<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 2-5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 WIRING DIAGRAM TAP LAYOUT PLGAC (R) (B) (R) (W) (L) CN66 (W) SWITCH BOX CN69 CN64 CN65 DISPLAY CN68 CONTROLER (CPU BORAD) DCH CN60 MSCH (B) (R) (W) T W V S R U A1 A2 96 THR 6 (B) 4 2 (R) (W) 95(L) CN62 (R) (W) AC FAN CN61 TF FCH BATT In broken line is 476AH/5A or above Frequency Tap position 50 Hz A 60 Hz B Power supply voltage Tap position 200 V 1 210 V 2 220 V 3 A B 1 2 3 A B 1 2 3 A B 1 2 3 2-6 BEFORE CHARGING If the ampere capacity at the charging location is insufficient because other electrical appliances are being used, ask an electrical work contractor to provide an exclusive circuit for the charger. See the "On-vehicle Charger List" (page 2-2) for the AC power supply capacity. Tap Changer 1. Measure the power supply voltage to be used for charging. Tester range: AC (250 or 1000 V) Note: Measure the power supply voltage at night (or, if that is impossible, during a time when electrical appliances are not being operated). 2. Set the tap changer. (1) Disconnect the battery plug. (2) Open the battery hood (3) Remove the controller panel cover. (4) Remove the tap cover of each phase corresponding to the power supply voltage measured in step 1 above. (5) Set the taps. (6) Connect the battery plug. (7) Connect the charger to the power supply outlet and press the NORMAL button. (8) Measure the voltage between the set taps. Caution: After tap changer setting, if the error code "F6-2" is displayed during charging, change them to the upgraded ones. Note: Taps are set to 220 V and 60 HZ at the time of shipment. Be sure to set the tap changer for voltage and frequency change of phase U, V and W. For about a week after tap changer setting, keep track of the battery charging state (specific gravity and electrolyte level) to make sure the tap setting is appropriate. Tap Measured voltage 200 V 199 V or less 210 V 200 to 209 V 220 V 210 to 219 V 2-7 SWITCH BOX REMOVAL INSTALLATION Removal Procedure 1 Remove the right instrument panel. 2 Disconnect the wiring connector. 3 Remove the switch box ASSY. Installation Procedure The installation procedure is the reverse of the removal procedure. 1 3 2 2-8 Point Operations [POINT 1] Inspection: Inspect each switch in the ON and OFF positions. (CN69) Inspection: Inspect the applied voltage of the LED.Check the applied voltage of the LED at the display connector (CN70). (CN69 must be connected.) Measurement terminals ON OFF Tester range NORMAL button 28 0 1 EQUAL button 38 0 CN70 CN70 14 13 12 11 10 30 29 28 27 26 25 24 23 22 9 8 UP LED EQUAL LED NORMAL LED CN70 Charging in progress (LED on) Charging stopped (LED off) Tester range NORMAL LED Between 9 and 30 (between YB and BW) 2 V 0 V 10 VDC EQUAL LED Between 10 and 30 (between YG and BW) 2 V 0 V CN70 Upon end of test mode (LED on) Other state (LED off) Tester range UP LED Between 11 and 30 (between YW and BW) 2 V 0 V 10 VDC 2-9 MAGNETIC SWITCH ASSY REMOVAL INSTALLATION T=Nm(kgfcm)[ftlbf] Removal Procedure 1 Disconnect the battery plug. 2 Remove the toe board (front, rear) and tilt cylinder cover. 3 Remove the step 4 Disconnect the wiring connector. 5 Remove the magnetic switch ASSY W/bracket. Installation Procedure The installation procedure is the reverse of the removal procedure. 3 5 1 2 2-10 Point Operations [POINT 1] Inspection: Magnetic switch contact continuity inspection. Inspection: Magnetic switch coil continuity inspection. Inspection: Thermal relay contact continuity inspection. Inspection: Inspect the reset switch. Check that the thermal relay is deactivated upon pressing the reset switch while the thermal relay is activated.Do not adjust the thermal relay operating current. If charging stops due to thermal relay activation while the charger is in use, always check the thermal relay activating cause and reset after taking corrective action. Press the reset switch lightly to reset the thermal relay. * Test the thermal relay as follows: Press the reset switch. Tester range 1 Measurement terminals TW, SV and RU Standard: MSch ON 0 MSch OFF Tester range 1 Measurement terminals A1A2 Standard: CLK-20JT-F 700 CLK-35JT-F 400 Tester range 1 Measurement terminals 9596 Standard: Not operating 0 Operating Test switch Reset switch No operated Operated 96 95 96 95 2-11 TRANSFORMER ASSY REMOVAL INSTALLATION T=Nm(kgfcm)[ftlbf] Removal Procedure 1 Disconnect the battery plug. 2 Open the battery hood. 3 Remove the control panel cover. 4 Disconnect wiring of the transformer ASSY. 5 Remove the transformer ASSY set bolts. 6 Remove the transformer ASSY by hoisting it. Installation Procedure The installation procedure is the reverse of the removal procedure. 2 3 5 6 2-12 Point Operations [POINT 1] Inspection: Measure the insulation resistance. [POINT 2] Inspection: Measure the primary coil continuity. Inspection: Measure the secondary coil continuity. Inspection: Inspect the fuse. Standard: 0 Measuring instrument DC 500 V megohmmeter Measurement terminals Each coil terminal frame Standard: 1 M or more Tester range 1 Measurement terminals U1V1, V1W1, W1U1 Standard: 0 Tester range 1 Measurement terminals U2V2, V2W2, W2U2 Standard: 0 2-13 Inspection: Measure the diode continuity. Inspect the diodes installed on the radiating fin plate and remove only if an abnormality is found. Reassembly: As two diodes with different polarity are used, be sure to avoid incorrect installation. Reassembly: Install each diode by tightening to the specified torque. SKR71/02, SKN71/02: 4 Nm (41 kgfcm) [3 ftlbf] SKR100/04, SKN100/04: 10 Nm (102 kgfcm) [7 ftlbf] Tester range 1K Measurement terminals Forward Anode (-) Cathode (+) Reverse Anode (+) Cathode (-) Standard: Forward Continuity Reverse 2-14 Inspection after installation 1. Inspect each wiring connection. Note: Check each wiring connection by referring to the charger wiring diagram. 