Toyota 7FBCU 15-55 Manual

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7FBCU 15-55

GENERAL

BATTERY

CONTROLLER

MULTI-DISPLAY FUNCTIONS

TROUBLESHOOTING

MOTOR

DRIVE UNIT

FRONT AXLE

REAR AXLE

STEERING

BRAKE

BODY

MATERIAL HANDLING SYSTEM

MAST

CYLINDER

OIL PUMP

OIL CONTROL VALVE

SAS FUNCTIONS

APPENDIX

NAME

INDEX

SECTION

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Page 1 7FBCU 15-55 INDEX NAME SECTION GENERAL BATTERY CONTROLLER MULTI-DISPLAY FUNCTIONS TROUBLESHOOTING MOTOR DRIVE UNIT FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE SAS FUNCTIONS APPENDIX <Tillbaka till Index...
Page 2: Table Of Contents
GENERAL Page Page EXTERIOR VIEWS RECOMMENDED LUBRICANT ......0-2 QUANTITY & TYPES ....0-18 VEHICLE MODEL ......0-3 LUBRICATION CHART ....0-19 FRAME NUMBER ......0-4 PERIODIC MAINTENANCE ..0-21 HOW TO USE THIS MANUAL ..0-5 PERIODIC REPLACEMENT OF EXPLANATION METHOD ....
Page 3: Exterior Views
EXTERIOR VIEWS...
Page 4: Vehicle Model
VEHICLE MODEL Model Load C apacity Vehicle Model Voltage R emarks C ode 7 F B C U15 36V/48V 3000 lbs 30-7 F B C U15 ↑ Dust proof 7 F B C U18 ↑ 3500 lbs 30-7 F B C U18 ↑...
Page 5: Frame Number
FRAME NUMBER Frame No. Punching Position Punching position Vehicle Model Punching format Vehicle Model Punching format 7 F B C U15 7 F B C U35 7 F B C U18-60011 7 F B C U45-60011 * 7 F B C U18 60011 7 F B C U18 7 F B C U45...
Page 6: How To Use This Manual
HOW TO USE THIS MANUAL EXPLANATION METHOD 1. O peration procedure (1) The operation procedure is described in either pattern A or pattern B below. P attern A: E xplanation of e ach operation step with illustration. P attern B: E xplanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summariz ed as point operations.
Page 7: Terminology
2. How to re ad components figures (E xample) (1) The components figure uses the illustration 3201 in the parts catalog for the vehicle model. Ple ase refer to the catalog for checking the FIG number in parts catalog part name. The number at the right shoulder of e ach components figure...
Page 8: Operational Tips
(6) R eplace, gaskets, packing and O-rings with new ones e ach time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts. O bserve the specified tightening torque at the time of re assembly.
Page 9: Jack-Up Point
JACK-UP POINT Strictly observe the following instructions when jacking up the vehicle. • When a load is on the fork, unload it and park the vehicle on a flat floor. B e sure to avoid an inclined or rugged place. •...
Page 10: Hoisting The Vehicle
HOISTING THE VEHICLE When hoisting the vehicle, use the mast hook on the front of the vehicle and a wire net on the re ar whe el. Caution: • Use wire ropes having sufficient strength. • Never hoist the forklift by the weight hook holes or head guard.
Page 11: Attentive Points On Sas
(valves, piping, etc.). P eriodic replacement of the hydraulic oil is very important. 7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts, etc.).
Page 12: Circuit Tester
0-11 CIRCUIT TESTER Circuit testers are available in both the analog and digital types. They should be used selectively according to the purpose of me asurement. Analog type: This type is convenient for observing movement during operation, but the me asured value should only be used for reference or rough judgement.
Page 13 0-12 2. Difference in result of me asurement with 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.
Page 14: Standard Bolt & Nut Tightening Torque
0-13 STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below. 1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table. 2.
Page 15: Tightening Torque Table
