours Every 2000 hours ELECTRICAL SYSTEM Motor Rotation sound abnormality I Looseness in the connecting parts T Insulation resistance M Battery Charging level (Display) I Electrolyte level I Electrolyte specific gravity M Looseness in the connecting parts I Abnormality in the upper portion of the battery and/or the case I Insulation resistance M Voltage measurement of each battery cell after charging M Charger Timer function (Timer test) I Looseness in the connecting parts T HVR function voltage measurement M Operating condition of the magnetic switch, contact contamination, roughness I Magnet switch Contact looseness, damage, abrasion I Operating condition, contamination and abrasion of the auxiliary contact I Mounting condition of the arc shooter I Operating condition and timing I Looseness of the coil installation locations I Mounting condition and looseness of the main circuit lead wire I Micro switch Operating condition and timing I Damage and looseness of installation locations I Direction lever Operating condition, damage I 0-21 Controller Operating condition I Interior contamination, damage C Motor input voltage M Fuses Looseness of the installation locations I Wiring (incl. charging cable) Harness deterioration, damage and looseness of the clamp I Looseness of the connections, taping condition I Connecting condition and damage of the battery connector I POWER TRANSMISSION SYSTEM Drive unit Oil leak I Oil level I Bolt or nut looseness T DRIVE SYSTEM Front axle Damage and deformation I Rear axle Damage and deformation I Looseness of rear axle bearing I Abnormal noise of rear axle bearing I Wheels Tire pressure M Tire crack, damage and abnormal wear I Tire tread depth M Metal piece, stone and other foreign matter on tire I Loosening of wheel nut and bolt T Rim, side ring and disc wheel damage I Looseness and abnormal noise of front wheel bearing I Looseness and abnormal noise of rear wheel bearing I STEERING SYSTEM Steering wheel Play, loosening, looseness I Function I Steering valve Oil leak I Looseness of the installation locations T Wheels for steering Turning angle to left and right I Inspection timing Every month Every 3 months Every 6 months Every 12 months Item Every 170 hours Every 500 hours Every 1000 hours Every 2000 hours 0-22 Power steering Oil leak I Looseness of the installation locations I Damage of power steering hose I BRAKING SYSTEM Brake pedal Reserve M Braking performance I Parking brake Operating force and pull margin I Braking performance I Rod and cable Looseness and damage I Operating condition I Disc brake Clearance between disc and pad M Wear of sliding portion and pad I Disc wear and damage I Looseness of the disc installation locations I Operating condition I Return spring fatigue I MATERIAL HANDLING SYSTEM Fork Damage or wear of fork or stopper pin I Fork deformation and wear I Cracks at fork root and welded part of tooth I*1 Mast and lift bracket Deformation and damage of each part and crack at welded part I Wear and damage of roller I Mast and lift bracket looseness I Wear and damage of mast support bushing I Wear and damage of roller pin I Wear and damage of mast strip I Chain and chain wheel Chain lubrication I Deformation, damage and slackness of chain I Abnormality of chain anchor bolt I Wear, damage and revolution of chain wheel I Various attachments Abnormality and installation condition of each part I Inspection timing Every month Every 3 months Every 6 months Every 12 months Item Every 170 hours Every 500 hours Every 1000 hours Every 2000 hours 0-23 HYDRAULIC SYSTEM Cylinder Looseness, deformation and damage of rod and rod end I Cylinder operation I Natural drop and natural forward tilt M Oil leak and damage I Wear and damage of pin and cylinder bearing I Loosening and damage of cylinder mounting T Lifting speed M Uneven movement I Oil pump Oil leak and abnormal sound I Hydraulic oil tank Oil level and contamination I Oil leak I Tank and oil strainer cleaning C Hydraulic oil filter Filter clogging C Control lever Loose linkage I Operation I Oil control valve Oil leak I Safety valve function I Relief pressure measurement M Hydraulic hose and piping Oil leakage, deformation and damage I Looseness T SAFETY DEVICES, ETC. Head guard and backrest Looseness of the installation locations T Deformation, crack and damage I Crack at welded portion I Lighting system Function and installation condition I Direction indicator Function and installation condition I Horn Function and installation condition I Backup buzzer Function and installation condition I Rear view mirror Rear reflection status I Dirt, damage I Inspection timing Every month Every 3 months Every 6 months Every 12 months Item Every 170 hours Every 500 hours Every 1000 hours Every 2000 hours 0-24 Instruments Operation I Seat Loosening and damage of mounting I Seatbelt damage and function I Deadman seat operation I Body Damage and cracks in frame, cross mem- bers, etc. I Bolts and nuts looseness T SAS Functions I Loosening and damage at sensor mounting portion I