2. Measure the insulation resistance. 3. Measure the no-load secondary voltages. Remove the counterweight (See P11-6) Connect the charger plug to a power supply outlet (with the transformer P1 and N1 cables disconnected), start charging (by pressing the NORMAL ON/OFF switch), and measure the following voltages. "F7" error is displayed when charging is started with either the P1 or the N1 cable of the transformer disconnected for the purpose of measuring the no-load voltage of the transformer, but this is not abnormal. AC voltage DC voltage Measuring instrument DC 500 V megohmmeter Measurement terminals Each coil terminalframe Standard: 1 M or more Tester range AC 250 V AC 500 V Measurement terminals U2V2, V2W2, W2U2 Standard: 50/60(Hz) K47-230C048-413: 53/54 V Other than the above: 54/56 V Tester range 250 VDC Measurement terminals P1 and N1 terminals P1 terminal: (+) probe N1 terminal: (-) probe Standard: 50/60(Hz) K47-227C048-405: 72/75 V K47-230C048-413: 71/73 V K47-260C048-409: 71/74 V 2-15 TIMER TEST OPERATING PROCEDURE 1. Connect the power plug to the receptacle on the vehicle. 2. The initial timer test screen appears on the display. 3. When buttons (1) and (2) and are pressed at the same time to start the timer test, "NOW TESTING!" will appear on the screen. The bars indicating charge light up at a rate of one per second as the test proceeds. When ten bars are lit up after 10 seconds, the test is complete and "TEST COMPLETED" appears on the screen. The LEDs on the operation panel come on in the order of (3)(4)(5). The magnetic switch turns on when "NOW TESTING!" is displayed, and turns off upon display of "TEST COMPLETED" about ten seconds later. 4. The initial screen reappears when any of buttons (1) to (2) is pressed. 2-16 TROUBLESHOOTING When a Diagnosis Error Code Is Displayed Error Code F6-1: Safety timer activated Inspection1 AC input voltage check on the power supply side Inspection2 AC power plug terminal voltage check Inspection3 Charger timer test Press the NORMAL button and check if the magnetic switch is closed and held in that position. Inspection4 DC line fuse continuity check AC power supply defect or power failure Power cable defect Display defect See "3. The magnetic switch is not closed when the button is pressed." on page 2-24. See "4.Charging completes normally but the charge is insufficient." on page 2-24. NG NG NG (0V, abnormal voltage dorp or lacking phase) OK (AC200~220V) OK (AC200~220V) (0V, abnormal voltage dorp or lacking phase) NG NG Blown fuse (W) OK (0W) OK (closed and held) F7 error OK 2-17 INSPECTION 1. Power supply voltage check OK (200 to 220 V) To inspection 2 NG (0 V, abnormal voltage drop or lack of phase) Power supply defect INSPECTION 2. Power supply plug terminal voltage inspection OK (200 to 220 V) To inspection 3 NG (0 V, abnormal voltage drop or lacking phase) Power cable defect INSPECTION 3. Charger timer test See the TIMER TEST section (page 2-15). OK (200 to 220 V) See "4. Charging cpmpletes normally but the charge is insufficient." of "No diagnosis error code is displayed" on page 2-24. NG (0 V, abnormal voltage drop or lack of phase) Display defect INSPECTION 4. DC side fuse continuity inspection AC power plug disconnected, charging buttons off and fuse removed OK (0 ) See "4. Charging cpmpletes normally but the charge is insufficient." of "No diagnosis error code is displayed" on page 2-24. NG ( ) Blown fuse Measurement terminals Power supply terminal Tester range 250 VAC Standard 200 to 220 V Measurement terminals Power plug terminals Tester range 250 VAC Standard 200 to 220 V Measurement terminals Both terminals of DC fuse Tester range 1 Standard 0 2-18 Error Code F6-2: Overheat Detection (only when battery capacity is 476 AH or above) INSPECTION 1. Thermometal cut-out operating voltage check OK (approx. 5V) Transformer thermometal cut-out defect NG Harness defect, display defect Measurement terminals CN68-1(139)(+)CN68-2(14)(main harness side) Tester range DC10V Standard Approx. 5V Individual transformer check (See page 2-12.) Tap changer voltage check (See page 2-6.) Fan operation check (also used for controller) Start charging Inspection 1 Thermometal cut-out operating voltage check (CN68 check) (F6-2 error code display soon) Transformer defect Tap adjustment defect NG NG NG(0V) NG No abnormality (Abnormal voltage rise) OK OK OK OK(Operated) Transformer thermometal cut-out defect OK(approx. 5V) NG(Not operated) Fan defect Harness defect Display defect Disconnected fan connector In case of a transformer defect, there may be another cause. After replacing the transformer, check as follows. 