0-14 TIGHTENING TORQUE TABLE Specified torque H exagon H exagon Diameter Pitch Class he ad bolt flange bolt ⋅ ⋅ kgf-cm ft-lbf kgf-cm ft-lbf 48 in-lbf 52 in-lbf 1.25 1.25 1.25    1150 56 in-lbf 65 in-lbf 1.25 1.25 1.25 1050...
Page 16: Precoat Bolts
0-15 PRECOAT BOLTS (Bolts with se al lock agent coating on thre ads) Do not use the precoat bolt as it is in either of the following cases: (a) After it is removed. (b) When the precoat bolt is moved (loosened or S e al lock agent tightened) by tightness check, etc.
Page 17: Wire Rope Suspension Angle List
0-16 WIRE ROPE SUSPENSION ANGLE LIST Suspension Suspension Lifting angle Tension C ompression Lifting angle Tension C ompression method method 0° 1.00 time 0 time 90° 1.41 time 1.00 time 90° 30° 30° 1.04 time 0.27 time 120° 2.00 time 1.73 time 120°...
Page 18: Components Weight
0-17 COMPONENTS WEIGHT Member Model Weight kg (lbs) B attery A S S Y S e e page 1-2. ⋅ Approx. 90 (198) Drive motor A S S Y 20 ~ 32 Approx. 120 (265) 35 ~ 55 Approx. 190 (419) ⋅...
Page 19: Recommended Lubricant Quantity & Types
0-18 RECOMMENDED LUBRICANT QUANTITY & TYPES D escription Application Q uantity l (U S gal) Classification Type ⋅ 18 model 3.8 (1.00) ⋅ 18 (de ad-man spec.) model Drive unit 5.5 (1.45) 20 ~ 32 model A PI Hypoid ge ar oil 35 ~ 55 model 2.0 (0.53) G L-4...
Page 20: Lubrication Chart
0-19 LUBRICATION CHART 15 ~ 32 Model ⋅ (20 ~ 30 model) 15 15 (15 18 model) Inspection Inspect every 8 hours (daily) R eplacement II. Inspect every 40 hours (we ekly) MP Gre ase III. Inspect every 170 hours (monthly) E ngine Oil IV.
Page 21 0-20 35 ~ 55 Model Inspection Inspect every 8 hours (daily) R eplacement II. Inspect every 40 hours (we ekly) MP Gre ase III. Inspect every 170 hours (monthly) E ngine Oil IV. Inspect every 1000 hours (6 monthly) Hypoid ge ar Oil V.
Page 22: Periodic Maintenance
0-21 PERIODIC MAINTENANCE Inspection Method ⋅ I : Inspection R epair or replacement if required. ⋅ M : Me asurement R epair or adjustment if required. T : R etightening C : Cle aning L: Lubrication * : F or new vehicle *1: Flaw detector E very E very E very...
Page 23 0-22 Every Every Every Every Inspection Period month 3 months 6 months 12 months Every Every Every Every Item 170 hours 500 hours 1000 hours 2000 hours Harness deterioration, champ damage and ← ← ← looseness Wiring ← ← ← (including Looseness in connecting parts, taping condition charging cord)
Page 24 0-23 Every Every Every Every Inspection Period month 3 months 6 months 12 months Every Every Every Every Item 170 hours 500 hours 1000 hours 2000 hours BRAKING SYSTEM ← ← ← Play and reserve Brake pedal ← ← ← Braking effect ←...
Page 25 0-24 E very E very E very E very Inspection P eriod month 3 months 6 months 12 months E very E very E very E very Item 170 hours 500 hours 1000 hours 2000 hours H Y D R A ULIC S Y S T E M ←...
Page 26 0-25 E very E very E very E very Inspection P eriod month 3 months 6 months 12 months E very E very E very E very Item 170 hours 500 hours 1000 hours 2000 hours D amage and cracks of frame, cross members, etc.
Page 27: Periodic Replacement Of Parts And Lubricants
0-26 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS : R eplacement E very E very E very E very R eplacement timing month 3 months 6 months 12 months E very E very E very E very Item 170 hours 500 hours 1000 hours 2000 hours Drive unit oil...
Page 28 BATTERY Page BATTERY COMPARTMENT AND REQUIRED WEIGHT ................1-2 SERVICE STANDARD ..........1-3 DISPLAY ................1-3 TROUBLESHOOTING ..........1-4 BATTERY ASSY ............. 1-5 ⋅ REMOVAL INSTALLATION ..........1-5 INSPECTION ..............1-6...
Page 29: Battery Compartment And Required Weight
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. S e e N ew Model F e atures (Pub. No. P U312) for the battery recommendation. C ompartment dimensions Minimum required battery mm (in.)
