Toyota Forklitf Mode 7FB1525 vol 1 Forklift Service Repair Manual

trọn bộ tài liệu hướng dẫn, tháo lắp, sửa chữa chi tiết và full code lỗi cho xe Toyota Forklitf Mode 7FB1525 . Được phát hành từ hãng TOYOTA Industries. Mọi thắc mắc xin liên hệ qua mail : Ngoanhquocngogmail.com

This Manual (Volume 1) contains maintenance, specifications and repairprocedures for the chassis, body and material handling system of theTOYOTA ELECTRIC POWERED FORKLIFT 7FB10 to 30 series and7FBJ35

For diagnosis and service procedures of electrical controller, refer to Volume

2 (Pub No CE316-1)

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

corre-This manual deals with the above models as of September 1999 Pleaseunderstand that disagreement can take place between the descriptions in themanual and actual vehicles due to change in design and specifications Anychange or modifications thereafter will be informed by Toyota Industrial Equip-ment Parts & Service News

OIL CONTROL VALVE

SAS FUNCTIONS (OPT)

CONTROLLER

APPENDIX

Sections indicated by solid characters are included in this manual.

Sections indicated by half-tone characters: See vol 2.

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

WIRE ROPE SUSPENSION

EXTERIOR VIEWS

VEHICLE MODEL

ClassificationSeries

Vehicle model

7FB107FBH107FB147FBH147FB157FBH1540-7FB157FB187FBH187FB207FBH2040-7FB207FB257FBH2540-7FB257FB307FBJ35

Disassembly Procedure

1 Remove the cover [Point 1]

2 Remove the bushing [Point 2] ç Operation explained later

3 Remove the gear

(1) The operation procedure is described in either pattern A or pattern B below

Pattern A: Explanation of each operation step with illustration

Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,

fol-lowed by explanation of cautions and notes summarized as point operations

Example of description in pattern B

T = 46.1 ~ 48.1 (470 ~ 490) [34.0 ~ 35.5]

0

FIG number in parts catalog

2 How to read components figures

(1) The components figure uses the illustration

in the parts catalog for the vehicle model

Please refer to the catalog for checking the

part name

The number at the right shoulder of each

components figure indicates the Fig

num-ber in the parts catalog

3 Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation:

Cleaning and washing of removed parts as required

Visual inspection (partially described)

proce-Standard: Values showing allowable range in inspection and adjustment

Limit: Maximum or minimum allowable value in inspection or adjustment

Abbreviation (code)SASSSTSTDT=

T/C

U/SW/

L/

MeaningSystem of active stabilitySpecial service toolStandardTightening torqueTorque converter &transmissionNumber of teeth (¡¡)UndersizeWithLess

(Example)

Conventional unitkgfkgf•cmkgf/cm2

mmHgrpmkgf/mmccPScalg/PS•h

Conversion rate*1 (1 [conventional unit] = X [SI unit])

Conversion between Conventional and SI Units

Value in SI unit = Conversion rate × value in

(1) Never apply impacts to electronic parts such as a crocomputer or relay.

mi-(2) Never let electronic parts be exposed to a high perature or humidity

tem-(3) Do not touch connector pins since they may be formed or be damaged due to static electricity

de-OPERATIONAL TIPS

1 Safe operation

(1) After jacking up, always support with wooden blocks or rigid stands

(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in loadcapacity

(3) Always disconnect the battery plug before the inspection or servicing of electrical parts

2 Tactful operation

(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressuregauge, etc.) and SSTs before starting operation

(2) Before disconnecting wiring, always check the cable color and wiring state

(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the partsneatly to prevent confusion

(4) When disassembling and inspecting such a precision part as the control valve, use clean tools andoperate in a clean location

(5) Follow the described procedures for disassembly, inspection and reassembly

(6) Replace, gaskets, packing and O-rings with new ones each time they are disassembled

(7) Use genuine Toyota parts for replacement

(8) Use specified bolts and nuts Observe the specified tightening torque at the time of reassembly.(Tighten to the center of the specified tightening torque range.)

If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torquetable

3 Protection of functional parts

(1) Thoroughly check each connector for any failure in or imperfect connection before reconnecting thebattery plug after the end of vehicle inspection or maintenance

Failure in or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers.