2-19 Error Code F7: Charging start failure INSPECTION 1. Connection check (1) Check that the P1 and N1 terminals of the transformer and controller are connected correctly without any looseness. (2) Check that CN60, CN66 and CN61 are connected correctly. (3) Check that the AC and DC plugs are free from contact defect. (No roughness of the terminal or heating during power conduction.) (4) Check that the power cable is not damaged. OK Transformer operating sound check Not OK Connection defect INSPECTION 2. Transformer fuse (Fch) inspection (See page2-12.) OK (0 ) To inspection 3 NG ( ) Open fuse (Fch) Inspection 1 Connection check Is the transformer operating sound heard upon charging switch on? Inspection 2 Transfromer fuse check (See page P2-12.) Inspection 4 Magnetic switch (MSch) voltage check Inspection 6 Charging button check Connection defect NG NG (Not heard) Incompatible NG Tap adjustment defect NG NG NG NG NG OK Check compatibility between battery capacity upon charging switch on? (See page 2-2.) OK (Heard) Inspection 5 Tap changer check (See page 2-6.) OK OK Transformer defect Transformer defect Switch box defect Display defect MSch defect OK(0W) (W) OK OK OK Fuse (Fch) open Inspection 3 Transformer primay voltage check 2-20 INSPECTION 3. Transformer primary voltage inspection CN61 connector disconnected, AC plug connected and charging switch ON OK (200 to 220 V) Transformer defect NG (other than standard) To inspection 4 INSPECTION 4. Magnetic switch voltage inspection CN66 connector disconnected AC plug connected, charging switch ON/ OFF operated) OK (200 to 220V) MSch defect NG (other than standard) To inspection 6 CN61 Measure- ment terminals 476AH or more (1) CN61-1 (U)-CN61-2 (V) (TAB side) (2) CN61-2 (V)-CN61-4 (W) (TAB side) (3) CN61-4 (W)-CN61-1 (U) (TAB side) Below 476AH (1) CN61-1 (U)-CN61-2 (V) (REC side) (2) CN61-2 (V)-CN61-3 (W) (REC side) (3) CN61-3 (W)-CN61-1 (U) (REC side) Tester range 250 VAC Standard 200 to 220 V CN66 CN60 Measurement terminals (1) CN66-1(R)-CN66-2(95)(REC side) Tester range 250 VAC Standard Charging buttons ON: 200 to 220 V, Charging bottoms OFF: 0 V 2-21 INSPECTION 5. Tap changer check (See page 2-6.) OK Transformer defect NG Tap adjustment defect INSPECTION 6. Charging button inspection CN69 connector disconnection OK Display defect NG Switch box defect CN69 Pressed state Released state Tester range (1) NORMAL button Between 2 and 8 0 1 (2) EQUAL button Between 3 and 8 0 2-22 Error code F8: Charging completion failure INSPECTION 1. Magnetic switch (MSch) voltage inspection (See page 2-20.) INSPECTION 2. Charging button inspection (See page 2-21.) Inspection 1 Magnetic switch (MSch) voltage check Inspection 2 Charging button check Switch box defect Magnetic switch (MSch) defect OK Display defect OK NG NG 2-23 No diagnosis error code is displayed 1. The vehicle does not move at all. (Charging screen appears even though the power plug is not connected.) Display defect 2. Charging screen does not appear even though the AC power plug is connected. INSPECTION 1. Power supply voltage inspection See Inspection 1 for diagnosis error code F6-1 (page 2-17). OK (AC 200 to 220 V) To inspection 2 NG (0 V, abnormal voltage drop or lacking phase) AC power supply defect or power interruption INSPECTION 2. Power plug terminal voltage inspection See Inspection 2 for diagnosis error code F6-1 (page 2-17). OK (AC 200 to 220 V) To inspection 3 NG (0 V, abnormal voltage drop or lacking phase) Power cable defect Connect the AC power plug and move the vehicle. Inspection 1 AC input voltage check on the power supply side Display defect Power cable defect (Dose not move) AC power supply defect Power failure NG OK (0V, abnormal voltage drop or lacking phase) NG (0V, abnormal voltage drop or lacking phase) NG (The vehicle moves.) OK (AC200~220V) Inspection 2 AC power plug terminal voltage check Display defect OK (AC200~220V) 2-24 3. The magnetic switch is not suctioned when the charging button is pressed. INSPECTION 1. Magnetic switch voltage inspection (See page 2-20.) INSPECTION 2. Charging button inspection (See page 2-21.) 4. Charging completes normally but the charge is insufficient. 5. Charging progress indicator does not proceed during the timer test. Display defect Display screen check Inspection 1 Magnetic switch voltage check See "2.The charging screen does not appear though the AC power plug is connected." on page 2-23. (No display) NG NG OK (Charging screen display) OK NG Inspection 2 Charging button check Switch box defect Display defect Magnetic switch (MSch) defect OK Battery and transformer capacity compatibility check (See page 2-2.) Tap voltage check (See page 2-6.) NG OK OK Capacity incompatibility Individual transformer check (See page 2-12.) Battery electrolyte specific garvity and temperature check after completion of charging Transformer defect ANL : I/O MONITOR1 I/O1-8 Battery voltage check (comparison between displayed value and actually measured value) NG OK within 2 % from the actually measured value OK CPU board defect NG Battery defect (Check if corrected by equal charging) Tap adjustment defect Decreased capacity due to lowering of electrolyte temperature Decreased capacity due to battery service life (other than OK) NG NG 2-25 6. The LED on the button panel (charger operation panel) does not come on. INSPECTION 1. Charger timer test (See page 2-15.) INSPECTION 2. LED applied voltage inspection (See page 2-8.) (CN69 connector must be connected.) CN70 Charging in progress (LED on) Charging stopped (LED off) Tester range NORMAL LED Between 9 and 30 (between YB and BW) 2 V 0 V 10 VDC EQUAL LED Between 10 and 30 (between YG and BW) 2 V 0 V CN70 Upon end of test mode Other state (LED off) Tester range UP LED Between 11 and 30 (between YW and BW) 2 V 0 V 10 VDC Inspection 1 Charger timer test Inspection 2 LED voltage check OK OK (2V during charging) NG Display defect NG (LED on) (0V during charging) Display defect Switch box defect 2-26 OFF-VEHICLE CHARGER APPLICABLE CHARGER LIST Maker Battery voltage Power supply voltage Charger model Trans- former capacity (kVA) (50/60 Hz) Applicable capacity (AH/5HR) Output plug Power capacity (50/60 