Toyota 7FBEF15-20 Electric Forklift Service Manual

< Tillbaka till Servicemanual 7FBEF 15-20
Downloaded from www.Manualslib.com manuals search engine
Index
FOREWORD
This manual mainly describes the development objectives of new Toyota forklift
7FBEF15 to 20 models, outlines of main component units, structures and functions of
new mechanisms and other technical features.
Please read it carefully for sales and service activities.
This manual has been edited for the vehicles launched into the market in May
2003.
Any later change shall be informed through Toyota Industrial Equipment Parts &
Service News.
Please refer to the repair manual and parts catalog for the matters necessary
for servicing.
TOYOTA Material Handling Company
A Division of TOYOTA INDUSTRIES CORPORATION
Downloaded from www.Manualslib.com manuals search engine
SECTION INDEX
NAME
SECTION
GENERAL
0
DEVELOPMENT OBJECTIVE
1
ELECTRICAL SYSTEM
2
POWER TRAIN
3
TRAVELING, STEERING AND BRAKE SYSTEMS
4
INSTRUMENTS
5
FRAME AND AUXILIARY EQUIPMENT
6
MATERIAL HANDLING AND HYDRAULIC SYSTEM
7
SAS CONTROL SYSTEM
8
OUTLINE OF MAJOR OPTIONS
9
APPENDIX
10
Downloaded from www.Manualslib.com manuals search engine
0-1
GENERAL
Page
VEHICLE EXTERIOR VIEWS ...................................... 0-2
MODEL LINEUP .............................................................. 0-3
2
3
0
3
Downloaded from www.Manualslib.com manuals search engine
0-2
VEHICLE EXTERIOR VIEWS
■
Vehicle exterior views
Front View
Rear View
Downloaded from www.Manualslib.com manuals search engine
0-3
MODEL LINEUP
■ Vehicle model lineup
Payload
(L.C. 500 mm)
New model
Previous model
Voltage
1.5 ton
7FBEF15
5FBE15
48V
1.6 ton
7FBEF16
−
48V
1.8 ton
7FBEF18
5FBE18
48V
2.0 ton
7FBEF20
−
48V
L.C.: Load center
Downloaded from www.Manualslib.com manuals search engine
2
3
0
3
0-4
Downloaded from www.Manualslib.com manuals search engine
1-1
DEVELOPMENT OBJECTIVE
Page
DEVELOPMENT OBJECTIVE ..................................... 1-2
2
3
FEATURES (SELLING POINTS) ................................ 1-3
MAJOR DIFFERENCES BETWEEN NEW AND
PREVIOUS MODELS ................................................. 1-9
Downloaded from www.Manualslib.com manuals search engine
1
1-2
DEVELOPMENT OBJECTIVE
■ Development objective
Toyota 5FBE series, 1,500-kg to 1,800-kg three-wheel, counter battery type forklift have favorably been
accepted by a large number of customers thanks to their ease of use and reliability since the model
change in 1993.
After the model changes by competitors in later years, however, disparities in specifications and
equipment compared to 7FB series and 7FBR series have been pointed out.
Growing environmental concerns in the market, on the other hand, has been adding to the importance of
battery vehicles.
■ Development concepts
1
Optimum material handling operation matching each customer's needs by making the most of
the features of AC-motor drive system.
2
Adoption of the SAS (mast control and steering synchronizer) developed in the 7 series and
highly evaluated in the market for realization of high stability comparable with that of the 7
series.
3
Easier ingress and egress by adoption of the open step, small-diameter steering wheel and tilt
steering with memory.
4
Addition of 1,600- and 2,000-kgf models to the 1,500- and 1,800-kgf models in the previous
series.
The AC drive system, especially was implemented in 1999 ahead of other companies by consolidation of
our time-tested technologies. Its features have fully been utilized not only in performances but also in
operating feel.
We propose these models as three-wheel counter battery forklift trucks without an equal in performance
and operating feel.
Downloaded from www.Manualslib.com manuals search engine
1-3
FEATURES (SELLING POINTS)
■ Major selling points
The greatest feature of the new models is adoption of the AC motor drive system. New features of the 7FB
series have also been adopted in many places.
1. Adoption of AC Motor Drive System
What is AC motor drive system?
The conventional DC motor drive system uses a controller for battery current chopping (ON and OFF)
to control the motor power by changing the chopping ratio to realize from inching at the time of starting
up to the maximum power.
The controller in the AC motor drive system converts the battery current to a three-phase alternate
current, whose sine wave form (frequency and waveform height) varies to control the motor power.
The table below compares the motor voltage, motor structure and the controller between the AC
system and DC system.
Comparison between the DC and AC systems
Motor voltage
Motor structure
Controller
Motor
Mean voltage
Commutator
Brush
M
Battery
ON
DC
system
ON ON
Controller
Battery voltage
Microcomputer
control
Motor voltage
Contactor
• Conversion from battery DC
voltage into the mean voltage by the chopper
Sine wave
• Need of brush and commutator maintenance
• Complicated structure
• Relatively easy by mean DC
voltage control
• Need of contactor for rotating direction change
Motor
Stator core
Stator coil
Controller
Battery
AC
system
M
Battery voltage
1 Phase
Motor voltage
• Conversion from battery DC
voltage into the AC voltage
by the controller
Downloaded from www.Manualslib.com manuals search engine
• No brush and commutator
(maintenance-free)
• Compact and lightweight
Microcomputer
control
• Conversion from DC into
three-phase AC by the module
• No need of contactor for
rotating direction change
2
3
1
1-4
Features of AC motor drive system
The table below shows three major features of the AC motor drive system. The AC motor drive system
has already been adopted in the industrial world by making the most of these features.
System feature
Product feature
1
Simple, compact motor structure
Realization of higher performance in the same
product size
2
Realization of new control by three-phase
AC control
Realization of new performance and feel thanks
to wider motor control range
3
No motor brush and contactor
Reduction of maintenance cost for motor brush
and contactor
It has been known to worldwide forklift engineers that the AC motor drive system, as stated above, is a
very excellent system for battery forklift trucks.
Selling points of the new models fully utilizing these features are explained below.
2. Power Select Function
The performance best matching the operator can be selected by single switch operation.
The traveling performance in loaded state is improved in new models by making the most of the
simple, compact structure of the AC motor. One switch selects any of the following modes.
• Mobility-preference mode featuring the shortest cycle time (H mode)
• Efficiency-preference mode for short cycle time and long working hours (P mode)
• Operation-hour-preference mode featuring the longest operation hours with the performance
equivalent to that of previous models (S mode)
To satisfy individual customer requirements, a power control select function is provided for setting the
traveling mode by selection from six modes including H, P and S.
The operation efficiency is greatly improved by selection of the optimum performance for each
customer need like H mode selection for a job requiring the power and performance or S mode
selection for continuous operation for many hours.
Power select function
[7FBEF15]
Cycle time
(sec/cycle)
:Fixed mode
[H mode]
85
[P mode]
90
Previous model
[S mode]
95
180min 220min 260min 300min
Downloaded from www.Manualslib.com manuals search engine
Operation time
(DIN 4PzS 440L)
1-5
Especially, the loaded traveling and material handling performances in the H mode have been
improved over 30%. As a result, our 30-m operation cycle time has been shortened by about 10% or
more.
2
3
1.5 ton
Lifting speed
mm/sec
NL610
65%UP
600
540
480
FL430
480
1
420
350
280
260
NL: No load
FL: Full load
H mode
P mode
S mode
5FBE15
STILL
Traveling speed
Km/h
NL16.5 30%UP
FL15.0
16.0
15.0
14.0
14.0
13.5
12.5 12.5
11.5
NL: No load
FL: Full load
H mode
P mode
S mode