Damage, deformation, oil leakage and loos- ened installation of functional parts I Loosening and damage of wire harnesses I Rusting and corrosion of load sensor I Others Grease up L Inspection timing Every month Every 3 months Every 6 months Every 12 months Item Every 170 hours Every 500 hours Every 1000 hours Every 2000 hours 0-25 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS : Replacement Replacement cycle Every month Every 3 months Every 6 months Every 12 months Item Every 170 hours Every 500 hours Every 1000 hours Every 2000 hours Drive unit gear oil Hydraulic oil Hydraulic oil filter New vehicle initial replacement Rear wheel bearing grease Power steering hose Every 2 years Power steering rubber parts Every 2 years Hydraulic hose Every 2 years Lift chain Every 3 years 0-26 1-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 18 BATTERY Page BATTERY COMPARTMENT AND REQUIRED WEIGHT. . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SERVICE STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . 1-3 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 BATTERY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 1-5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 REPLACING BATTERY PLUG TERMINAL . . . . . . . . . . 1-9 1-2 BATTERY COMPARTMENT AND REQUIRED WEIGHT When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required weight as shown in the table below. Compartment dimension mm (in) Minimum required bat- tery Weight (W/ case) kg (lb) Remarks Depth X Width Y Height Z 7FBE1013 451 (17.8) 998 (39.3) 613 (24.1) 520 (1147) 7FBE1518 551 (21.7) 655 (1444) 7FBE20 638 (25.1) 655 (1444) Width Y HeightZDe pth X 1-3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 18 SERVICE STANDARDS DISPLAY Battery Charge Indicator The battery charge indicator indicates 10 levels of battery charge on the LCD. Low Remaining Battery Charge Warning When the battery charge becomes below the set level, the battery charge indicator blinks and the alarm will sound for five seconds after the key switch is set to the ON position. Battery Overdischarge Warning When the battery charge decreases further below the set level after the remaining battery charge 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 1.280 [20C (68F)] Specific gravity 1.150 [20C (68F)] Discharge end voltage 42.5V Electrolyte Refined dilute sulfuric acid Fluid to be added Distilled water Insulation resistance 1M or more Battery discharged state % LEDs 10 F 9 8 7 6 5 4 3 2 1 E 0 to 10 (exclusive) { { { { { { { { { { 10 to 20 (exclusive) { { { { { { { { { 20 to 30 (exclusive) { { { { { { { { 30 to 40 (exclusive) { { { { { { { 40 to 50 (exclusive) { { { { { { 50 to 60 (exclusive) { { { { { 60 to 70 (exclusive) { { { { 70 to 80 (exclusive) { { { 80 to 90 (exclusive) { { 90 to 100 (exclusive) { 100 or more 1-4 TROUBLESHOOTING Plate corrosion Sulfation Plate warpage and ative substance freeing End of life Defective electrolyte Improper charging Short circuit between cells Insufficient electrolyte Long storage without operation Defect of electrolyte Excessive ambient temperature Overdischarge Repeated overdischarge/ overcharge Excessive charging current Battery defectImperfect terminal connection Fouled terminal or connecting plug Crack or chipping of cell Overcharge Improper water supply Damaged separator Deposition of freed active substance at bottom of cell Short circuit Electrolyte leakage and reduction Loosened or corroded connection 1-5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 18 BATTERY ASSY REMOVAL INSTALLATION Removal Procedure 1 Disconnect the battery plug. 2 Open the seat stand. 3 Release the steering release lever. 4 Remove the battery ASSY.[Point 1] Installation Procedure The installation procedure is the reverse of the removal procedure. Point Operations [POINT 1] Removal Installation: SST 25009-13201-71 1 2 4 SST 1-6 INSPECTION 1. Electrolyte level inspection Open the cap, and if the white line on the red float has dropped, water should be added. Add water until the white line appears. Stop water addition when the white line appears, since addition is excessive when the tip end of the float comes into contact with the stopper. As a level gauge is provided at the front of the battery case, the electrolyte level can generally be checked at a glance, but open the cap to check the level when making a periodic inspection. The green light of the level gauge lights up to indicate activation of the level gauge sensor, and the red light flashes to indicate the necessity of adding water. Note: Never change the installation location of the sensor. Reference: The consumption of electrolyte can be calculated by the following equation: Consumption (cc) = 5 hour capacity 0.0336 number of cells number of charges Red light Green light Normal level Off On Insufficient level Blinking On Vehicle model Number of cells Battery capacity (AH/5HR) 7FBE10 24 280 7FBE13 7FBE15 390 7FBE18 7FBE20 1-7 2. Electrolyte inspection Electrolyte inspection Battery electrolyte is normal when it is transparent. Check turbidity when inspecting the specific gravity.If it cannot be checked clearly, put the electrolyte in a beaker for inspection. 