Hz) Weight (kg) [lb] 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 Japan Storage Battery 48 V 200 V SG3-69- 60JBY-2 5.4/4.7 280 to 312 SB175A 20 40 [88.2] { { SG3-69- 80JBY-2 7.3/6.5 365 to 390 30/20 44 [97.0] { { { { { SG3-69- 100JBY-2 9.2/8.1 476 to 565 30 60 [132.3] { { { SG3-69- 130JBY-2 12.0/11.0 645 40 64 [141.1] { 400 V SG3-69- 60JBY-2 5.4/4.7 280 to 312 10 40 [88.2] { { SG3-69- 80JBY-2 7.3/6.5 365 to 390 15/10 44 [97.0] { { { { { SG3-69- 100JBY-2 9.2/8.1 476 to 565 15 60 132.3] { { { SG3-69- 130JBY-2 12.0/11.0 645 20 64 [141.1] { YUASA 48 V 200 V ZTC48- 54AD 4.5 280 to 312 15 40 [88.2] { { ZTC48- 80AD 6.6 365 to 390 20 60 [97.0] { { { { { ZTC48- 100AD 8.3 476 to 565 30 60 [97.0] { { { ZTC48- 120AD 9.2 645 30 63 [138.9] { 400 V ZMC48- 54AD 4.5 280 to 312 10 40 [88.2] { { ZMC48- 80AD 6.6 365 to 390 10 60 [97.0] { { { { { ZMC48- 100AD 8.3 476 to 565 15 60 [97.0] { { { ZMC48- 120AD 9.2 645 15 63 [138.9] { 2-27 GS GENERAL SPECIFICATIONS 200 V POWER SUPPLY VOLTAGE Item SG3-69-60JBY-2 SG3-69-80JBY-2 Magnetic switch Type CLK-15JT CLK-20JT (MSch) Rating AC 200 V 50/60 Hz AC 200 V 50/60 Hz Thermal relay Type T-11 T-18 (THR) Set value 15 A 18 A Transformer Capacity 5.4/4.7KVA 7.3/6.5 KVA (50/60 Hz) (TF) Insulation Class H Class H Silicon diode Type SKR71/02 SKR71/02 (Dch) SKN71/02 SKN71/02 Timer (AMT) Operating Voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H Fuse (Fch) Capacity 80 A 80 A AC power supply capacity 14/13 A 19/17A Charger weight 42 kg 44 kg 2-28 400 V POWER SUPPLY VOLTAGE Item SG3-69-100JBY-2 SG3-69-130JBY-2 Magnetic switch Type CLK-26JT CLK-35JT (MSch) Rating AC 200 V 50/60 Hz AC 200 V 50/60 Hz Thermal relay Type T-18 T-35 (THR) Set value 22 A 30 A Transformer Capacity 9.2/8.1 KVA 12.0/11.0 KVA (50/60 Hz) (TF) Insulation Class H Class H Silicon diode Type SKR130/02 45M20 (Dch) SKN130/02 45MA20 Timer (AMT) Operating Voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H Fuse (Fch) Capacity 100 A 150 A AC power supply capacity 24/21 A 31/27 A Charger weight 60 kg 64 kg Item SG3-69-60JBY-2 SG3-69-80JBY-2 Magnetic switch Type CLK-15JT CLK-15JT (MSch) Rating AC 400 V 50/60 Hz AC 400 V 50/60 Hz Thermal relay Type T-11 T-11 (THR) Set value 7.5 A 11 A Transformer Capacity 5.4/4.7 KVA 7.3/6.5 KVA (50/60 Hz) (TF) Insulation Class H Class H Silicon diode Type SKR71/02 SKR71/02 (Dch) SKN71/02 SKN71/02 Timer (AMT) Operating Voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H Fuse (Fch) Capacity 80 A 80 A AC power supply capacity 7.1/6.3 A 9.5/8.4 A Charger weight 42 kg 44 kg 2-29 Item SG3-69-100JBY-2 SG3-69-130JBY-2 Magnetic switch Type CLK-15JT CLK-26JT (MSch) Rating AC 200 V 50/60 Hz AC 200 V 50/60 Hz Thermal relay Type T-11 T-18 (THR) Set value 15 A 22 A Transformer Capacity 9.2/8.1 KVA 12.0/11.0 KVA (50/60 Hz) (TF) Insulation Class H Class H Silicon diode Type SKR130/02 45M20 (Dch) SKN130/02 45MA20 Timer (AMT) Operating Voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H Fuse (Fch) Capacity 100 A 150 A AC power supply capacity 12/11 A 15/14 A Charger weight 60 kg 64 kg 2-30 WIRING DIAGRAM For 200 V For 400 V 2-31 BEFORE CHARGING If the ampere capacity at the charging location is insufficient because other electrical appliances are being used, ask an electrical work contractor to provide an exclusive circuit for the charger. This circuit should be provided with circuit breakers or fuses having the capacities shown on P2-27. TAP Changer Setting 1. Measure with a circuit tester the supply voltage used for charging. Circuit tester range: AC(250 V or 1000 V) Note: Measure the supply voltage at night (or during recess when electrical appliances are not used.) 2. Set the tap charger (1) Remove the cover of each tap. (2) Select the appropriate tap according to the supply voltage measured in step 1 above. (3) Manually close the magnetic switch, and measure the voltage at each tap terminal. 200 V 400 V Note: The tap of the 200 V type is set to 220 V at time of shipment. Tap changer setting shall be made for the U, V and W phases. After setting the tap changer, be sure to check the battery charging status (specific gravity and fluid level) for about a week to confirm proper tap setting. Tap Measured voltage 200 V 199 V or less 210 V 200 to 209 V 220 V 210 to 219 V 230 V 220 to 229 V Tap Measured voltage 340 V 339 V or less 360 V 340 to 359 V 380 V 360 to 379 V 400 V 380 to 399 V 420 V 400 to 419 V 440 V 420 to 439 V 460 V 440 to 459 V 2-32 TROUBLESHOOTING Estimated cause Inspection method Standard Remedial action The thermal relay on the AC side is tripped as soon as charging starts Short circuit of MSch MSch coil continuity inspection Measurement terminals: A1 and A2 OK: Several hundred NG: Abnormally low resistance MSch replacement TF insulation defect or short circuit between coils TF insulation inspection Measurement terminals: Between each coil and frame Inspection of short circuit between TF primary and secondary coils Measurement terminals: Between pri- mary and secondary coil terminals OK: 0.2 M or more NG: Less than 0.2 M OK: 0.2 M or more NG: Less than 0.2 M TF replacement Dch defect Dch resistance inspection in forward and reverse directions Measurement terminals: Both terminals (anode and cathode) of Dch Anode Cathode Forward: Anode Cathode + Reverse: Anode + Cathode OK: Forward Several 10 or more Reverse NG: Forward 0 Reverse 0 Dch replacement Other short circuit in main circuit Inspect the short-circuited portion by separating each circuit. Repair of defective por- tion Charging does not start though operated correctly for starting charging. Interruption