Cycle time
(TOYOTA 30m operation cycles)
sec/cycle
11%UP
95
5FBE15
STILL R20
Operation time
(DIN 4PzS 440L, TOYOTA 30m operation cycles)
95
270
min
240
230
85
185
91
H mode
P mode
S mode
Downloaded from www.Manualslib.com manuals search engine
5FBE15
H mode P mode S mode
5FBE15
1-6
3. Improved Efficient Operation Hour
The accelerator-off regeneration system is added to the AC drive system for longer operation
compared to the previous models. The power up function is also adopted for longer efficiency
operation hours.
Power keep function
(Setting to the P mode at the Efficiency-preference and the S mode for Operation-hour-preference)
The power keep function has been developed as the new control in new models for maintaining the
discharged battery performance by making use of the wider motor control range of the AC motor drive
system.
• The efficiency operation hours allowing operation without feeling performance degradation
is improved by 40% by adoption of the power keep function and extension of the operation
hours.
• The number of operation cycles without feeling performance degradation is also improved by
40%.
This new function actually improves the operation efficiency at each customer greatly.
Low remaining battery charge warning
Full load performance
1.1
New model
Battery usage
limit range
1
Decrease in
performance
0.9
Previous model
0.8
Lift interruption
25%UP
0.7
0%
20%
40%
Previous model (1.5t)
Efficiency operation hour:2H20m
(440AH/5hr)
60%
80%
100%
Battery discharge level (%)
40%UP
Previous model (1.5t:S mode)
Efficiency operation hour:3H20m
(440AH/5hr)
However, note that efficient operation becomes hard when the battery level indicated by the battery
charge indicator becomes one bar (battery discharge to about 90%).
1.5 ton
min
350
52% UP
270
17% UP
230
7FBEF15 7FBEF15
5FBE15
S mode
S mode
(DIN 5PzS550L) (DIN 4PzS440L)
Downloaded from www.Manualslib.com manuals search engine
1-7
4. Easy Ingress/Egress and Dwelling Ability
Easy Ingress/Egress
An open step is provided for easy ingress/egress.
The tilt steering is also provided with a memory as on the 7FB series to allow full forward tilting of the
steering column to ensure smoother ingress/egress.
Step height
Step height
Step height 545mm
(21.5in)
430mm
(16.9in)
New model Previous model
Dwelling Ability
Compared to previous models, the head clearance is increased by 25 mm (0.98 in) to 1,025 mm (40.4
in).
5. Maintenance Cost Reduction
Maintenance items specific to battery vehicles are as follows:
1) Addition of distilled water for battery
2) Pump motor brush replacement
3) Pump contactor replacement in controller
4) Drive motor brush replacement
5) Drive contactor replacement in controller
Since the AC motor has no brush and contactor as explained earlier, brush replacements are
unnecessary. Depending on the operating conditions at each customer, the annual maintenance cost
can be reduced as much as 80%.
The newly adopted acceleration-off regeneration system regenerates the electrical braking energy
upon accelerator pedal release during traveling in the battery by making the most of the wider motor
control range of the AC motor drive system. This accelerator-off regeneration system not only extends
the operation hours and improves the running stability by electrical braking but also reduces the brake
load and lining wear for less brake maintenance cost.
Downloaded from www.Manualslib.com manuals search engine
1-8
6. Safety Functions
The new models are installed with the SAS safety functions adopted on the 7FB series to ensure
equivalent safety. Though the safety functions are summarized below, refer to the SAS Control
Equipment section for further details.
Safety Function List
Safety control
Mast
control
Functional outline
Active mast front tilt angle control
Decreases the front tilt angle at a high fork height
or under a heavy load, and increases it at a low
fork height or under a low load.
Active mast backward tilt speed control
Retards the backward tilting speed at a high fork
height, and increases it at a low fork height.
Key-lift interlock
If the key switch is in the OFF position, the lift
operation is disabled even when the material handling lever is operated.
Automatic fork leveling control
Forward tilting by pressing the button causes the
mast to be stopped automatically when the fork is
leveled.
The steering knob is not shifted during full
hydraulic power steering.
Steering synchronizer (EHPS)
EHPS: ELECTRONICALLY CONTROLLED FULLY-HYDRAULIC POWER STEERING
On three-wheel battery counter vehicles, the automatic control rear stabilizer is not provided because
of no rear wheel swing mechanism.
7. Anti-rollback
A function for easy starting on a slope (reduction of rollback on a slope) is provided.
8. Model Series
The 1.6- and 2.0-ton models have been developed anew to enrich the model line-up.
The 1.0- and 1.25-ton models have been discontinued.
Capacity (kgf)
1000
1250
1500
1600
1800
2000
7FBE
5FBE
: Continuation
: New
9. Maximum battery capacity
The battery compartment length in the longitudinal direction has been widened by 87 mm on the 1.5ton model and 193 mm on the 1.8-ton model to accept the same DIN-size batteries for the STILL R20
on all series models.
Capacity (kgf)
1500
1600
1800
2000
7FBE
5PzS550L
6PzS660L
6PzS660L
6PzS660L
5FBE
4PzS440L
Downloaded from www.Manualslib.com manuals search engine
4PzS440L
1-9
MAJOR DIFFERENCES BETWEEN NEW AND PREVIOUS MODELS
−:Not applicable
New models
Item
Applicable
models
Motor
Controller
Traveling system
1.5 ton
1295 mm
All models
1490 mm
1.6 to 2.0 ton
−
−
1070 mm
1.5 to 1.8 ton
1075 mm
All models
1125 mm
2.0 ton
−
−
Overall height
1980mm
All models
1950mm
All models
Drive motor
AC: 4.9 kW × 2
All models
DC: 3.3 kW × 2
All models
Pump motor
AC: 9.2 kW
All models
DC: 8 kW
All models
PS motor
−
−
DC: 0.75 kW
All models
Main controller
Traveling, material
handling and steering control
All models
Traveling/material
handling control
All models
Steering controller
−
All models
Contactor type
All models
Steering system
Steering synchronizer, EHPS system
All models
FHPS system
All models
Parking brake lever
Parking brake lever
ratchet type
All models
Parking brake lever
ratchet type
All models
18 × 7−8
1.5 to 1.8 ton
18 × 7−8-14PR
1.5 ton
200/50-10
2.0 ton
18 × 7−8-16PR
1.8 ton
15 × 4.1/2-8(dual)
1.5 to 1.8 ton
16 × 6-8(dual)
2.0 ton
16 × 6-8-10PR(dual)
All models
Mast control
• Active mast front
tilt angle control
• Mast backward
tilt angle control
• Automatic fork
leveling control
• Key-lift interlock
All models
−
−
Steering synchronizer EHPS
All models
−
−
Head clearance
1025mm
All models
1000mm
All models
Step height
430mm
All models
−
−
Rear combination
lamp
High-mount embedded type
All models
Add-on type
All models
Overall width
Front tire
Tires
Rear tire
SAS equipment
Frame
Auxiliary
equipment
Applicable
models
1385 mm
Wheel base
General
Previous models
SAS specifications
Downloaded from www.Manualslib.com manuals search engine
1-10
Downloaded from www.Manualslib.com manuals search engine
2-1
ELECTRICAL SYSTEM
Page
BATTERY .......................................................................... 2-2
MOTORS ........................................................................... 2-4
2
3
MAIN CONTROLLER .................................................... 2-10
2
Downloaded from www.Manualslib.com manuals search engine
2-2
BATTERY
■ General
1. Battery Compartment and Necessary Weight
When purchasing the battery locally, always adjust the weight to satisfy the minimum weight shown in
the table below.
Compartment dimensions mm (in)
Vehicle model
Length X
STD
R/O
Width Y
Height Z
830 (32.7) 627 (24.7)
Minimum required battery
weight (with case) Kg (lb)
7FBEF15
630 (24.8)
7FBEF16 to 20
738 (29.1)
↑
↑
985 (2172)
7FBEF15
630 (24.8)
↑
↑
830 (1830)
7FBEF16 to 20
738 (29.1)
↑
↑
985 (2172)
R/O: Battery roll-out specifications
X
th
ng
Z
Height
Le
Y
Width
Downloaded from www.Manualslib.com manuals search engine