4 Confirming defect status

Do not start immediate disassembly or replacement, but first confirm if such disassembly or ment is actually needed

replace-5 Handling of waste fluid, etc

When draining waste fluid from the vehicle, always receive it with an appropriate container

Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any otherharmful substance may cause adverse affect to people or environmental destruction, sort each wasteand always ask an authorized contractor for appropriate disposal

6 Handling of electronic parts

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 Be sure to avoid an inclined orrugged place

• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point Jacking up at anyother point will be dangerous

• Never operate while the vehicle is held with a jack Always support the frame with a wooden blockafter jacking up

• In any case, never let a part of the body (including hands and feet) be under the jacked-up vehicle

: Jack-up point :

Wooden block or stand setting point

123 123

CAUTION FOR TOWING

1 When towing the forklift, always lift the rear wheelsaway from the ground

2 The traveling speed in towing must not exceed themaximum traveling speed of the forklift

3 Always set the key switch to OFF and the directionswitch to the neutral position before starting towing

In case of towing by connection with a wire rope withthe operator on the forklift, however, set the key switch

to ON (PS operation) and always set the directionswitch to the neutral position

4 Before towing, either remove the fork or take an tion to prevent fork contact with the ground due tobounding

ac-Slinging the head guard can be done in twoillustrated ways

HOISTING THE VEHICLE

Always hoist each part of the vehicle at the specified position Never hoist at any other position because it

is very dangerous

When hoisting the vehicle, sling with a fiber or

wire rope at the mast hook hole and the rear

end of the head guard

CIRCUIT TESTER

Circuit testers are available in both the analog and digital types They should be used selectively according

to the purpose of measurement

Analog type: This type is convenient for observing movement during operation, but the measured value

should only be used for reference or rough judgement

Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement

1 Difference in measurement results with the digital type and analog type

* The result may be different between measurements with the analog type and digital type

Always use a circuit tester according to its operation manual

Cautions when the polarities are different between the analog type and digital type are describedbelow

(1) Analog circuit tester

(2) Digital circuit tester

Measurement result exampleTester range: kΩ range

Forward

Reverse

Analog typeContinuity exists

2 MΩForward direction Reverse direction

Forward direction Reverse direction

2 Difference in result of measurement 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

The resistance values of the same semiconductor sured with two types of circuit testers having different powersupply voltages are different

mea-This manual describes the results of measurement with acircuit 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 tovary the circuit resistance Even when the same diode is measured, the measurement result varieswith the measurement range

Always use the range described in the repair manual formeasurement

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 The nut tightening torque can be judged from the mating bolt type

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1 Identification by bolt shape

Shape and class

Bolt head No

No mark

No mark

Two protrudinglines

Two protrudinglines

Three protrudinglines

Four protrudinglines

2 Identification by part No

Hexagon head bolt

Length (mm)

Part No

9 2 1 3 2 - 4 0 6 1 4

Diameter (mm)Class

Length (mm)

TIGHTENING TORQUE TABLE

68101214166810121416681012141668101214166810121416

1.01.251.251.251.51.51.01.251.251.251.51.51.01.251.251.251.51.51.01.251.251.251.51.51.01.251.251.251.51.5

Specified torqueHexagon

head bolt

N•m

Hexagonflange bolt

5.4132547751136.4163259911377.819387211017011255295147226122961108172265

kgf-cm ft-lbf

651603306009301400801954007301100175011026053097015002300125300620110017502700

551302604807601150

56 in-lbf12244367101

69 in-lbf1429538012781938701081669224580127195

N•m kgf-cm ft-lbf

5.914285383

—

60145290540850

—

52 in-lbf10213961

—7.5

183665100157

7517536067010501600

65 in-lbf132648761168.8

214379123191

9021544081012501950

78 in-lbf1632599014112

2858103167

—

12029059010501700

—

9214376123

—14

3268123196299

145330690125020003050

9245090145221

48 in-lbf919355583

PRECOAT BOLTS

(Bolts with seal lock agent coating on threads)

1 Do not use the precoat bolt as it is in either of the ing cases:

follow-(a) After it is removed

(b) When the precoat bolt is moved (loosened or ened) by tightness check, etc

tight-Note:

For torque check, use the lower limit of the able tightening torque range If the bolt moves, re- tighten it according to the steps below.

allow-2 Method for reuse of precoat bolts(1) Wash the bolt and threaded hole (The threaded holemust be washed even for replacement of the bolt.)(2) Perfectly dry the washed parts by air blowing

(3) Coat the specified seal lock agent to the threaded tion of the bolt

por-HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1 When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces withclean cloth to remove foreign matters and dirt Also check no dent or other damage on the contactsurfaces before installation

2 When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten thefitting

3 The maximum tightening torque must not exceed twice the standard tightening torque

Standard tightening torque N•m (kgf-cm)[ft-lbf]

