Toyota Forklitf Mode 8FBN1530, 508FBN1520 Vol.2 Repair Manual

trọn bộ tài liệu hướng dẫn, tháo lắp, sửa chữa chi tiết và full code lỗi cho xe Toyota Forklitf Mode 8FBN1530, 508FBN1520 . Được phát hành từ hãng TOYOTA Industries. Mọi thắc mắc xin liên hệ qua mail : Ngoanhquocngogmail.com

Trang 2

This Manual (Volume 2) contains diagnosis, service procedures of electrical controller and display of the TOYOTA ELECTRICAL POWERED FORKLIFT 8FBN15 to 30, 50-8FBN15·18·20 series.

For maintenance, specifications and repair procedure for the chassis, body and material handling system, refer to Volume 1 (Pub No CE349).

Please use these manuals for providing quick, correct servicing of the sponding forklift models.

corre-This manual deals with the above models as of January, 2012 Please stand that disagreement can take place between the descriptions in the manual 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.

Trang 3

Section indicated by solid characters are included in this manual.

Section indicated by half-tone characters: Refer to vol 1 (Pub No CE349).

Trang 4

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONTROLLER

Page GENERAL 3-2

Trang 6

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTOR-PIN ASSIGNMENT

CN101

G85703002_

Trang 8

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

44 SSTR+ SSTR+ STEERING WHEEL ANGLE SENSOR AND ULTRA SONIC SENSOR POWER SUPPLY (combined use)

Trang 9

15 PSSW+ PSSW+ POWER SUPPLY for MINI LEVER SWITCH (LOAD METER, AUTOMATIC FORK LEVERING and SWITCH for 4/5-WAY SW)

(only SSC combined with SW)

Trang 10

DRIVE·MATERIAL HANDLING AC DRIVER

Trang 13

4

*T1

1

113

5

139

8

7 *T39

1314

12

*T211109

8 7 *T3

Trang 14

Some components can be inspected after they are removed from the vehicle, some components can be inspected

as installed on the vehicle

Main controller must be inspected as installed on the vehicle since the battery voltage must be applied

Disassembly Procedure

• Overhauling the contactor panel is rarely necessary In most cases, failed parts is replaced after finding out the cause of the failure from inspection Therefore, make sure to repair correctly by referring to the figures of configuration and ASSY.

• Do not disassemble drive·material handling AC driver and the main controller, as they should be replaced in a form of ASSY.

Caution for part replacement

• Observe the specified tightening torque for tightening bolts Insufficient torque and overlooking of tightening may cause other failure.

• When disconnecting the bars and harness, record the connecting location and place tags When connecting them again, be sure to confirm with the record and tags to prevent incorrect connection Incorrect connection may cause other failure.

• After installation, check that there is no interference of the bar and harness connection with other portion.

Trang 15

• Abnormality in related harnesses

• Looseness of the related connectors

• Bending or damage of connector pin and defective contact of any related connector pin.

If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be damaged

Always replace the board after careful inspection

Measurement method and standard list

How to read the list

09230-13240-71 Measure the voltage or resistance for main controller. For use CN101 to CN104

09240-13241-71 Measure the voltage for AC driver For use CN110 to CN111

Conditions Standard RemarksCN101-1

(45, DSF)

CN101-26(51, LS-) Key switch OFF, DSF ON. Approx 0V

Connector pin No

Conditions for measurement

Tester Probe

+

-G85703015_

Trang 16

MAIN CONTROLLER

CPU board

Material Handling Lever

CN101 connector basic conditions (battery plug connected, key switch ON)

CN101-1

(3, SOLLU+)

CN102-16(4, SLLL-)

Lift lock solenoid ONLift lock solenoid OFF

Approx 11VApprox 0VCN101-2

(6, SLTFB+)

CN102-19(7, SLTFL-)

Tilt forward solenoid ONTilt forward solenoid OFF

Variation upon changeover from upward to downward lifting Approx 0V to 10VCN101-6

(32, SLTA1+)

CN101-12(33, STPL-)

Variation upon changeover from forward to backward tilting Approx 0V to 10V

Resistance measurement with

CN101-11

(37, SA1PS-)

CN101-6(32, SLTA1+)

CN101-12

(33, STPL-)

CN101-6(32, SLTA1+)

Resistance measurement with battery plug disconnected Approx 7ΩCN101-13

(34, STPS-)

CN101-6(32, SLTA1+)

(39, SA2PL-)

CN101-5(9, SLLA2+)

CN104CN103

CN102CN101

G85703016_

Trang 17

CN101-16

(11, SLPS-)

CN101-5(9, SLLA2+)

(10, SLPL-)

CN101-5(9, SLLA2+)

Key switch OFFKey switch ON

Approx 0VBattery voltageCN102-4

(19, VBMBSL)

CN104-4(N2, N2)

(17, SOLCOM)

CN104-4(N2, N2)

Approx 0VBattery voltage

Trang 18

(17, SOLCOM)

CN104-4(N2, N2)

Approx 0VBattery voltage

CN102-7

(329, SLS+)