830 (1830)
Remarks
2-3
2. Battery Specifications
No batteries are provided.
Please use the batteries conforming to DIN 43 531A.
Use 320A connectors.
2
3
RIGHT
LEFT
180
(7.1)
-+
250
(9.8)
2
FRONT
320A
CONNECTOR
3. Battery List
The table below shows recommended batteries.
Refer to the general description for batteries with regard to the minimum required weight.
DIN 43 531A
Installed battery
Vehicle models
Voltage
Supplier
VARTA
7FBEF15
48
OLDHAM
CHLORIDE
VARTA
7FBEF16 to 20
48
OLDHAM
CHLORIDE
Downloaded from www.Manualslib.com manuals search engine
Battery case
Dimensions mm (in)
Model
Capacity
[AH/5HR]
5PzS550L
550
5PzS600Hx
600
↑
↑
↑
24CYQ5
500
↑
↑
↑
24CYH5
550
↑
↑
↑
5PzS500
500
627 (24.7)
↑
↑
5PzS550H
550
↑
↑
↑
6PzS660L
660
6PzS720Hx
720
↑
↑
↑
24CYQ6
600
↑
↑
↑
24CYH6
660
↑
↑
↑
6PzS600
600
735 (28.9)
↑
↑
6PzS660H
660
↑
↑
↑
length
width
height
630 (24.8) 830 (32.7) 627 (24.7)
738 (29.1) 830 (32.7) 627 (24.7)
2-4
MOTORS
Drive motor
■ General
1. A compact, high-performance, maintenance-free AC induction motor optimum for battery forklift trucks
has been newly developed as the drive motor.
2. The motor is maintenance-free because it has no brush.
■ Specifications
Vehicle model
Voltage
(V)
Rated output
(kW)
(60-min rating)
Type
Size
Diameter × Length
mm (in)
Mass
kg (lb)
7FBEF15 to 20
48
4.9
3-phase AC
φ180 (7.1) × 227 (8.9)
37 (82)
■ Drive motor features
The induction motor (see the figure below) developed for the new models this time has the following
features:
• The drive unit is integrated with the motor (built-in structure) to attain a compact size.
• The iron core shape and winding are optimized for motor efficiency improvement.
• A high-precision rpm sensor for direct detection of the motor speed is adopted to realize elaborate
functions such as power select and power keep.
• A motor temperature sensor is adopted to ensure stabilized output and to prevent burning due to
overloaded use.
■ Caution
Depending on the use at each customer (continuous heavy-load operation for example), the vehicle
performance may temporarily be dropped to protect the controller and motor from overheating. This is due
to restriction of the current to the motor as a result of specified temperature detection by the temperature
sensor built in the controller or the motor. This is not an abnormality. Since the respective warning appears
on the monitoring display, stop the operation and restart after the warning indication disappears.
Length
Field core
Drive unit
Field winding
Rpm sensor bearing
Diameter
Downloaded from www.Manualslib.com manuals search engine
Rotor
2-5
■ Structure and principle of AC induction motor
The AC induction motor has no brush and commutator unlike the conventional DC motor, so there is no
sliding part. It, therefore, has the following features:
1. The motor size can be reduced by dimension L for the brush and commutator if the output is the same.
2. In the size is same, the core size can be increased by dimension L for the brush and commutator,
resulting in a higher output.
3. Because of less number of parts and no sliding part, it features high reliability and efficiency. For new
models, a new AC induction motor best suitable for forklift trucks has been developed and adopted.
AC motor (for new models)
2
3
DC motor (for previous models)
Field core
Field winding
Field core
Field winding
Commutator
Brush
2
Rotor
L
Rotor
The rotor consists of the core made up of piled thin electromagnetic steel plates through the grooves in
which aluminum conductor bars pass. Both ends of conductor bars are shorted by end rings on both sides
of the core as illustrated in (b) below. When the bars and end rings are taken off, the shape is like a cage
for a squirrel or mouse as shown in (c) below. It is therefore called a cage rotor.
(a) Core
End ring
(b) Rotor ASSY
Conductor bar
(aluminum conductor bar)
End ring
(c) Cage rotor
Downloaded from www.Manualslib.com manuals search engine
2-6
■ Motor operation principle
Right-hand screw rule and Fleming's rule are to be explained here before explanation on the motor
operation principle.
1. Right-hand screw rule
Direction of
Raise the thumb of the right hand with other fingers
current
folded. When the thumb is placed in the current
flowing direction in this state, the magnetic field is
Magnetic
generated vertically to the thumb or in the direction of
field
Magnetic
the folded fingers.
field
Direction of
current
2. Fleming's right-hand rule
Place a linear substance in freely movable state on a
fixed material as shown at right. If the linear
substance is moved in the illustrated direction when
the magnetic field is generated as illustrated, an emf
current is generated in the illustrated direction.
Magnetic
field
Direction of
Magnetic field
Direction of
motion
Direction of
current
Magnetic field
Direction of
current
3. Fleming's left-hand rule
Place a linear substance in freely movable state on a
fixed material as shown at right. If a current flows in
the fixed material when the magnetic field is
generated as illustrated, a force is applied to the linear
substance in the illustrated direction.
Direction of force
Direction of
Magnetic
Magnetic field
field
Magnetic field
Direction of
force
Direction of
current
Downloaded from www.Manualslib.com manuals search engine
Direction of
motion
Direction of
current
2-7
Operation principle
1. When a current flows in a fixed direction in the field winding as shown below, magnetic field is
generated around the field winding as illustrated according to the right-hand screw rule and magnetic
poles (N and S poles) are generated.
2. Clockwise rotation of the magnetic poles here is the same as counterclockwise rotation of rotor bars.
3. A current is induced in each rotor bar in the illustrated direction according to Fleming's right-hand rule.
4. The induced current in each rotor bar generates a clockwise force according to Fleming's left-hand
rule.
5. A rotating torque is generated by the electromagnetic force as explained above. The rotating speed of
the rotor is slightly less than that of the filed poles.
6. Actually, the outer field winding does not move. The sine wave of each phase of the three-phase
alternate current generates a rotational magnetic field to generate a rotating torque of the rotor.
Field winding
Rotational
direction
magnetic
of pole
N pole
Rotational
direction
magnetic
of pole
Field winding
Magnetic field
Direction
of current
Direction of
current induced
in the bar
Direction
of force
Magnetic
field
Direction
of force
Rotational
direction of
cage rotor
Direction
of current
S pole
Current flow from the rear to the front
Magnetic field
Current flow from the front to the rear
Rotational direction
magnetic of pole
Downloaded from www.Manualslib.com manuals search engine
Rotor (Field winding)
2-8
7. The rotational magnetic field is as explained below.
(1) Assume that three coils are placed on the outer side the rotor. When these three coils (a1-a2, b1-b2
and c1-c2) are connected and a three phase alternate current flows, the magnetic flux varies as
shown in the figure below to generate a 2-pole rotational magnetic field. The rotating magnetic field
makes one turn in one cycle of the three-phase AC. Since the field rotates once in one cycle of the
three-phase AC, the inner rotor also makes one turn.
t1
ia
Current (i)
ic
c1
t2
t3
ib
t4
ic
b2
a2
a1
ia
b1
Time (t)
c2
ib
S
S
N
N
S
S
N
N
(2) See the internal structure of the motor. Six coils in three pairs are placed on the outer side of the
rotor. When the six coils (a1a1' - a2a2', b1b1'-b2-b2' and c1c1'-c2c2') are connected in three
phases to receive a three-phase alternate current, the magnetic flux varies as shown in the figure
below to generate a four-pole rotational magnetic field. In this case, the rotational magnetic field
makes a 1/2 turn in one cycle of the three-phase AC. In a motor with three phases of magnetic field
(using six coils in three pairs), the inner rotor can generate twice as much torque as was in the case