Page 30: Service Standard
SERVICE STANDARD Specific gravity upon full charge 1.280 [20°C (68°F)] Specific gravity upon end of discharge 1.150 [20°C (68°F)] 36 V 32.0 V Discharge end voltage 48 V 42.5 V Electrolyte R efined dilute sulfuric acid Fluid to be added Distilled (deioniz ed) water Insulation resistance 1MΩ...
Page 31: Troubleshooting
TROUBLESHOOTING...
Page 32: Battery Assy
BATTERY ASSY ⋅ REMOVAL INSTALLATION Always remove or install the battery in no-load state (without any load on the fork). Removal Procedure Disconnect the battery plug. O pen the battery hood. R emove the re ar toe board. Loosen battery stoppers (R H and LH) and the fixing bolts. R emove the battery A S S Y.
Page 33: Inspection
INSPECTION Electrolyte inspection B attery electrolyte is normal when it is transparent. C heck turbidity when inspecting the specific gravity. If it cannot be checked cle arly, put the electrolyte in a be aker for inspection. Specific gravity inspection Use a hydrometer and me asure the specific gravity of the electrolyte.
Page 34 Insulation resistance inspection Use an insulation resistance meter (megohmmeter) and me asure the resistance betwe en the battery and battery case. Insulation resistance:1 MΩ or more Note: • When the insulation resistance is less than 1 MΩ, wash the battery with water after removing it from the vehicle.
Page 35 CONTROLLER Page Page GENERAL BOARD INSPECTION ..... 2-30 .......... 2-2 DISASSEMBLY........ 2-67 SPECIFICATIONS ......2-3 REASSEMBLY......... 2-68 COMPONENTS ......... 2-4 DISPLAY INSPECTION ....2-79 CONTROLLER ........ 2-15 DIRECTION SWITCH ....2-80 TRAVELING/MATERIAL HANDLING ⋅ CONTROLLER ASSY REMOVAL INSTALLATION ..... 2-80 ⋅...
Page 36: General
GENERAL The following controller is installed on the 7 F B C U series: • Traveling/Material handling system: Traveling/Material handling controller (15 ~ 32 model) • Traveling system: Traveling controller (35 ~ 55 model) • Material handling system: Material handling controller (35 ~ 55 model) •...
Page 37: Specifications
SPECIFICATIONS ⋅ ⋅ 18 model 20 ~ 32 model 18 model 20 ~ 32 model 35 ~ 55 model (chopper-less) (chopper-less) (chopper) (chopper) F 1 (F or drive) 275A 325A 500A 600A 700A    F 2 (F or pump) 225A 325A ...
Page 38: Components
COMPONENTS Traveling/Material Handling Controller (15 ~ 32 Model) 2401 C hopper-less...
Page 39 2401 C hopper-less C hopper...
Page 40 2401 C hopper...
Page 41 Traveling Controller (35 ~ 55 Model) 2401...
Page 43 Material Handling Controller (35 ~ 55 Model) 2402...
Page 44 2-10 Contactor Panel (15 ~ 32 Model) 2402 C hopper-less C hopper...
Page 45 2-11 2402 C hopper-less Dust proof C hopper Dust proof...
Page 46 2-12 Contactor Panel (35 ~ 55 Model) 2402...
Page 47 2-13 PS Controller 2402 F H P S E H P S...
Page 48 2-14 SAS Controller 2401...
Page 49: Controller
2-15 CONTROLLER ⋅ TRAVELING/MATERIAL HANDLING CONTROLLER ASSY REMOVAL INSTALLATION (15 ~ 32 MODEL) Caution: Before starting the job, measure the voltage between P14 and N1; if there is any voltage, insert a resistor at approx. 100 Ω between P14 and N1 to discharge the capacitor. ⋅...
Page 50: Traveling Controller Assy Removal Installation (35 ~ 55 Model)
2-16 ⋅ TRAVELING CONTROLLER ASSY REMOVAL INSTALLATION (35 ~ 55 MODEL) Caution: Before starting the job, measure the voltage between P4 and N1; if there is any voltage, insert a resistor at approx. 100 Ω between P4 and N1 to discharge the capacitor. ⋅...
Page 51: Material Handling Controller Assy Removal Installation (35 ~ 55 Model)
2-17 ⋅ MATERIAL HANDLING CONTROLLER ASSY REMOVAL INSTALLATION (35 ~ 55 MODEL) Caution: Before starting the job, measure the voltage between P12 and N2; if there is any voltage, insert a resistor at approx. 100 Ω between P12 and N2 to discharge the capacitor. ⋅...