Hose insidediameter mm (in)

Seal lock agent

WIRE ROPE SUSPENSION ANGLE LIST

Suspensionmethod

10980(1.12)[2469.5]

4410(0.45)[992.3]

6960(0.71)[1565.6]

13730(1.4)[3087]

6080(0.62)[1367]

21570(2.2)[4851]

8830(0.9)[1985]

14020(1.43)[3153]

27460(2.8)[6174]

5880(0.6)[1323]

21280(2.1)[4631]

8530(0.87)[1918]

13440(1.37)[3021]

26480(2.7)[5954]

5200(0.53)[1169]

18630(1.9)[4190]

7650(0.78)[1720]

11770(1.2)[2646]

23540(2.4)[5292]

4310(0.44)[970]

14710(1.5)[3308]

6280(0.64)[1411]

9810(1.0)[2205]

18630(1.9)[4190]

12160(1.24)[2734]

43150(4.4)[9702]

17650(1.8)[3969]

27460(2.8)[6174]

54920(5.6)[12348]

11770(1.2)[2646]

41190(4.2)[9261]

17060(1.74)[3937]

26480(2.7)[5954]

52960(5.4)[11907]

10400(1.06)[2337]

37270(3.8)[8379]

15300(1.56)[3440]

23540(2.4)[5292]

47070(4.8)[10584]

8630(0.88)[1940]

29420(3.0)[6615]

12550(1.28)[2322]19610(2.0)[4410]

37270(3.8)[8379]

Single-ropesuspension

COMPONENTS WEIGHT

Member weight list

Vehicle model

1 ton series(excluding 40-7FB15)

2 ton series(excluding 40-7FB20•25), and 40-7FB153.0 ton•J3.5 ton, and 40-7FB20•25

1 ton series

2 ton series3.0 ton•J3.5 ton1.0 ton (*1)1.35 ton1.5 ton (*1) (*2)

1.8 ton2.0 ton2.5 ton (*1) (*2)

3.0 tonJ3.5 ton

1 ton series (excluding 40-7FB15)

2 ton series (excluding 40-7FB20•25)and 40-7FB15

3 tonJ3.5 ton

MemberBattery ASSY

Drive motor ASSY

Pump motor ASSY

Front axle & drive

unit W/drive motor

Rear axle ASSY

Counterweight

Oil control valve

Oil pump

Seat stand ASSY

V mast ASSY W/lift bracket

(W/lift cylinder, L/fork, lifting height:

3,000 mm)

Weight

Approx 450

Approx 280Approx 400Approx 75Approx 75Approx 85Approx 400 (*1Approx 415)Approx 470

Approx 545 (*1 Approx 545)(*2 Approx 700)

Approx 720Approx 825Approx 1205 (*1 Approx 1165)(*2 Approx 915)

Approx 1380Approx 1800

Approx 410Approx 465Approx 570Approx 680

*1 : 7FBH series *2 : 40-7FB series

See page 1-2See page 6-2See page 6-8

Unit: kg

Approx 20Approx 4Approx 45

RECOMMENDED LUBRICANT QUANTITY & TYPES

Amounts and Types of Specified Lubricants

1 ton series(excluding 40-7FB15)

2 ton series(excluding 40-7FB20•25), and40-7FB15

3.0 ton•J3.5 ton, and40-7FB20•25

1 ton series

2 ton series(excluding 40-7FB20•25)40-7FB20•25

3.0 tonJ3.5 ton

Type

Hypoid Gear Oil (SAE85W-90)

STD models: Hydraulic Oil

(ISO VG32)Refrigerator model: Mobil Aero HFE

STD models: SAE J-1703 DOT-3

Refrigerator model 45S: Brake fluid

Arctic S

MP GreaseDistilled water

Appropriate amountAppropriate amountAppropriate amountValues shown above are for reference.See page 7-8 for details

LUBRICATION CHART

¡ Inspection and supply

l Replacement

MP Grease Engine Oil Hypoid gear Oil (SAE85W-90) Hydraulic Oil (ISO VG32) Brake Fluid

Refrigerator type S45: Brake Fluid Arctic S Molybdenum disulfide gress

1 Chain

2 Drive unit

3 Tilt cylinder front pin

4 Mast support bush

5 Front wheel bearing

6 Tilt steering lock mechanism

7 Steering knuckle king pin

8 Rear wheel bearing

9 Tie rod end pin

10 Rear axle cylinder end pin

11 Brake master cylinder

12 Oil tank

13 Rear axle beam front pin

14 Swing lock cylinder lower pin

15 Rear axle beam rear pin

I Inspect every 8 hours (daily)