CN102-14(330, SLS-)

Knob position correcting solenoid ON

Knob position correcting solenoid OFF

Approx 11VApprox 0V

(330, SLS-)

CN102-7(329, SLS+)

Resistance measurement with battery plug disconnected Approx 10Ω

-CN102-16

(4, SLLL-)

CN101-1(3, SOLLU+)

Resistance measurement with battery plug disconnected Approx 10Ω

CN102-20

(25, VRA12)

CN102-26(51, POT-)

Attachment 1 lever in the neutral position

Attachment 1 lever in the forward

to backward position

Approx 2.3VApprox 0.5V to 4V *1

CN102-21

(24, VRA11)

CN102-26(51, POT-)

CN102-22

(23, VRT2)

CN102-26(51, POT-)

Tilt lever in the neutral positionTilt lever in the forward to backward position

Approx 2.3VApprox 0.5V to 4V

CN102-23

(22, VRT1)

CN102-26(51, POT-)

Tilt lever in the neutral positionTilt lever in the forward to backward position

Approx 2.3VApprox 0.5V to 4V

Key switch OFF, Resistance variation when brake pedal fully depressed

Approx 0.9V to 2.9V

Except for models with 50-CN102-26

Trang 19

CN102-30

(52, VRA1)

CN102-26(51, POT-)

Key switch OFF, Resistance variation when accelerator pedal fully depressed

Approx 0.9V to 4.1V

CN102-33

(71, VRB1)

CN102-26(51, POT-)

Key switch OFF, Resistance variation when brake pedal fully depressed

Approx 0.6V to 2.6V

Except for models with 50-

Key switch ON

Variation upon changeover from forward to backward tilting Approx 1V to 4V

Trang 20

(21, VRL2)

CN102-26(51, POT-)

Lift lever in the neutral position Lift lever in the forward to backward position

Approx 2.3VApprox 0.5 to 4V

Key switch OFF, mast in uppermost position Key switch OFF, mast in lowermost position

Approx 0VApprox 5V

CN103-25

(221, SHL)

CN103-6(51, LS-)

Key switch OFF, mast height switch ON

Key switch OFF, mast height switch OFF

Approx 0VApprox 5V

CN103-26

(20, VRL1)

CN102-26(51, POT-)

Lift lever in the neutral position Lift lever in the forward to backward position

Approx 2.3VApprox 0.5 to 4V

-CN103-28

(220, VRH)

CN102-26(51, POT-)

Resistance variation when raising and lowering the lift Approx 0.5 to 4.3VCN103-29

(59, SPLF)

CN102-26(51, POT-)

Forks on the ground Resistance variation when raising and lowering the lift with a load

Approx 1V or lessApprox 0.5V to 4.5V

Key switch OFF, automatic fork leveling switch ON

Key switch OFF, automatic fork leveling switch OFF

Approx 0VApprox 5V

Trang 21

Key switch ON

(1, CBAT+)

CN104-9(2, CBAT-) Key switch ON

Key switch OFF

Key switch OFF, seat switch ONKey switch OFF, seat switch OFF

Approx 0VApprox 5V

CN104-19

(46, DSR)

CN103-6(51, LS-)

Key switch OFF, direction switch backward

Key switch OFF, direction switch neutral

Approx 0VApprox 5V

CN104-20

(66, SPB)

CN103-6(51, LS-)

Key switch OFF, parking brake switch release

Key switch OFF, parking brake switch lock

Approx 0VApprox 5V

-CN104-22

(90, SH1)

CN103-6(51, LS-)

Mast in uppermost position, key switch OFF

Mast raising, key switch OFF

Approx 0VApprox 5V

Trang 22

(65, SWBK)

CN103-6(51, LS-)

Key switch OFF, brake not operated

Key switch OFF, brake operated

Approx 0VApprox 5V

Only for models with 50-CN104-24

Key switch OFF, direction switch forward

Key switch OFF, direction switch neutral

Approx 0VApprox 5V

-CN104-28

(68, SHS)

CN103-6(51, LS-)

Key switch OFF, load switch ONKey switch OFF, load switch OFF

Approx 0VApprox 5V

Trang 23

DRIVE AC DRIVER

-L: Approx 0.5V or H: Approx 1.5V

8

9 10 11 12 13 14

15

16 17 18 19 20 21 22 23

G85703017_

Trang 24

MATERIAL HANDLING AC DRIVER

Trang 25

CONTACTOR PANEL ASSY

-CN127-2

(97, RY+)

N1 terminal(N1, N1)

Apply the negative probe to the N1 terminal to measure voltage Approx 48V

Apply the negative probe to the N1 terminal to measure voltage

CN128

1 · 2 ton 3 ton

G85703018_

Trang 26

CN128 connector basic conditions (3 ton series only) (battery plug connected, key switch ON)

CN136 connector basic conditions (battery plug connected, key switch OFF)

Apply the negative probe to the N1 terminal to measure voltage Approx 80VCN128-4

(1, CBAT+)

N1(N1, N1)

(1, CBAT+)