or missing phase of input power supply Voltage measurement at main outlet for power supply Measurement terminals: Between outlet terminals OK: 200 to 220 V (charger for 200 V) 380 to 440 V (charger for 400 V) NG: 0 V In case of missing phase, repair after check- ing the case. Disconnection in the AC plug Voltage measurement between R, S and T terminals of MSch OK: 200220V (charger for 200 V) 380 to 440 V (charger for 400 V) NG: 0 V Repair the plug if any phase is missing or no voltage is detected. Blown fuse on DC side DC side fuse continuity inspection Measurement terminals: Both terminals of fuse OK: 0 NG: Fuse replacement MSch coil discon- nection MSch coil continuity inspection Measurement terminals: Between MSch terminals A1 and A2 OK: Several hundred NG: MSch replacement AMT defect AMT inspection Measurement terminals: Between AMT terminals 1 and 5 in wiring diagram OK: 0 V NG: 200 V (Charger for 200 V) 400 V (Charger for 400 V) AMT replacement 2-33 THR contact defect THR contact inspection Measurement terminals: Between THR terminals 95 and 96 OK: Non operated state 0 Operated state NG: Non operated state THR reset- ting by lever operation or MSch ASSY replacement Incomplete charging TF tap charger defect AC input voltage measurement Measurement terminals: Between TF tap charger terminals Change the wiring to match the input voltage Missing phase in input power supply Voltage measurement at mains outlet for power supply Measurement terminals: Between mains outlet terminals OK: 200 to 220 V (Charger for 200 V) 380 to 440 V (Charger for 400 V) In case of a missing phase, repair after check- ing the cause. THR tripping THR continuity inspection Measurement terminals: Between THR terminals 95 and 96 OK: Non operated state 0 Operated state NG: Non operated state Reset lever operation after check- ing the THR tripping cause Dch defect (open circuit) Inspection of Dch resistance in forward and reverse directions Measurement terminals: Both terminals (anode and cathode) of Dch Anode Cathode Forward: Anode Cathode + Reverse: Anode + Cathode OK: Forward Several ten or more Reverse NG: Forward Reverse Dch replacement Disconnection of TF coil Measurement terminals: Between TH coil terminals OK: Continuity NG: TF replacement MSch contact defect MSch secondary voltage measurement Measurement terminals: Voltage mea- surement between MSch terminals U, V and W OK: 200 to 220 V (Charger for 200 V) 380 to 440V (Charger for 400 V) NG: 189 V or less (Charger for 200 V) 319 V or less (Charger for 400 V) MSch contact repair or MSch ASSY replacement TF terminal tighten- ing defect Inspection of each TF terminal tightening state No loosening of each terminal Retightening of each termi- nal Timer setting at short time Setting time check in test mode See timer test section. AMT replacement Estimated cause Inspection method Standard Remedial action 2-34 Other contact defect in charging circuit Inspection of tightening state and con- nector state at each portion No loosening at each portion Defective portion repair or retighten- ing Low battery charge Inspection of battery fluid specific grav- ity, battery voltage and fluid level If the battery voltage is less than the standard, inspect the voltage per cell. NG (Measurement after charging): Specific gravity: 1.150 or less Voltage per cell: 1.75V or less Total voltage of whole cells 24 V battery: 21 V or less 48 V battery: 42.5 V or less 72 V battery: 61 V or less Battery replacement Estimated cause Inspection method Standard Remedial action 2-35 SERVICE STANDARDS Item Service Standard Power supply voltage V For 200 V 200 to 230 V For 400 V 340 to 460 V No-load secondary voltage (The values are the same for 200 V and 400 V.) AC V SG3-69-45JBY-2 Approx. 56 SG3-69-60JBY-2 Approx. 55 SG3-69-80JBY-2 Approx. 57 SG3-69-100JBY-2 Approx. 58 SG3-69-130JBY-2 Approx. 56 SG3-100-100JBY-2 Approx. 85 No-load secondary voltage DC V 24 V Approx. 37 36 V Approx. 56 48 V 74 to 78 72 V Approx. 114 MSch coil resistance CLK-11HT15HT Approx. 970 CLK-20HT25HT Approx. 490 CLK-35HT Approx. 300 CLK-50HT Approx. 250 Dch resistance in forward Approx. 25 Dch resistance in reverse Dch tightening torque Nm (kgfcm) [ft-lb] 20M1020MA10 2.35 (24) [1.74] 20M2020MA20 2.35 (24) [1.74] 20M3020MA30 2.35 (24) [1.74] 45M1045MA10 16.7 (170) [12.3] 45M2045MA20 16.7(170) [12.3] 45M3045MA30 16.7 (170) [12.3] 70M1070MA10 22.0 (224) [16.2] Insulation resistance(500 V Megger) M 0.2 or more 2-36 DISASSEMBLY INSPECTION REASSEMBLY Disassembly Procedure 1 Remove the charger cover. 2 Perform inspections before disassembly. [Point 1] 3 Remove the magnetic switch ASSY (MSch). [Point 2] 4 Remove the timer ASSY (AMT). 5 Remove the resistor (R1R2). 6 Remove the fuse (Fch). [Point 3] 7 Remove the diode (Dch). [Point 4] 8 Remove the transformer (TF). Note: Put a tag indicating the connecting position at the time of disassembly to prevent incorrect connection at the time of reassembly. Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. 