II Inspect every 40 hours (weekly) III Inspect every 170 hours (monthly)

IV Inspect every 1000 hours (6 monthly)

V Inspect every 2000 hours (annual)

6

4 6

1

1 9

15

8

6

1 10

7

I

IV

II III 5

4 5 1

2 3

1 1

3

1

1 4 3

7

2

5

8 6 1

9 10

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

Rotation soundLooseness in the connecting partsInsulation resistance

Brush wear and sliding condition(For PS motor only)

Commutator contamination, damage(For PS motor only)

Brush, spring wear(For PS motor only)Charging levelElectrolyte levelElectrolyte specific gravityTerminal loosenessAbnormality in the upper portion of thebattery case

Insulation resistanceVoltage measurement of each battery cellafter charging

Timer functionTerminal loosenessHVR function voltage measurementOperating condition of the magnetic switch,contact contamination, roughness

IIMII

II

Item

Mounting condition of the arc shooterOperating condition and timingsLooseness of the coil mounting partsMounting condition of the main circuit leadwire, looseness

Operating condition and timingDamage and looseness of installing partsOperation condition, damage

Operation conditionInterior contamination, damageMotor input voltage

LoosenessHarness deterioration, champ damage andlooseness

Looseness in connecting parts, tapingcondition

Connecting condition and damage of thebattery connector

II

IIIIC

III

DRIVE SYSTEM

Tire inflation pressureTire cuts, damage and uneven wearingLoose rim and hub nuts

Tire groove depthMetal chips, pebbles and other foreignmatter trapped in tire grooves

Rim, side bearing and disc wheel damageAbnormal sound and looseness of frontwheel bearing

MITMIII

Play and loosenessFunction

Oil leakLooseness of mountingOil leak

Mounting and linkage loosenessDamage of power steering hoseKing pin looseness

Cranks and deformation

Play and reserveBraking effectOperating forceBraking effectRod and cable looseness and damageLeak, damage and mounting conditionLeak and fluid level

Function, wear, damage, leak and mountinglooseness

Every

12 monthsEvery

2000 hours

Every

6 monthsEvery

1000 hours

Every

3 monthsEvery

500 hours

Every

1 monthEvery

170 hoursl

M*

lllTll

l

Mllllll

BRAKING SYSTEM

Shoe operating conditionAnchor pin rustingReturn spring fatigueAutomatic adjuster functionDeformation, cracks and damageLoose mounting

Abnormality of fork and stopper pinMisalignment between left and right forkfingers

Cracks at fork root and welded partDeformation and damage of each part andcrack at welded part

Mast and lift bracket loosenessWear and damage of mast support bushingWear, damage and rotating condition ofrollers

Wear and damage of roller pinsWear and damage of mast tripTension, deformation and damage of chainChain lubrication

Abnormality of chain anchor boltWear, damage and rotating condition ofchain wheel

Abnormality and mounting condition of eachpart

Loosening and damage of cylinder mountingDeformation and damage of rod, rod screwand rod end

Cylinder operationNatural drop and natural forward tilt(hydraulic drift)

Every

12 monthsEvery

2000 hours

Every

6 monthsEvery

1000 hours

Every

3 monthsEvery

500 hours

Every

1 monthEvery

170 hoursM

ll

ll

l

lllll

l

TllM

Lifting speedUneven movementOil leak and abnormal soundOil level and contaminationTank and oil strainerOil leak

Loose linkageOperationOil leakRelief pressure measurementRelief valve and tilt lock valve functionsOil leak

Deformation and damageLoose joint

Cracks at welded portionDeformation and damageLoosening of mountingDeformation, crack and damageFunction and mounting conditionFunction and mounting conditionFunction and mounting conditionFunctions

Function and mounting conditionDirt, damage

Rear reflection statusLoosening and damage of mountingSeatbelt damage and function

Every

12 monthsEvery

2000 hours

Every

6 monthsEvery

1000 hours

Every

3 monthsEvery

500 hours

Every

1 monthEvery

170 hoursllMlll

llll

lllT

llTllllllllll

12 monthsEvery

2000 hours

Every

6 monthsEvery

1000 hours

Every

3 monthsEvery

500 hours

Every

1 monthEvery

170 hours

llll

←

Drive unit oil

Hydraulic oil

Hydraulic oil filter

Wheel bearing grease

Brake fluid

Brake master cylinder rubber parts

Wheel cylinder cup seals

Brake fluid reservoir hose

Power steering hose

Power steering rubber parts

600 hours

EverymonthsEvery

200 hours

Every0.5 monthEvery

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

l : Replacement

Every

6 monthsEvery1,200 hours

Every

12 monthsEvery2,400 hours

vehicle initial replace-ment

ll

l

BATTERY COMPARTMENT AND REQUIRED WEIGHT

When the battery is to be purchased locally, always adjust the weight to satisfy the minimum requiredweight as shown in the table below