N1(N1, N1)

(1, CBAT+)

N1(N1, N1)

Apply the negative probe to the N1 terminal to measure voltage Approx 80V

-CN128-8

(99, VFAN)

N1(N1, N1)

Fan ONApply the negative probe to the N1 terminal to measure voltage

Approx 30V

CN128-9

(99, VFAN)

N1(N1, N1)

Approx 30V

CN128-10

(99, VFAN)

N1(N1, N1)

Approx 30V

CN128-11

(99, VFAN)

N1(N1, N1)

Battery plug disconnected, and the CN136 connector

CN136-2

(41, B48V)

P2 (P2, P2)

CN136-3

(1, CBAT+)

CN136-4(2, CBAT-)

Apply the negative probe to the CN136-3 to measure voltage Approx 11 ΩCN136-4

(2, CBAT-)

CN136-3(1, CBAT+)

CN136-5

(44, VBMB)

P3(P3, P3)

CN136-6

(19, VBMBSL)

P3(P3, P3)

CN136-7

(42, KYSAT)

N1(N1, N1)

1·2 ton series:

Approx 48V

3 ton series:

Approx 80V

Trang 27

CN137-1

(303, CSBAT+)

CN137-2(305, CSBAT-)

Apply the negative probe to the CN137-2 to measure voltage Approx 5VCN137-2

-CN137-3

(304, CSBAT)

CN137-2(305, CSBAT-)

Apply the negative probe to the CN137-2 to measure voltage

Drive motor, pump motor, all auxiliary machines OFF

Battery plug disconnected, and

-CN142-3 - Battery plug disconnected, and CN142 disconnected

CN143-1

(42, KYSAT)

N1(N1, N1)

1·2 ton series:

Approx 48V

3 ton series:

Approx 80V

Trang 28

Trang 29

*1 PIN CODE ENTRY SYSTEM

*2 Multifunction display/ DX only

*3 Cold storage specification only

Trang 30

TEN-KEY (W/ PIN code entry system)

6 7 8 9 10

G85703020_

Trang 31

CHARGER SWITCH BOX (OPTION)

*1: This connector is not used in 8FBN model, but wire harness is connected

7 8 9 10 11 12

G85703021_

Trang 32

BATTERY ELECTROLYTE LEVEL SENSOR

L: approx 1.8V orH: approx 2.7V

CN68

2 1

G85703022_

CN35 1

G85703023_

Trang 33

MAIN CONTROLLER REMOVAL·INSTALLATION

Removal Procedure

1 Turn the key switch OFF and disconnect the battery plug

2 Remove the rear cover

3 Open the battery hood and remove the controller upper cover (bolt: 4 pcs.)

4 Remove the rear pillar cover LH

5 Remove the rear pillar cover RH

6 Remove the battery guard (upper)

Controller upper

cover

Rear coverBolt

G85703006_

Bolt

LH cover

BoltClip

Trang 34

7 Disconnect the harness and cable from the contactor panel.

8 Remove the bolt

Note:

Use a 25cm long extension.

9 Remove the contactor panel

G85703012_

G85703010_

Main controllerBolt

Connector

Bolt

BoltBolt

G85703011_

Trang 35

After replacing the main controller, configure the setting for each function with initial setting values Also, refer to MATCHING in section 4 DISPLAY FUNCTION and perform matching.

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure

Trang 36

MATERIAL HANDLING AC DRIVER

REMOVAL·INSTALLATION (1 ton series and 50-8FBN20)

1 Disconnect the harness and cables from the terminals

of the material handling AC driver, which is indicated

by the arrows in the illustration

Trang 37

3 Remove the AC driver from the rear frame, using service bolt (adjustment bolt)

Trang 38

• Use either one of the following types of silicone grease.

KS-609 (Shin-Etsu Chemical Co.,Ltd.)

FLOIL G-600 (KANTO KASEI Ltd.)

• Apply threadlocker (LOCTITE 243) to the bolts when tightening the AC driver.

• Remove excess grease after installing the AC drivers.

Material handling

AC driver

G85703028_

Trang 39

REMOVAL·INSTALLATION (2 · 3 ton series, except 50-8FBN20)

1 Disconnect the harness and cables from the terminals

of the material handling AC driver, which is indicated

by the arrows in the illustration

Tightening torque: T = N·m (kgf·cm) [ft·lbf]

T = 11.2 ~ 16.8 (114 ~ 171) [8.26 ~ 12.4]

2 Remove the bolts (4 pieces)

3 Insert a tool into the notched portion under the AC driver, and remove the AC driver from the rear frame

Trang 40

(Silicone grease may also be applied on the surface of the rear frame.)

• Use either one of the following types of silicone grease.

KS-609 (Shin-Etsu Chemical Co.,Ltd.)

FLOIL G-600 (KANTO KASEI Ltd.)

• Apply threadlocker (LOCTITE 243) to the bolts when tightening the AC driver.

• Remove excess grease after installing the AC drivers.

G85703031_

Định dạng
Số trang	462
Dung lượng	16,36 MB