2-37 Point Operation [POINT 1] Inspection: Inspect the magnetic switch contact continuity. Inspection: Inspect the magnetic switch coil continuity Inspection: Inspect the thermal relay contact continuity. Note: Do not adjust the thermal relay operating current. If the thermal relay is operated to stop charging while the charger is in use, always check the cause of thermal relay operation, and reset the thermal relay after taking the remedial action. Push the reset lever lightly to reset the thermal relay. Inspection: Inspect the transformer insulation resistance. Circuit tester range 1 Measurement terminals TW, SV, RU Switch Msch ON 0 Msch OFF Resistance between A1 and A2 Circuit tester range See the Service Standards list. 1 Circuit tester range 1 Measurement terminals 9596 Switch Not operated 0 Operated state Measurement terminals Between each coil and frame Standard value 0.2 M or more 2-38 Inspection: Inspect the transformer continuity. [POINT 2] Inspection: Inspect the magnetic switch contact continuity. Inspection: Inspect the magnetic switch coil continuity. Inspection: Inspect the thermal relay contact continuity. Note: Do not adjust the thermal relay operating current. If the thermal relay is operated to stop charging while the charger is in use, always check the cause of thermal relay operation, and reset the thermal relay after taking the remedial action. Circuit test range 1 Measurement terminals Primary side U1V1, V1W1 and W1U1 Secondary side U2V2, V2W2 and W2U2 Standard value 0 Circuit tester range 1 Measurement terminals TW, SV, RU Switch ON 0 OFF Resistance between A1 and A2 Circuit tester range See the Service Standard list. 1 Circuit tester range 1 Measuring terminals 9596 Switch Not operated 0 In operated state 2-39 Push the reset lever lightly to reset the thermal relay. [POINT 3] Inspection: Inspect the transformer insulation. Standard: 0 [POINT 4] Inspection: Inspect the diode in installed state on the fin. Remove it only when an abnormality is found. Inspection: As two diodes having different polarities are used, install in the correct direction. Note: In the case of the charger for batteries with the capacity at 320 AH/5 HR or less, the diode mounting direction is the reverse of the direction shown in the figure. Circuit tester range 1 Measurement terminals Forward Anode () Cathode (+) Reverse Anode (+) Cathode () Standard value Forward See the Service Standards list. Reverse 2-40 [POINT 5] Inspection: Inspect the transformer insulation. Inspection: Inspect the transformer coil continuity. Primary coil Secondary coil Measurement terminals Between each coil and frame Standard value 0.2 M or more Circuit tester range 1 Measurement terminals U2V2, V2W2 and W2U2 Standard value 0 Circuit tester range 1 Measurement terminals U2V2, V2W2 and W2U2 Standard value 0 2-41 Inspection after Reassembly 1. Inspect each wiring for correctness. Note: Check correct wiring at each part by referring to the charger wiring diagram. 2. Inspect the transformer insulation resistance. 3. Measure the no-load secondary voltage. Connect the charger plug to the charger receptacle and start the timer. AC voltage DC voltage Measurement terminals Between each coil and frame Standard value 0.2 M or more Circuit tester range AC 250 V AC 500 V Measurement terminals U2V2, V2W2 and W2U2 Standard value See the Service Standards list Circuit tester range 250 VDC Measurement terminals Both terminals of charger plug (+) terminal (+) probe () terminal () probe Standard value See the Service Standards list. 2-42 AMT Test Method 1. Main timer inspection (1) Turn on the AC power switch. (2) Disconnect the battery plug. (to unload the charger and operate the voltage relay.) (3) Close the magnetic switch (MSch) forcibly by using an insulating bar and press the NORMAL button (black-blue) or EQUAL button (black-blue) for 5 seconds or more until the TEST LED (red) and CHARGING PROGRESS INDICATOR LEDs (three LEDs excluding the uppermost one) light up. Release the button as soon as they light up, and measure with a stop watch the time until the uppermost LED comes on. (4) If the UP LED lights up within the following period of time after TEST LED lights up and all LEDs then immediatelly go out, the main timer is functioning normally. When NORMAL button is pressed: UP LED lights up in about 6 seconds later When EQUAL button is pressed: UP LED lights up in about 18 seconds later 2. Total timer inspection (1) Turn on the POWER switch. (2) Connect the battery in discharged state (as the main timer is operated first because of voltage relay operation in the fully charged state). (3) Press the NORMAL or EQUAL button for 5 seconds, the TEST LED lights up and charging starts. Release the button when the TEST LED lights up and measure with a stop watch the time until the CHECK LED lights up. (4) If the CHECK LED lights up within the following period of time after the TEST LED lights up, the total timer is functioning normally. (The UP LED does not light up.) CHECK LED lights up in 90 to 100 seconds (5) The LED go off when the battery plug is disconnected. Caution: If the NORMAL, EQUAL or STOP button is pressed when a fully charged battery is connected, the main timer operates first to light the UP LED and not the CHECK LED. This does not indicate a total timer defect. Inspect again as described above after replacing the battery with a discharged one. 2-43 YUASA GENERAL SPECIFICATIONS 200 V POWER SUPPLY VOLTAGE Item ZTC48-54AD ZTC48-80AD Magnetic switch Type CLK-20JT CLK-20JT (MSch) Rating AC 200 V 50/60 Hz AC 200 V 50/60 Hz Thermal relay Type T-18 T-18 (THR) Set value 15 A 21 A Transformer Capacity (50/60 Hz) 4.5 KVA 6.6 KVA (TF) Insulation Class B Class B Silicon diode Type 20M20 20MA20 20M20 20MA20 (Dch) Timer (AMT) Operating voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H DC Ammeter (A) Type DCF-6 DCF-6 Indicating range 0 to 75 A 0 to 150 A Fuse (Fch) Capacity 75 A 100 A 2-44 400 V POWER SUPPLY VOLTAGE Item ZTC48-100AD ZTC48-120AD Magnetic switch Type CLK-20JT CLK-35JT (MSch) Rating AC 200 V 50/60 Hz AC 200 V 50/60 Hz Thermal relay Type T-18 T-35 (THR) Set value 