Page 52: Traveling And Material Handling Controller Inspection
2-18 TRAVELING AND MATERIAL HANDLING CONTROLLER INSPECTION Some components can be inspected after they are removed from the vehicle, while others can only be inspected as installed on the vehicle. Inspect the C P U board, D C/MD board, S C P U board and D C/P D board as installed on the vehicle since the battery voltage must be applied.
Page 53 2-19 2. C O (overall capacitor) (1) Inspection method C onfirm complete discharge of C O before inspection. Portion to be Me asurement terminals Tester range inspected Ω × 1k Both terminals on the re ar side of C O Standard: Bring tester probes into contact with both terminals of C O .
Page 54 2-20 35 ~ 55 model (F or material handling) 4. C ooling fan (1) Inspection method F an connector disconnected Model Portion to be inspected Me asurement terminals Standard Tester range FA N N O .1 C N132-1 (17) - C N132-2 (N2) 15 ~ 32 FA N N O .2 C N133-1 (7) - C N133-2 (8)
Page 55: Contactor Panel Assy Removal Installation (15 ~ 32 Model)
2-21 ⋅ CONTACTOR PANEL ASSY REMOVAL INSTALLATION (15 ~ 32 MODEL) ⋅ T = N m (kgf-cm) [ft-lbf] Dust proof model T = 11 ~ 15 (112 ~ 153) [8.1 ~ 11.1] Nut connecting panel to cable T = 15 ~ 19 (153 ~ 194) [11.1 ~ 14.0] Removal Procedure Disconnect the battery plug.
Page 56: Contactor Panel Assy Removal Installation (35 ~ 55 Model)
2-22 ⋅ CONTACTOR PANEL ASSY REMOVAL INSTALLATION (35 ~ 55 MODEL) ⋅ T = N m (kgf-cm) [ft-lbf] Dust proof model T = 11 ~ 15 (112 ~ 153) [8.1 ~ 11.1] Nut connecting panel to cable T = 15 ~ 19 (153 ~ 194) [11.1 ~ 14.0] Removal Procedure Disconnect the battery plug.
Page 57: Contactor Panel Inspection
2-23 CONTACTOR PANEL INSPECTION 1. Power supply contactor (1) Inspection method Disconnect the contactor connector, and me asure the resistance of the contactor coil. Portion to be Model Me asurement terminals Standard Tester range inspected 15 ~ 32 ⋅ MP C oil C hopper less Approx.
Page 58: Ps Controller Assy Removal Installation (15 ~ 32 Model)
2-24 ⋅ PS CONTROLLER ASSY REMOVAL INSTALLATION (15 ~ 32 MODEL) Removal Procedure Disconnect the battery plug. R emove the toe board (re ar). R emove the control panel A S S Y. Disconnect the electrical wiring. Installation Procedure The installation procedure is the reverse of the removal procedure.
Page 59: Ps Controller Inspection (15 ~ 32 Model)
2-25 PS CONTROLLER INSPECTION (15 ~ 32 MODEL) FHPS R emove the cover and perform the operation with the controller installed on the vehicle. 1. P22-N1 voltage me asurement ⋅ B attery plug connected key switch O N P22  N1 Me asurement terminals Circuit tester range D C 200 V...
Page 60 2-26 3. F 3 (P S circuit fuse) inspection B attery plug disconnected, F 3 removal Me asurement terminals Both terminals of F 3 Ω × 1 Circuit tester range 0 Ω Standard...
Page 61 2-27 EHPS Similarly as the traveling/material handling controllers, some components can be inspected after removal from the vehicle while others cannot unless they are installed on the vehicle. The E H P S board is to be inspected as installed on the vehicle because they must be applied with the battery voltage.
Page 62 2-28 2. S H (shunt) (1) Inspection method Disconnect the S H wiring. Portion to be inspected Me asurement to be inspected Standard Tester range Ω × 1 Both terminals of S H C ontinuity shall exist. 3. F 3 (P S circuit fuse) inspection F 3 removal Me asurement terminals Both terminals of F 3...
Page 63: Sas Controller Assy Removal Installation