of a single-phase motor (using three coils).
Current (i)
t1
t2
ia
c2 b1’
a1’
b2
b2’
c1
t4
ic
ia
c1’
b1
c2’
a2
a1
t3
ib
Time (t)
a2’
ib
S
N
ic
N
N
N
S
S
Downloaded from www.Manualslib.com manuals search engine
S
N
S S
N
N
N
S
S
2-9
Pump motor
■ General
1. An AC induction motor most suitable for compact, high-performance, maintenance-free battery forklift
trucks is adopted newly as the pump motor just like the drive motor.
2. The motor output is increased by making use of the induction motor to improve the performance both
in loaded and unloaded states.
3. The motor is maintenance-free because of no brush.
Length
Diameter
Field winding
Field core
Rpm sensor
bearing
Rotor
■ Specifications
Vehicle model
Voltage
(V)
Rated output
(kW)
(5-min rating)
7FBEF15 to 20
48
9.2
Downloaded from www.Manualslib.com manuals search engine
Type
Size
Diameter×Length
mm (in)
Mass
kg (lb)
3-phase AC
φ180 (7.1) × 290 (11.4)
31 (68)
2-10
MAIN CONTROLLER
■ General
AC System
This controller is multi-functional making use of most advanced electronic technologies such as inverter
control using a microcomputer, the function for CAN communication between the main controller and the
drive/pump motor driver, and the function for communication with multi-screen display.
The power select and power keep functions have been realized by making use of the AC motor drive
system features.
Power select function
The traveling/material handling performance can be selected from H, P and
S modes by operating the buttons.
The operating performance is maintained even when the battery discharge
Power keep function
proceeds for longer, efficiency operation (only when the P or S mode is
selected).
AC motor maximum output
AC power system output
characteristics
DC power system output
characteristics
(DC motor maximum output)
Rpm
Torque
Torque
AC and DC power system output
characteristics with fully charged battery
AC power system output
characteristics with discharged battery
DC power system output
characteristics with
discharged battery
Rpm
The AC motor realized greater output than the DC motor in the same size.
The AC motor drive system output characteristics are determined by the combination of the alternate
current and frequency output from the controller.
Optimum combinations for multiple characteristics are mapped and stored in the controller for power
selection by map switchover.
The output characteristics of the DC motor drive system, on the other hand, are determined by the
controller output voltage itself. The characteristic of the motor itself when the battery voltage is applied
(chopper duty: 100%) is the maximum output. The performance, therefore, drops as the battery voltage
decreases.
On the other hand, the AC motor drive system maintains the performance by changing the AC current and
frequency combination according to the battery discharge level. The power keep function is thus realized.
Downloaded from www.Manualslib.com manuals search engine
2-11
■ Controller configuration
Traveling/Material Handling Controller System Configuration
Drive
AC
motor
Traveling
AC driver
Drive
AC
motor
Traveling
AC driver
Drive motor thermo-sensor
Drive rpm sensor
Drive motor thermo-sensor
Drive motor rpm sensor
Direction switch
Traveling accelerator potentiometer
Battery
Brake switch
Main
controller
Pump
AC motor
Tire angle sensor
Material handling switch
Material
handling
AC driver
Solenoid valve
Display
Pump motor thermo-sensor
Pump motor rpm sensor
Traveling/material handling controller
Downloaded from www.Manualslib.com manuals search engine
2-12
Internal Configuration of Traveling/Material Handling Controller
Battery
Traveling/material handling controller
Main controller
CPU board
Power supply
contactor
Cooling fan
CPU
Sensors and
switches
RAM
I
/
O
Traveling AC driver
Drive
AC
motor
Traveling AC driver
Drive
AC
motor
ROM
I
/
O
CAN
I/O
EEPROM
Material handling
AC driver
Solenoid
drive
circuit
Display
Pump
AC motor
Lift solenoid valve
Tilt solenoid valve
Steering synchronizer
solenoid valve
Comfortable operability is
realized by making fine
control using microcomputer.
CANBus
Controller Area Network
Bus
CPU
(Central Processing Unit)
Central processing unit
ROM
(Read-only Memory)
Read-only memory (Contains the control program.)
RAM
(Random Access Memory)
Memory allowing reading and writing (The contents are
erased when the power is turned off.)
EEPROM
(Electrically Erasable, Programmable
Read-only Memory)
Electrically programmable memory (Contains the data
required for control and error codes.)
I/O
(Input/Output)
Input/output interface
CANI/O
(Controller Area Network Input/Output
interface)
CAN input/output interface
Downloaded from www.Manualslib.com manuals search engine
2-13
■ Major controller functions
1. Two traveling motor control
Two independent AC drive systems are adopted for controlling the motors for front wheels LH and RH.
The outputs from motors LH and RH are controlled according to the steering angle for smooth
operation.
2. Accelerator-off regeneration braking
Regeneration braking is provided to regenerate the electrical braking energy into the battery when the
accelerator pedal is released during traveling. This will extend the operable hours, lengthen the brake
lining life and realizes easy, stable traveling with engine-brake-like feel. This function is active even
when the direction switch is in the neutral position.
3. Brake Pedal Regeneration Braking
Regeneration braking also functions upon ordinary braking to extend the operable hours and lengthen
the brake lining life. This function is active even when the direction switch is in the neutral position.
4. Switch-back regeneration braking
Regenerating braking also functions at the time of switch-back operation.
Smoother operation feel is obtained than on previous models.
5. Power keep function
The performance is maintained even when battery discharge proceeds for longer efficiency operation
hours. (Only when the P or S mode is selected.)
6. Power select function
The traveling/material handling mode is selectable from H, P and S by button operation on the multiscreen display.
7. Power control select function
The traveling/material handling performance mode setting and performance setting to other than H, P
and S are possible by operation on the multi-screen display.
8. Auto-off function
If the vehicle is left with the key switch kept at the ON position, the controller forcibly turn the key
switch off for power saving. To use the vehicle again, turn the key switch to OFF and ON.
9. Deadman Switch Function
Traveling is disabled while the operator is not on the seat.
10. Anti-rollback function
The anti-rollback function is provided for easier starting on a slope.
11. Traveling speed limiter
The traveling speed is limited to the maximum level set with the multi-screen display.
12. Thermal protector
The temperature sensor installed in each controller/motor informs the operator of temperature rise to
the specified level by indication on the multi-screen display and restricts the controller output for
protection.
13. Remaining battery charge calculating function
The battery voltage drop by discharge is detected and calculated by the controller for indication of the
remaining charge on the multi-screen display.
14. Diagnosis function
Any abnormality in the operating systems like the motor driver and accelerator or any sensor
abnormality is detected for indication by respective code on the multi-screen display, and a necessary
action is taken.
15. Analyzer function
When the multi-screen display is in the analyzer mode, defective part detection and functional check of
each operating system and motor driver are possible.
16. Over-discharge warning function
When the remaining battery charge drops below the specified level, it warns on the multi-screen
display and material handling during traveling is disabled. This function protects the battery and inform