25 A 33 A Transformer Capacity (50/60 Hz) 8.3 KVA 9.2 KVA (TF) Insulation Class H Class H Silicon diode Type 45M20 45MA20 45M20 45MA20 (Dch) Timer (AMT) Operating voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H DC Ammeter (A) Type DCF-6 DCF-6 Indicating range 0 to 150 A 0 to 150 A Fuse (Fch) Capacity 100 A 150 A Item ZMC48-54AD ZMC48-80AD Magnetic switch Type CLK-15JT CLK-15JT (MSch) Rating AC 400V 50/60 Hz AC 400 V 50/60 Hz Thermal relay Type T-11 T-18 (THR) Set value 8 A 11 A Transformer Capacity (50/60 Hz) 4.5 KVA 6.6 KVA (TF) Insulation Class B Class B Silicon diode Type 20M20 20MA20 20M20 20MA20 (Dch) Timer (AMT) Operating voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H DC Ammeter (A) Type DCF-6 DCF-6 Indicating range 0 to 75 A 0 to 150 A Fuse (Fch) Capacity 75 A 100 A 2-45 WIRING DIAGRAM Item ZMC48-100AD ZMC48-120AD Magnetic switch Type CLK-20JT CLK-20JT (MSch) Rating AC 400 V 50/60 Hz AC 400 V 50/60 Hz Thermal relay Type T-11 T-18 (THR) Set value 15 A 18 A Transformer Capacity (50/60 Hz) 8.3 KVA 9.2 KVA (TF) Insulation Type H Type H Silicon diode Type 45M20 45MA20 45M20 45MA20 (Dch) Timer (AMT) Operating voltage setting Microcomputer control Microcomputer control Timer setting Microcomputer control Microcomputer control Total timer setting 16 H 16 H DC Ammeter (A) Type DCF-6 DCF-6 Standard 0 to 150 A 0 to 150 A Fuse (Fch) Capacity 100 A 150 A 2-46 COMPONENTS 2-47 BEFORE CHARGING Off-vehicle Charger Circuit Setup If the ampere capacity at the charging location is insufficient because other electrical appliances are being used, a separate circuit exclusively for the charger should be installed. This circuit should be provided with circuit breakers or fuses having the capacities shown below. Type Power Supply Voltage (V) Fuse Capacity (A) ZTC48-54AD 200 to 230 15 ZMC48-54AD 340 to 460 10 ZTC48-80AD 200 to 230 20 ZMC48-80AD 340 to 460 10 ZTC48-100AD 200 to 230 25 ZMC48-100AD 340 to 460 15 ZTC48-120AD 200 to 230 30 ZMC48-120AD 340 to 460 15 2-48 Tap Changer Setting 1. Measure with a circuit tester the power supply voltage to be used for charging. Circuit tester range: AC (250 V or 1000 V) Note: Measure the power supply voltage at night (or, if that is impossible, during a time when electrical appliances are not being operated). 2. Set the tap changer (1) Remove the cover of each tap. (2) Select the appropriate tap corresponding to the power supply voltage measured in step 1 above. (3) Manually close the magnetic switch, and measure the voltage at each tap terminal. 200 V 400 V Note: Tap are set to 220 V at the time of shipment. Be sure to set the changer for phases U, V and W. For about a week after tap changer setting, keep track of the battery charging state (specific gravity and electrolyte level) to make sure the tap setting is appropriate. Tap Measured voltage 200 V 199V or less 210 V 200 to 209 V 220 V 210 to 219 V 230 V 220 to 229 V Tap Measured voltage 340 V 339V or less 360 V 340 to 359V 380 V 360 to 379V 400 V 380 to 399V 420 V 400 to 419V 440 V 420 to 439V 460 V 440 to 459V 2-49 TROUBLESHOOTING Estimated cause Check method Standard Remedial action Thermal relay (THR) actuation as soon as charging starts TF insulation defect or short-circuit in coil TF insulation inspection Measurement terminals: Between each coil terminal and frame Inspection of short-circuit between pri- mary and secondary coil of TF OK: 3 M or more NG: 3 M or less OK: 3 M or more NG: Less than 3 M TF replacement Dch defect (short-circuit) Inspection of Dch forward and reverse resistance Measurement terminals: Both termi- nals of Dch (Anode - Cathode) Anode Cathode Forward: Anode Cathode + Reverse: Anode + Cathode OK: Forward: Over 10 k Reverse: NG: Forward: 0 Reverse: 0 Dch replacement Charging does not start even when the CHARGE ON/OFF switch is pressed to ON. (The timer does not operate.) AC power service interruption or lacking phase Voltage measurement at input recep- tacle Measurement terminals: Between receptacle terminals OK: 200 to 230 V (Charger for 200 V) 340 to 460 V (Charger for 400 V) NG: 0 V Repair after checking the cause for lacking phase Microcomputer timer (BMT) defect AMT inspection Measurement terminals: AMT 2-3 in wiring diagram OK: 0 V NG: 200 V (Charger for 200 V) 400 V (Charger for 400 V) AMT replacement Open circuit in MSch coil MSch coil conduction inspection Measurement terminals: MSch A1-A2 OK: See the service standard NG: MSch replacement THR contact defect THR contact inspection Measurement terminals: THR 95-96 OK: Non-operated state: 0 Operated state: NG: Non-operated state: THR reset lever opera- tion or MSch ASSY replacement Abnormal noise from MSch MSch contact rough- ening Visual inspection of MSch contact NG: Excessive roughen- ing or burn of contact surface MSch replacement Dust entrance or cor- rosion at movable part Visual inspection of MSch contact NG: Dust accumulation or corrosion on mov- able contact MSch con- tact correc- tion or MSch replacement 2-50 The ammeter does not defect. Blown Fch Fch conduction check Measurement terminals: Both termi- nals of Fch OK: 0 NG: Fch replacement Open circuit in TF TF coil conduction inspection Measurement terminals: Between TF terminals OK: 0 NG: TF replacement Dch defect (open circuit) Dch forward and reverse resistance inspection Measurement terminals: Both termi- nals of Dch Forward Forward: Anode Cathode + Reverse: Anode + Cathode OK: Forward: Over 10 k Reverse: NG: Forward: Reverse: Dch replacement Ammeter defect Inspection of conduction between ammeter terminals Measurement terminals: Both