2-29 ⋅ SAS CONTROLLER ASSY REMOVAL INSTALLATION Note: SAS controller has a built-in yaw rate sensor. Care should be taken in handling it by preventing the dropping, contact with other objects and so forth. If dropped, replace with a new one. Don’t apply the impact wrench in removing/installing the set bolts from/to the oil control valve connector bracket and SAS controller.
Page 64: Inspection
2-30 BOARD INSPECTION If the cause of the trouble is judged to exist in any board, check the applied voltage and the resistance at each connector. Also check the following items, since they may damage the board in its normal state or cause a new problem.
Page 65 2-31 (2) C P U board: C N141 to C N143 me asuring method and standard list How to re ad the list Tester (+) probe Tester (-) probe C onnector pin No. C onnector No.⇔C onnector No. C onditions Standard R emarks C N101-1...
Page 66 2-32 C onnector No.⇔C onnector No. C onditions Standard R emarks C N101-15  Imme asurable (342, IS P S+) Vehicle with C N101-16 C N101-12 Approx. 0 V motor brush (196, BMP S) (51, LS-) we ar warning Vehicle with C N101-17 C N101-12 Approx.
Page 67 2-33 C onnector No.⇔C onnector No. C onditions Standard R emarks C N103-5  Imme asurable (144, SMT D K) C N103-6  Imme asurable (143, S D TMK) C N103-7  Imme asurable (142, S D TMA) C N103-8 ...
Page 68 2-34 C onnector No.⇔C onnector No. C onditions Standard R emarks  C N104-11 Unused C N104-12 C N104-17 Approx. 0 V (76, C S P-) (N2, N2) C N104-13 C N104-17 Approx. 0 V (76, C S D-) (N2, N2) C N104-14 C N104-17 K ey switch O F F...
Page 69 2-35 C onnector No.⇔C onnector No. C onditions Standard R emarks  C N105-12 Unused  C N105-13 Unused  C N105-14 Unused C N106 basic conditions (battery plug connected, key switch O N, direction lever at N, and motor cable disconnected) C onnector No.⇔C onnector No.
Page 70 2-36 DC/MD board C N111 basic conditions (battery plug connected, key switch O N, direction lever at N, and motor cable disconnected) C onnector No.⇔C onnector No. C onditions Standard R emarks C N111-1 C N112-18 Approx. 36 V/48 V (41, B48V) (N2, N2) C N111-2...
Page 71 2-37 C onnector No.⇔C onnector No. C onditions Standard R emarks C N112-8 C N112-18 Approx. 36 V/48 V (44, V BMB) (N2, N2)  C N112-9 Unused C N112-10 C N112-11 Me asurement with (-) probe in Approx. 11 V (1, MB + (MD+)) (2, MB- (MD-)) contact with C N112-11...
Page 72 2-38 C onnector No.⇔C onnector No. C onditions Standard R emarks C N113-11 C N113-24 13 ~ 15 V (156, TMD B D1+) (N2, TMD B D-S D) C N113-12 C N113-25 13 ~ 15 V (158, TMD C U1+) (P7, TMD C U-S D) C N113-13 C N113-26...
Page 73 2-39 Traverling/material handling controller (15 ~ 32 model) C N137 basic conditions (battery plug connected, key switch O N, direction lever at N, and motor cable disconnected) C onnector No.⇔C onnector No. C onditions Standard R emarks C N137-1 C N137-3 B attery plug disconnected Approx.
Page 74 2-40 SAS controller (15 ~ 32 model) ST board C N141 basic conditions (battery plug connected, key switch O N) C onnector No.⇔C onnector No. C onditions Standard R emarks C N141-1 C N141-11 Approx. 5 V (137, SL/L+) (320, S T P O T-) C N141-2 C N141-11 Approx.
Page 75 2-41 C N142 basic conditions (battery plug connected, key switch O N) C onnector No.⇔C onnector No. C onditions Standard R emarks C N142-1 C N142-7 48 V/36 V (303, V BMB2) (N2, N2) C N142-2 C N141-11 S WMH1 O N Approx.
Page 76 2-42 C N143 basic conditions (battery plug connected, key switch O N) C onnector No.⇔C onnector No. C onditions Standard R emarks B attery plug disconnected Approx. 10 Ω C N143-1 C N143-7 R esistance me asurement (330, S O LT-) (327, S O LT S+) LS T R O N Approx.
Page 77 18-61 CONNECTING DIAGRAM (15 ~ 32 MODEL)
Page 78 CONNECTING DIAGRAM (35 ~ 55 MODEL) 18-62...
Page 79 18-63 WIRING DIAGRAM (15 ~ 32 MODEL)
Page 80 18-64 WIRING DIAGRAM (35 ~ 55 MODEL)

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