the operator of the need to charge the battery.
Downloaded from www.Manualslib.com manuals search engine
2-14
17. Return-to-neutral function
When the direction lever is in the forward or reverse position or when the key switch is turned on while
the accelerator pedal is depressed, traveling is disabled unless the direction lever and accelerator
pedal are returned to their neutral positions.
18. Parking brake ON alarm
An alarm tone sounds when traveling is attempted without releasing the parking brake.
19. Parking Brake OFF Warning
Warning alarm sounds if the operator leaves the seat without applying the parking brake.
Downloaded from www.Manualslib.com manuals search engine
3-1
POWER TRAIN
Page
DRIVE UNIT...................................................................... 3-2
2
3
3
Downloaded from www.Manualslib.com manuals search engine
3-2
DRIVE UNIT
■ Difference from previous models
The drive unit size has been reduced by changing the train of gears from that on previous models, and the
motors LH and RH are arranged transversely on the same axis.
■ General
1. The drive unit adopted for new models has transversely installed traveling motors similarly as on
previous models.
2. Changing the gear train from the previous 4-axis, 3-stage to the 2-axis, 2-stage reduction mechanism
with semi-built-in traveling motors has reduced the drive unit size.
3. Hypoid gear oil (API: GL-4, SAE: 75W-85W) is adopted as the common lubricant for all models (same
as for previous models).
■ Structure
Gears
• First-stage reduction adopts the helical gear featuring high transmission efficiency.
• Second-stage reduction adopts the planetary gear featuring high space efficiency.
Reduction ratio
New models
Previous models
All models
27.040
17.482
■ Drive unit structural drawing
First axis
(Motor input shaft)
Drive motor
Helical gear
Planetary gear
Second axis
(Front axle shaft)
Downloaded from www.Manualslib.com manuals search engine
4-1
TRAVELING, STEERING AND BRAKE SYSTEMS
Page
ACCELERATOR .............................................................. 4-2
REAR AXLE ..................................................................... 4-3
2
3
TIRES ................................................................................. 4-4
STEERING ........................................................................ 4-6
BRAKE .............................................................................. 4-10
4
Downloaded from www.Manualslib.com manuals search engine
4-2
ACCELERATOR
■ Standard Pedal
The accelerator is mounted on the front protector bracket.
A plastic pedal is adopted as on the conventional models for smooth start in depression.
The pedal effort is decreased from 1.5 kg to 0.7 kg by revising the accelerator structure.
■ D2 pedal (option)
The accelerator pedal and the direction switch are integrated.
This pedal allows quick, smooth control of the vehicle speed and changeover between forward and
reverse traveling directions. The traveling direction can be changed without freeing one hand from the
steering wheel.
Downloaded from www.Manualslib.com manuals search engine
4-3
REAR AXLE
■ General
Double tires are installed as the standard feature for rear wheels of all vehicle models for longer tire life.
2
3
4
Downloaded from www.Manualslib.com manuals search engine
4-4
TIRES
■ General
1. Pneumatic shaped cushion (PSC) tires are adopted as standard tires.
The table below shows standard tires.
2. Pneumatic tires are adopted optionally for the 1.5- to 1.8-ton models.
3. See the OPTION LIST for details of the optional tires.
Standard Tire Setting List
Front tire
Vehicle
model
Type
Tire size
Rim size
Tire pressure
kPa(kgf/cm2)[psi]
7FBEF15
PSC
18×7-8/4.33 SOLID
4.33R-8
−
7FBEF16
PSC
18×7-8/4.33 SOLID
4.33R-8
−
7FBEF18
PSC
18×7-8/4.33 SOLID
4.33R-8
−
7FBEF20
PSC
200/50-10/6.50 SOLID
6.50F-10
−
Rear tire
Vehicle
model
Type
Tire size
Rim size
Tire pressure
kPa(kgf/cm2)[psi]
7FBEF15
PSC
15×41/2-8/3.00 SOLID
3.00D-8
−
3.00D-8
−
3.00D-8
−
4.33R-8
−
7FBEF16
1/2
-8/3.00 SOLID
PSC
15×4
7FBEF18
PSC
15×41/2-8/3.00
7FBEF20
PSC
SOLID
16×6-8/4.33 SOLID
■ Notes
• Wheels of new models are not interchangeable with those of previous models.
• The allowable load may vary when the tire type is changed. See the load table for details.
• When color tires are adopted, install tire bands because static electricity is likely to be generated in the
vehicle by the use on resin-coated floor or roads with high friction.
Downloaded from www.Manualslib.com manuals search engine
4-5
■ Option list
Front Tire
Model
Tire name
Pneumatic
shaped cushion
Tire
specification
Wheel
specification
Wheel
size
FR
U-LUG
Tire
18×7−8/4.33
Sidering
4.33R-8
FR
U-LUG
Tire
200/50-10/
6.50
Sidering
6.50F-10
FR
J-LUG
Tire
18×7−8/4.33
Sidering
4.33R-8
FR
J-LUG
Tire
200/50-10/
6.50
Sidering
6.50F-10
FR
J-LUG
Tire
18×7−814PR
Sidering
4.33R-8
FR
J-LUG
Tire
18×7−816PR
Sidering
4.33R-8
FR
U-LUG
Tire
18×7−8/4.33
Sidering
4.33R-8
FR
U-LUG
Tire
200/50-10/
6.50
Sidering
6.50F-10
Pneumatic
Pneumatic
shaped cushion
nonmarking
white
Tire size
7FBEF15 7FBEF16 7FBEF18 7FBEF20
STD
STD
STD
WATTS
STD
F01B
F01B
F01B
WATTS
F01J
WATTS
WATTS
F01J
F01J
WATTS
F01K
F01K
WATTS
F01K
WATTS
Rear Tire
Model
Tire name
Tire
specification
Tire size
Wheel
specification
Wheel
size
7FBEF15 7FBEF16 7FBEF18 7FBEF20
Tire
brand
RR
U-LUG
Tire
15×4.1/2−8/
3.00
Sidering
3.00D-8
RR
U-LUG
Tire
16×6−8/4.33
Sidering
4.33R-8
RR
J-LUG
Tire
15×4.1/2−8/
3.00
Sidering
3.00D-8
RR
J-LUG
Tire
16×6−8/4.33
Sidering
4.33R-8
Pneumatic
RR
J-LUG
Tire
15×4.1/2−812PR
Sidering
3.00D-8
F41J
F41J
F41J
WATTS
Pneumatic
shaped cushion
nonmarking
white
RR
U-LUG
Tire
15×4.1/2−8/
3.00
Sidering
3.00D-8
F41K
F41K
F41K
WATTS
RR
U-LUG
Tire
16×6−8/4.33
Sidering
4.33R-8
Pneumatic
shaped cushion
Downloaded from www.Manualslib.com manuals search engine
STD
STD
STD
WATTS
STD
F41A
2
3
WATTS
F01B
F01K
Tire
brand
F41A
F41A
WATTS
WATTS
F41A
F41K
WATTS
WATTS
4
4-6
STEERING
Steering system
■ General
Power Steering System
Full hydraulic steering system is adopted as the standard as on the previous models.
The power steering system on the previous models has used an exclusive motor pump to supply hydraulic
oil to the power steering system.
On the new models, the hydraulic oil from the oil pump is shunted by the priority valve to supply hydraulic
oil at an appropriate pressure to each power system.
Solenoid valve
Steering valve
Oil control valve
Oil pump
Priority valve
Rear axle cylinder
Rear axle
Oil tank
Downloaded from www.Manualslib.com manuals search engine
4-7
Priority valve
■ Operation
When the key switch is OFF
The spool in the priority valve is located to the left of the control spring.
P (Oil pump)
Spool
Control spring
When no steering operation is performed
Hydraulic oil flows from the pump through the spool to PP and LS pilot line.
As the CF line in the steering valve is shut and the pilot line is drained, internal pressure of CF goes
through inside the spool to PP and to the LH chamber, pushing the spool to the right side of the figure.
Downloaded from www.Manualslib.com manuals search engine
4-8
As the spool is pushed to the right side, the EF line circuit opens, allowing almost all the pump discharge to
flow from the EF line to the control valve.
When steering operation is performed
Turning the steering wheel opens the control orifice in the steering valve and opens the CF line.
The lower side pressure of the control orifice goes through the LS pilot line to the RH chamber, generating
the pressure difference with the LH chamber in which the pressure is equal to that of the upper control
orifice. The pressure difference differs depending on the opening of the control orifice (steering speed).
The spool is operated by this pressure difference to divide some pressure from the pump and supply
adequate hydraulic oil to the steering valve.
Downloaded from www.Manualslib.com manuals search engine
4-9
Steering system
■ General