termi- nals of ammeter OK: Over 10 or less NG: Ammeter replacement Insufficient charging or total timer actuation (CHECK LED ON) Lacking phase in AC power supply Voltage measurement at input recep- tacle Measurement terminals: Between receptacle terminals OK: 200 to 230 V (Charger for 200 V) 340 to 460 V (Charger for 400 V) NG: 0 V Repair after checking the cause for lacking phase Improper TF tap changer setting Input AC voltage measurement Measurement terminals: Between TF tap changer terminals Wiring change to the taps match- ing the input voltage MSch contact defect Measurement of secondary voltage at MSch contacts Measurement terminals: MSch, U, V and W terminals OK: 200 to 230 V (Charger for 200 V) 340 to 460 V (Charger for 400 V) NG: 189 V or less 329 V or less MSch con- tact repair or MSch replacement Open circuit in TF TF wiring conduction inspection Measuring terminals: TF coil terminals OK: 0 NG: TF replacement Dch defect (open circuit) Dch forward and reverse resistance measurement Measurement terminals: both termi- nals of Dch Forward Forward: Anode Cathode + Reverse: Anode + Cathode OK: Forward: Over 10 k Reverse: NG: Forward: Reverse: Dch replacement Microcomputer timer (BMT) defect Set time check in test mode See page 2-21 BMT replacement Estimated cause Check method Standard Remedial action 2-51 Blown Fch Fch conduction inspection Measurement terminals: Both termi- nals of Fch OK: 0 NG: Fch replacement Excessive charging or ammeter deflection Improper tap changer setting Input AC voltage measurement Measurement terminals: TF tap changer terminals Wiring change to the tap in refer- ence to the input voltage Microcomputer timer (BMT) operation Set time check in test mode See page 2-21 BMT replacement Total timer operation (CHECK LED blinking) Microcomputer timer defect BMT replacement Estimated cause Check method Standard Remedial action 2-52 SERVICE STANDARDS Item Service Standard Power supply voltage V for 200 V 200 to 230 V for 400 V 340 to 460 V No-load secondary voltage AC V ZM(T)C48-54AD Approx. 56 ZM(T)C48-80AD Approx. 55 ZM(T)C48-100AD Approx. 57 ZM(T)C48-120AD Approx. 58 No-load secondary voltage DC V for 48 V battery 72 MSch coil resistance CLK-11HT15HT Approx. 970 CLK-20HT25HT Approx. 490 CLK-35HT Approx. 300 Dch resistance in forward Approx. 25 Dch resistance in reverse Dch tightening torque Nm (kgfcm) [ft-lb] 20M2020MA20 2.35 (24) [1.74] 45M2045MA20 16.7 (170) [12.3] Insulation resistance (500 V megohmmeter) M 3 or more 2-53 BMT Test Method Be sure to use a fully charged battery for the test. 1. Main timer inspection (1) NORMAL test Press the NORMAL button on the BMT panel for 5 seconds or more to start the test. As soon as the NORMAL button is pressed, the magnetic switch is operated and the NORMAL and FINAL LEDs (green) on the BMT panel come on to indicate the start of charging. After 5 seconds, the NORMAL LED (green) starts blinking. The operation stops automatically when the FINAL timer setting (approx. 20 seconds) for the NORMAL test elapses, and the UP LED (green) comes on. To rest the BMT and turn of the UP LED (green), press the NORMAL button again. (2) EQUAL test Press the EQUAL button on the BMT panel for about 5 seconds or more to start the test. As soon as the EQUAL button is pressed, the magnetic switch is operated and the EQUAL and FINAL LEDs (green) on the BMT panel come on to indicate the start of charging. After 5 seconds, the EQUAL LED (green) starts blinking. The operation stops automatically when the FINAL timer setting (approx. 40 seconds) for the EQUAL test elapses, and the UP LED (green) comes on. To reset the BMT and turn of the UP LED (green), press the EQUAL switch again. 2. Total timer inspection Press the NORMAL and EQUAL buttons on the BMT panel are simultaneously for about 5 seconds or more. As soon as the these buttons are pressed, the magnetic switch is operated and the NORMAL LED (green) on the BMT panel comes on to indicate the start of charging. After 5 seconds, the NORMAL and EQUAL LEDs (green) start blinking. The operation stops automatically when the setting time for the total timer test (approx. 60 seconds) elapses, and the CHECK LED (red) blinks. To reset the BMT and turn of the CHECK LED (red), press the NORMAL or EQUAL button again. Caution: If a discharged battery is used for the main timer inspection, the FINAL LED (green) does not come on. In stead, the operation stops automatically when the setting time for the total timer test (approx. 60 seconds) elapses, and the CHECK LED (red) blinks. 2-54 3-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CONTROLLER Page GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 BEFORE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . 3-7 CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 MAIN CONTROLLER ASSY . . . . . . . . . . . . . . . . . . . . . 3-19 TRAVELING AC DRIVER . . . . . . . . . . . . . . . . . . . . . . . . 3-20 MATERIAL HANDLING AC DRIVER, CONTACTOR PANEL ASSY. . . . . . . . . . . . . . . . . . . . 3-21 CHECK MOTOR INPUT VOLTAGE . . . . . . . . . . . . . . . . 3-23 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 DIRECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 3-27 DISASSEMBLY INSPECTION REASSEMBLY . . . . . 3-29 ACCELERATOR POTENTIOMETER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . 3-31 FOOT BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 MATERIAL HANDLING LEVER SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . 3-32 Thank you very much for your reading. 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