3. Battery electrolyte specific gravity inspection Use a hydrometer to measure the specific gravity of the electrolyte. Specific gravity upon complete charging .... 1.280[20C(68F)] Specific gravity upon end of discharge .... 1.150[20C(68F)] The specific gravity of the electrolyte at 20C (68F) is used.68 Equation for converting specific gravity S20=St+0.0007 (t-20) S20: Specific gravity at 20C St: Specific gravity at tC t: Electrolyte temperature upon measurement (C) * How to use the hydrometer (1) Insert the nozzle of the hydrometer into the electrolyte port and allow the electrolyte to be sucked into its outer tube. (2) Let the hydrometer float correctly without contact with the outer tube, top or bottom, and read the scale at the highest point of the electrolyte surface as illustrated at left when the bubbles in the electrolyte disappear. (3) After the measurement, wash the inside and outside of the hydrometer well with clear water and store it after wiping water off with clean cloth. 1-8 4. Insulation resistance inspection Measure the resistance between the battery and battery case with an insulation resistance meter (megohmmeter). Insulation resistance .... 1 M or more Note: When 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 battery on the vehicle after confirming that the insulation resistance is 1 M or more. * Battery control table Prepare a control table for each battery to record and maintain the inspection results. Inspection date and time Inspected cell No. Specific gravity Electrolyte temperature Added water quantity Remarks Inspector 1-9 REPLACING BATTERY PLUG TERMINAL 1. Disconnect battery plug cable one by one. Caution: Never disconnect more than one cable at the same time.Fatal accident may result by short circuit. 2. Insert a screwdriver from the terminal side, push down the spring at the bottom of the terminal and pull the cable to draw out the terminal. 3. Peel off the tip of the cable for Approx. 30mm, solder sufficiently and insert it to the contact portion of the new terminal. Note: Be sure to prevent solder from pouring out and adhere to the contact surface of the terminal. 4. When crimping cables, never bend the terminal with a crimping tool. 5. Insert the terminal to the battery plug. Check that the tip of the terminal goes over the tip of the spring and securely set in the position. Terminal Screw driver Spring Spring Crimping method Crimping tool Pad (To prevent the contact piece from bending) Case Terminal Cable spring 1-10 2-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CHARGER (OPT) Page GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ON-VEHICLE CHARGER . . . . . . . . . . . . . . . . . . . . . . 2-2 APPLICABLE CHARGER LIST . . . . . . . . . . . . . . . . . . . 2-2 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 TAP LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 BEFORE CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 SWITCH BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 MAGNETIC SWITCH ASSY . . . . . . . . . . . . . . . . . . . . . . 2-9 TRANSFORMER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 TIMER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 OFF-VEHICLE CHARGER . . . . . . . . . . . . . . . . . . . . . 2-26 APPLICABLE CHARGER LIST . . . . . . . . . . . . . . . . . . . 2-26 GS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 YUASA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 2-2 GENERAL A fully automatic microcomputer-controlled on-vehicle charger (STD) and a fully automatic microcomputer-controlled off-vehicle charger (OPT) are provided.The on-vehicle charger is not provided on cold storage models. This manual explains mainly the on-vehicle charger. ON-VEHICLE CHARGER APPLICABLE CHARGER LIST {:OPT Transformer model Power supply voltage Transformer capacity (kVA) (50/60 Hz) Battery voltage (V) Applicable capacity (AH/5hr) Power supply capacity (A) (50/60 Hz) Applicable vehicle model 7 F B E 10 7 F B E 13 7 F B E 15 7 F B E 18 7 F B E 20 K47-227C048-405 200 4.0/3.9 48 280 to 312 15 { { K47-230C048-413 4.8/4.3 365 to 390 15 { { { { { K47-260C048-409 7.1/7.0 476 to 645 30 { { { Display Switch box Receptacle Transformer Magnet switch 2-3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SPECIFICATIONS Item Transformer model K47-227C048-405 K47-230C048-413 Magnetic switch (MSch) Type CLK-20JT-F Rating 20 A Thermal setting 18 A Transformer (TF) Capacity (50/60 Hz) 4.0/3.9 kVA 4.8/4.3 kVA Insulation H Diode (Dch) Type SKR71/02 (+) SKN71/02 (-) Fuse (Fch) Capacity 96 V, 80 A Item Transformer model K47-260C048-409 Magnetic switch (MSch) Type CLK-35JT-F Rating 35 A Thermal setting 30 A Transformer (TF) Capacity (50/60 Hz) 7.1/7.0 kVA Insulation H Diode (Dch) Type SKR100/04 (+) SKN100/04 (-) Fuse (Fch) Capacity 96 V, 100 A 2-4 COMPONENTS 2511 Thank you very much for your reading. 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