The rack and pinion of the turning drive portion in the full hydraulic power steering system are made
compact with integration. Removal and installation of the rear axle including the rack and pinion have
become easier.
Previous
Pinion
PS cylinder
New model
PS cylinder
Pinion
Steering wheel
■ General
1. The steering wheel outside diameter is changed from 380 mm (15.0 in) to 360 mm (14.2 in) for easier
operation.
2. Tilt steering with memory is adopted.
3. Since the steering tilt angle is memorized when the steering column is raised and returned to the
original position, no re-setting is necessary.
4. The steering wheel adjustable angle is widened from 6° on the previous models to 9°.
Downloaded from www.Manualslib.com manuals search engine
4-10
BRAKE
Brake pedal
■ General
1. The brake structure is changed from the hydraulic to the mechanical type on all models.
2. The pendant pedal link structure is adopted as on the previous models.
■ The regenerative brake
The regenerative brake sensor use a limit switch not only to improve the sensor system reliability but also
to facilitate maintenance when readjustment of the regenerative brake becomes necessary.
Sensor for regenerative brake
Brake pedal
Downloaded from www.Manualslib.com manuals search engine
4-11
Front brake
■ General
Hydraulic parts such as the master cylinder are discontinued by adoption of mechanical disc brake that
has excellent maintainability.
■ Brake specifocations
Type
Foot brake
Mechanical disc brake
Parking brake
Mechanical disc brake
Brake disc outside diameter mm (in)
203 (8.0)
Brake effective diameter mm (in)
165 (6.5)
Material
Brake pad
Dimension mm (in)
Area mm2 (in2)
Semi-metallic phenol resin
Outside diameter: R100 (3.94) × Inside diameter:
R65 (2.56) × Thickness: 6(0.24)
3528 (5.47) × 2 × 2
Brake ASSY
Motor & Drive unit
Brake disc
Downloaded from www.Manualslib.com manuals search engine
4-12
Parking brake
■ General
The lever type (ratchet type) is adopted as on previous models. The grip portion is shaped for easy
gripping.
Previous model
New model
■ Structure
When the brake lever is pulled from position A to position B in the figure below, the disc brake is
mechanically applied through a wire cable.
■ Operation method
1. Grip the knob and pull the lever from position A to
position B to apply the parking brake.
2. For releasing, throw the lever from position B to
position A while pressing the release button in the
illustration.
Release button
Position A
Position B
■ Lever operating force
Lever operating force
N(kgf)
100~200 (10.2~20.4)
* The figure above is maximized at the position when the lever is pulled about 35° from position A above.
Downloaded from www.Manualslib.com manuals search engine
5-1
INSTRUMENTS
Page
MULTIPLE DISPLAY ...................................................... 5-2
GENERAL FUNCTIONS ............................................... 5-10
DIAGNOSIS ...................................................................... 5-15
2
3
MASK FUNCTIONS ....................................................... 5-21
5
Downloaded from www.Manualslib.com manuals search engine
5-2
MULTIPLE DISPLAY
■ General
The multiple display indicates various types of vehicle information by switching the screen according to
need.
Display and Buttons
Initial screen upon key switch on
SAS
TOYOT A
EQU I P P ED
S P H
S P H
MENU
(1) (2)
3 0 /
9
(3)
AM
(4)
(8) (9)
11: 00
S P H
S P H
MENU
(5) (7)
(6)
During traveling
(10)
Upon error occurrence
10Km / h 1 1 : 0 0
S P H
A1
S P H
1
A1
2 A1
3
1 2 3 4 5 . Oh
S P H
MENU
S P H
MENU
(1)
Parking brake ON indicator
(6)
Power select indicator
(2)
2-speed travel speed set indicator
(7)
Multiple display area
(3)
Diagnosis ON indicator
(8)
2-speed travel speed control
(4)
Overheat warning indicator
(9)
Hour meter selector button
(5)
Battery charge indicator
(10) Power select button
Downloaded from www.Manualslib.com manuals search engine
5-3
(1) Parking brake ON indicator
This indicator comes on when the parking brake is activated. If the accelerator pedal is depressed with
the direction lever in the forward or reverse position, beeps sound to warn the operator.
(2) 2-speed travel speed set indicator
Each time the button is pressed, the indicator comes on or goes out. When this indicator is on, 2-speed
travel speed is on to limit the maximum vehicle speed to the set level.
(3) Diagnosis ON indicator
Blinks when the diagnosis function is activated because of some defect on the vehicle. At the same
time, the corresponding error code is displayed and buzzer sounds to warn the operator.
Up to three error codes can be displayed at a time. When more than three errors occur at a time, up to
six error codes are displayed with alternation at intervals of 2 seconds.
On a SAS model vehicle without matching performed for the SAS function, this indicator comes on to
warn the service person. Perform matching by referring to the MATCHING section.
(4) Overheat warning indicator
If the temperature of the main controller, traveling AC driver, material handling AC driver, drive motor or
pump motor rises beyond the specified level, the overheat warning indicator blinks. At the same time,
a buzzer sounds to warn the operator.
When the indicator is blinking, vehicle operation is restricted and the overheat section indication blinks.
Display Information
2
3
Overheat warning indicator
3 0 /
9
AM
Display information
Overheat section
C/R
Main controller
DCR
Traveling AC driver
PCR
Material handling AC driver
DM
Drive motor
PM
Pump motor
11 : 00
S P H
S P H
MENU
Overheat section
Vehicle Operation Restriction when Overheated
Overheat
section
Description of control
SpecificaMode
tion
STD ·
Main
Fisherman
controller
spec (OPT)
H
STD ·
Traveling
Fisherman
AC driver
spec (OPT)
H
Material
STD ·
handling Fisherman
AC driver spec (OPT)
H
P
S
P
S
P
S
Primary control
Secondary control
1. Character indication and indicator blink
2. Buzzer for 5 seconds
3. Change to half throttle
1. Character indication and indicator blink
2. Buzzer for 5 seconds
3. Change to half throttle
1. Character indication and indicator blink
2. Buzzer for 5 seconds
3. Restrict material handling output
Downloaded from www.Manualslib.com manuals search engine
Tertiary control
5
5-4
Overheat
section
Description of control
SpecificaMode
tion
H
STD
P
S
Drive
motor
H
Fisherman
spec (OPT)
P
S
H
STD
P
S
Secondary control
Tertiary control
1. Character indication 1. Character indication
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
seconds
3. Change to half
3. Change to S mode
throttle
−
1. Character indication
and indicator blink
2. Buzzer continues
3. Change to half
throttle
−
−
1. Character indication
1. Character indication
1. Character indication
and indicator blink
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
2. No buzzer
seconds
3. Change to half
3. Restrict drive output
3. Change to S mode
throttle
1. Character indication
1. Character indication
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
seconds
3. Change to half
3. Restrict drive
throttle
output
−
1. Character indication and indicator blink
2. Buzzer continues
3. Restrict material handling output
H
1. Character indication
1. Character indication
1. Character indication
and indicator blink
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
2. No buzzer
seconds
3. Restrict material
3. Change to S mode
3. Change to P mode
handling output
P
1. Character indication 1. Character indication
and indicator blink
and indicator blink
2. Buzzer for 5
2. Buzzer continues
seconds
3. Restrict material
3. Change to S mode
handling output
−
S
1. Character indication
and indicator blink
2. Buzzer continues
3. Restrict material
handling output
−
Pump
motor
Fisherman
spec (OPT)
Primary control
Downloaded from www.Manualslib.com manuals search engine
−
5-5
(5) Battery charge indicator
This indicator indicates the remaining battery charge in 10 stages.
A: Low remaining battery charge warning
The battery charge indicator blinks when the remaining battery charge drops to the set level or below.