821(32.3)

SERVICE STANDARDS

Display

DISPLAY Battery Capacity Indicator

The display lights up 6 LEDs (green) to indicate the batterycapacity When battery DISCHARGE reaches 100%, theoverdischarge warning function is activated This function,however, is limited to the vehicle with the display function

Overdischarge Warning Function

1 When this function is activated, it becomes impossible

to operate for traveling and material handling at a time.Simultaneous operation, if attempted, priority is given totraveling and material handling fails (This prevent thebattery from being damaged by large current flow.)

2 Soft starting in load lifting is delayed further to make theoperator feel decrease of the remaining battery capac-ity

¡

¡

¡

LED (green)

Battery LED (red)

Specific gravity upon perfect charging

Specific gravity upon end of discharge

1 MΩ or more

48 V specification

80 V specificationDischarge end voltage

1

SERVICE STANDARDS (OPT)

Specific gravity upon perfect charging

Specific gravity upon end of discharge

1 MΩ or more

48 V specification

80 V specificationDischarge end voltage

DISPLAY (OPT) Battery Capacity Indicator

The battery capacity indicator indicates the charge in the tery in 10 levels by means of the LCD

bat-Remaining Battery Charge Warning

When the remaining battery capacity drops below the set level,the capacity display blinks and the alarm sounds for 5seconds after the key switch is set to ON

Overdischarge Warning Function

When the battery capacity decreases further below the setlevel after the remaining battery charge warning, drive ormaterial handling operation, if tried, causes all capacity indi-cator segments to blink and the alarm sounds

1

BATTERY ASSY

Removal Procedure

1 Disconnect the battery plug

2 Open the seat stand

3 Remove the floor mat and toe board

4 Open the side hood RH

5 Remove the battery stopper

6 Remove the battery ASSY [Point 1]

1 Electrolyte level inspectionOpen the cap, and, if the white line on the red float hasfallen, add water until the white line appears

Since water addition is excessive if the float tip end comesinto contact with the stopper, stop water addition as soon

as the white line appears

Since a level gage is provided at a front of the batterycase, the electrolyte level can generally be checked at aglance but check the level by opening the cap at the time

of periodic inspection

The green lamp of the level gage comes on to indicateactuation of the level gage sensor, and the red lampflashes to indicate the necessity of water addition

Note:

Never change the mounting position of the plug with the sensor.

ReferenceThe consumption of the electrolyte can be calculated by thefollowing equation:

Consumption (cc) = 5 hour capacity x 0.0336 x number

of cells x number of charges

Number of cells Battery capacity (AH/5HR)

2 Electrolyte inspectionThe battery electrolyte is colorless and transparent innormal state Inspect any turbidity at the time of specificgravity inspection If not checked clearly, put the electro-lyte in a breaker for inspection.

3 Battery electrolyte specific gravity inspectionUse a hydrometer and measure the specific gravity ofthe electrolyte

Specific gravity upon perfect charging:

1.280 at 20°C (68°F) Specific gravity upon end of discharge:

Make the hydrometer in the outer tube float correctlywithout contact with the outer tube, its top or bottom.Wait until the air bubbles in the sucked electrolytedisappear Read the scale at the top of the raisedportion of the surface as shown at left

After the measurement, wash the inside and outside

of the hydrometer with clear water, and wipe the drometer thoroughly with clean cloth for storage

4 Insulation resistance inspectionMeasure the resistance between the battery and batterycase with an insulation resistance meter (megger).

Insulation resistance value:

Note:

re-move the battery from the vehicle and wash it with water.

thor-oughly Measure the insulation resistance again and install the battery on the vehicle after confirming that

* Battery control table

Prepare a control table for the battery to record and maintain the inspection results

APPLICABLE CHARGER LIST

Transformer Power Transformer Battery Applicable Power

model supply capacity voltage capacity capacity

voltage (50/60 Hz) (AH/5H) (50/60 Hz) SG3-69-60JBY 200 V 5.0/4.7 48 V 330 15/15 A