When the key switch is turned from OFF to ON in this state, a buzzer sounds for 5 seconds to warn the
operator.
B: Battery overdischarge warning (lift interrupt function)
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. In this case, material handling during
traveling cannot be performed.
Note:
The level can be set using TUNING function of the mask function. (See page 5-45.)
Low remaining battery charge warning
3 0 /
9
AM
S P H
Battery overdischarge warning
3 0 /
11 : 00
S P H
MENU
Number of segments corresponding to
the remaining battery charge.
9
AM
11 : 00
S P H
S P H
MENU
All battery charge indicator segments blink.
(6) Power select Indicator (traveling and material handling)
A box enclosing S, P or H indicates the mode selected at present. The setting can be changed by
pressing the power select button on the GENERAL screen.
If all symbols are enclosed, control is performed in the original mode (level set on the POWER
CONTROL LEVEL SETTING screen).
(7) Multiple display area
The date and time are normally displayed in this area. This area is also used for various function
settings and error code displays of the diagnosis function.
(8) 2-speed travel speed control
Press this button on the GENERAL screen to set the 2-speed travel speed on and off.
(9) Hour meter selector button
This button changes displayed items of multi-hour meter function. The built-in function is different on
the easy model (standard vehicle) and the all-round model (OPT). (See page 5-9.)
(10) Power select button
The button selects S, P or H mode. The selected mode can be changed each time the power select
button is pressed on the GENERAL screen.
Press the button and hold it for 2 seconds to set the level of each function.
Downloaded from www.Manualslib.com manuals search engine
2
3
5
5-6
(11) Low temperature warning indicator
Warn the low temperature of the traveling and material handling AC drivers. When the material
handling AC driver temperature becomes low, a buzzer sounds to warn the operator for 5 seconds. At
the same time, it restricts the material handling output.
The low temperature section indication blinks.
Display information
COL D
DCR
AM
Display information
Low temperature section
COLD DCR
Traveling AC driver
COLD PCR
Material handling AC driver
11 : 00
S P H
S P H
MENU
Low temperature section
(12) Wheel indicator
The turning direction is displayed by “ | ” on the
multiple display area.
Note:
• Display setting can be set by option setting of mask
function.
• Speedometer can not be displayed when wheel
indicator is set to be displayed.
3 0 /
⟨⟨
9
⟨⟨
AM
⟨⟨ | ⟩⟩
1 1 : 0 0
⟩⟩ ⟩⟩
S P H
S P H
MENU
Wheel indicator
In straight traveling state
3 0 /
⟨⟨
9
⟨⟨
AM
⟨⟨ | ⟩⟩
1 1 : 0 0
⟩⟩ ⟩⟩
During left turn
3 0 /
⟨⟨
9
AM
⟨⟨ | ⟨⟨ ⟩⟩
1 1 : 0 0
⟩⟩ ⟩⟩
During right turn
3 0 /
⟨⟨
9
⟨⟨
⟨⟨
AM 1 1 : 0 0
⟩⟩ | ⟩⟩ ⟩⟩
■ Specifications
LCD
Dot matrix + Fixed display
Buttons
Three buttons
Back light
LED type that comes on when the key switch is turned to ON
Heater
Temperature detection type (provided only on the cold-storage model)
Downloaded from www.Manualslib.com manuals search engine
5-7
■ Display indication list
Press button (3) for 2 sec. or more
Enter password
GENERAL screen
To be selected by the user
2-speed travel speed ON/OFF
Switching to hour meter display
Power select
To be set by the user
Traveling speed level
Speed alarm
Power control select
Clock set
ON or OFF setting of 2-speed travel speed
Checking traveling or material handling system operation time
Power mode selection
Setting of 2-speed travel speed level
Traveling speed setting for overspeed alarm
Fine adjustment of each of traveling and material handling power
control levels
Adjustment of indicated time
MASK FUNCTION screen
To be set by dealer or serviceman
DIAG MEMORY Checking past diagnosis error codes stored in memory
I/O MONITOR1
Checking the temperature and voltage of each functional part
Checking traveling-related sensors
I/O MONITOR2
ANALYZER
Checking material handling and mast control sensors
I/O MONITOR3
Checking steering knob synchronizer and other sensors
I/O MONITOR4
Forced ON/OFF test of each switch
ACTIVE TEST
Standard function adjustment
TUNING1
TUNING2 LIFTV Lift lever adjustment
TUNING
TUNING3 TILTV Tilt lever adjustment
TUNING4 ATT1V ATT 1 lever adjustment
TUNING5 ATT2V ATT 2 lever adjustment
DEMO MODE
Enabling simultaneous traveling and material handling before H/M start
H/M START
Starting the hour meter count
P/C LOCK
Power control lock selection
DESTI
Changing display for each destination
B LEVEL
Setting the traveling speed display
MPH
C/CNT RES
Setting the calculation constant for battery charge indicator
BATTERY
SHOU-TOKU
Setting the operation of the Auto-OFF function in relation to the seat switch
SEAT P-OFF
PARKING ERR
Setting the parking brake OFF warning
OPTION SET
TILT CONT
Setting the mast forward tilt angle restriction
KNOB CONT
TILT F-LIM
Setting the mast forward tilt/level function
B-TYPE
Setting the battery type
36V
2-WAY VALVE
Setting the specification of 2-way mini lever models
4-WAY VALVE
Setting the specification of 4-way mini lever models
USA
Setting the wheel indicator indication
WHEEL IND
SAS
Setting the SAS function
FISHERMAN
TILTL
Matching of the tilt/level angle
TILTF
Matching of the tilt forward restricted angle
LOAD
Matching of the NL load
TIRE
Matching of the tire angle sensor forward direction
MATCHING
LIFT
Matching of the lift lever neutral position
TILT
Matching of the tilt lever neutral position
ATT1
Matching of the ATT1 lever neutral position
ATT2
Matching of the ATT2 lever neutral position
Setting the tire constant
WHEEL DIA
WHEEL DIA
Downloaded from www.Manualslib.com manuals search engine
5-8
■ Abbreviations display on the screen
Abbreviation
Meaning
Abbreviation
Meaning
A1
Attachment switch 1
SSD2
Drive motor 2 rpm sensor
A2
Attachment switch 2
SSP
Pump motor rpm sensor
C/R
Controller
STS
Steering angle sensor
DCR
Traveling AC driver
STS1
Steering angle sensor 1
DM
Drive motor
STS2
Steering angle sensor 2
DSF
Forward direction switch
STSC
Steering angle sensor for straight
traveling
DSR
Backward direction switch
SWAC
Accelerator switch
FAN
Cooling fan
SWTK
Tilt knob switch
H/M
Hour meter
T
Forward and backward tilt switch
K-DIFF
Deviation of steering angle knob
position
TBD
Traveling AC driver control board
surface temperature
K-POS
Steering angle knob position
TBP
Material handling AC driver control
board surface temperature
KSOL
Steering synchronizer solenoid
TD
Drive motor temperature
LOAD
Material handling hydraulic pressure
TEMP
CPU board surface temperature
L
Lift switch
THCD
Main drive circuit temperature
LSB
Brake switch
THCP
Main pump circuit temperature
LSD
Seat switch
TILTF
Forward tilt restriction position
MH
Lifting height switch
TILTL
Tilt level position
P/C
Power control
TIRE
Tire angle sensor voltage
PCR
Material handling AC driver
TP
Pump motor temperature
PM
Pump motor
VB48
Battery voltage
POTA
Accelerator potentiometer
VBBD
Traveling AC driver power source
voltage
POTT
Tilt angle potentiometer
VBBP
Material handling AC driver power
source voltage
SPD
Main traveling speed
VBKS
Voltage after key switch
SPL
Load sensor
VBMB
Main controller input voltage
SSD1
Drive motor 1 rpm sensor
VBSOL
Solenoid power source voltage
Downloaded from www.Manualslib.com manuals search engine
5-9
■ General functions
1. General functions can generally been used or seen by the user.
2. Two types of multiple displays are available: the easy model (the standard specification), and the allround model (OPT). The display contents vary as follows:
Functions
Status display
function
Level setting
function
Multi-hour
meter
function
Warning function
{: General function :Not provided
Model
Easy model
All-round model
(standard)
(option)
Battery charge indicator
{
{
Speedometer
{
{
2-speed travel speed set indicator
{
{
Parking brake ON indicator
{
{
Power select indicator
{
{
Wheel indicator

{
Power select
{
{
Traveling power control level setting
{
{
Material handling power control level setting
{
{
2-speed travel speed level setting
{
{
Key ON hour meter
{
{
Traveling hour meter

{
Material handling hour meter

{
Traveling or Material handling hour meter

{
Odometer

{
Lap time meter

{
Trip meter

{
Calendar · clock
{
{
Battery overdischarge warning
{
{
Low remaining battery charge warning
{
{
Overheat warning
{
{
Low temperature warning
{
{
Parking brake ON warning
{
{
Parking brake OFF warning
{
{
Return to neutral warning
{
{
{*1
{*1
Overspeed alarm

{
Diagnosis display
{
{
Material handling operation lock
*1: Provided on the vehicle with mini lever (OPT).
Downloaded from www.Manualslib.com manuals search engine
5-10
GENERAL FUNCTIONS
■ Changing Display
Button (1)
GENERAL screen
3 0 /
9
AM
Button (2)
2-speed travel speed
ON/OFF setting
Hour meter display
selection
Power control selection
11 : 00
S P H
S P H
MENU
Button (3)
Press button (3)
for 2 seconds or more.
2-SPEED TRAVEL SPEED
LEVEL SETTING screen
S P E E D 1
L E V E L
5
8
S P H
S P H
MENU
Press button (3)
OVERSPEED ALARM
SETTING screen (OPT)
S P E E D
A L A RM
10Km / h
S P H
S P H
* This screen is displayed
only on the all-round model.
The easy model does not
have this screen.
MENU
Press button (3)
POWER CONTROL
FUNCTION SELECTION
screen
P O WE R
S E L E CT
Y E S / NO
S P H
S P H
MENU
Press button (3)
CLOCK SET FUNCTION
SELECTION screen
CL OCK
S E T
YES / NO
S P H
S P H
MENU
Press button (3)
(To GENERAL screen)
*1: OVERSPEED ALARM SETTING screen is displayed only on the all-round model (OPT).
This screen is skipped on the easy model (standard).
*2: Upon returning to the GENERAL screen after moving to each function setting screen, the power select
mode is set to “S”. If necessary, select the desired mode.
If necessary, select the desired mode.
Downloaded from www.Manualslib.com manuals search engine
5-11
■ Operating procedure of function setting
GENERAL screen
1. 2-speed travel speed on/off selection
Press button (1) for 2-speed travel speed control on/
off. The 2-speed travel speed is on if the indicator
comes on.
2-speed travel speed indicator
Button (1)
3 0 /
9
AM
11 : 00
S P H
S P H
MENU
2. Hour meter display selection
Press button (2) to select the hour-meter display.
The differences between the displayed contents of the easy model (standard setting) and the all-round
model (optional setting) are as follows:
Easy model (standard)
Button (2)
GENERAL screen
3 0 /
9
AM
G Trip meter
T R I P
RE S E T
11 : 00
S P H
1 2 3 4 5. 0
SW
2 S E C
S P H
MENU
S P H
Press
button (2)
S P H
MENU
Button (3)
Press button (2)
Press button (3)
Easy model
Press button (2)
A Key ON hour meter
K E Y
F Lap time meter
ON
L A P
0 . 0 h
S P H
S P H
1 2 3 4 5. 0
SW
2
S P H
MENU
S P H
MENU
Press button (2)
All-round model
Press button (2)
B:Traveling hour meter
C:Material handling hour meter
D:Traveling or material handling hour meter
E:Odometer
0 . 0 h
0 . 0 h
S P H
ODO
S P H
MENU
0 . 0 h
0 . 0
S P H
Press
button (2)
S P H
MENU
The lap time meter and trip meter can be reset by pressing button (1) for 2 seconds or more.
Press button (3) on each screen to return to the GENERAL screen.
Downloaded from www.Manualslib.com manuals search engine
5-12
Model
Function
Easy
model
All-round
model
Description
A
Key ON hour meter
{
{
Indicates the total key ON time
B
Traveling hour meter

{
Traveling operation time
C
Material handling hour meter

{
Material handling operation time
D
Traveling/material handling
hour meter

{
Total time of traveling and material handling
operation (when both operations occur at the
same time, only operation time of either
operation)
E
Odometer

{
Total distance traveled
F
Lap time meter

{
Lap time upon key ON
G
Trip meter

{
Trip distance
3. Power select mode switching (S, P or H)
Press button (3) on the GENERAL screen to change
the travel/material handling power select mode. When
all of S, P and H are highlighted by squares, the
control is performed in the mode set on the Power
Control Level SETTING screen.
S: Standard mode
P: Power mode
H: High power mode
3 0 /
9
AM
11 : 00
S P H
S P H
MENU
Button (3)
Power select indicator
2-SPEED TRAVEL SPEED LEVEL SETTING screen
The 2-speed travel speed level is set on this screen.
Press button (3) on the general screen for 2 seconds or
more to display the 2-SPEED TRAVEL SPEED LEVEL
SETTING screen.
1. Press button (1) to decrease the 2-speed travel speed
level.
2. Press button (2) to increase the 2-speed travel speed
level.
3. Press button (3) to display the next screen.
Blinks upon 2-speed travel Button (1)
speed level setting.
Button (2)
1
5
8
S P H
S P H
MENU
2-speed travel speed level
Button (3)
OVERSPEED ALARM SETTING screen (OPT)
The traveling speed level for the overspeed alarm is set on this screen.
Press button (3) on the 2-SPEED TRAVEL SPEED
LEVEL SETTING screen to display the OVERSPEED
ALARM SETTING screen.
1. Press button (1) to decrease the traveling speed
setting.
2. Press button (2) to increase the traveling speed
setting.
3. Press button (3) to display the next screen.
Button (1) Button (2)
10Km / h
S P H
Traveling speed setting
for overspeed alarm
Downloaded from www.Manualslib.com manuals search engine
S P H
MENU
Button (3)
5-13
POWER CONTROL FUNCTION SELECTION screen
The travel and material handling power control levels can be set independently using this screen.
1. Press button (1) on the POWER CONTROL
Button (1) Button (2)
FUNCTION SELECTION screen, select “YES” and
press button (3) to display the TRAVEL POWER
CONTROL LEVEL SETTING screen.
(1) TRAVELING POWER CONTROL LEVEL
P OWE R
S E L E C T
Y E S / NO
SETTING screen
S P H
S P H
1) Press button (1) to select the lower level.
2) Press button (2) to select the higher level.
3) Press button (3) to display MATERIAL
Button (3)
HANDLING POWER CONTROL LEVEL
Select "YES" and
SETTING screen.
press button (3)
(2) MATERIAL HANDLING POWER CONTROL
TRAVELING POWER CONTROL
LEVEL SETTING screen
LEVEL SETTING screen
1) Press button (1) to select the lower level.
2) Press button (1) to select the higher level.
3) Press button (3) to display the next screen.
S P H
2. To display the next screen, press button (2) on the
S P H
S P H
POWER CONTROL FUNCTION SELECTION screen,
select “NO” and press button (3); alternatively, press
button (3) on the MATERIAL HANDLING POWER
Press button (3)
CONTROL LEVEL SETTING screen.
MENU
MENU
MATERIAL HANDLING POWER
CONTROL LEVEL SETTING screen
S PH
S P H
S P H
MENU
Press button (3)
CLOCK SET FUNCTION
SELECTION screen
Downloaded from www.Manualslib.com manuals search engine
5-14
CLOCK SET FUNCTION SELECTION screen
The year, month, day, day of week, time and 12/24-hour display can be set independently.
Press button (2) on the POWER CONTROL FUNCTION SELECTION screen, select “NO”, and press
button (3), or press button (3) on the MATERIAL HANDLING POWER CONTROL LEVEL SETTING
screen to display the CLOCK SET FUNCTION SELECTION screen.
Button (1)
P OWE R
Button (2)
S E L EC T
Y E S / NO
Button (3)
Select "NO" and press button (3)
C L OCK
S E T
Y E S / NO
Press button (3)
C L OCK
S E T
Y E S / NO
Press button (3)
Press button (3)
Each press of button (3) will shift
the selection item in this order:
month, day, ... and minute.
End of clock setting
Press button (3)
1. Press button (1) on the CLOCK DISPLAY FUNCTION SELECTION screen, select “YES” and press
button (3) to display the CLOCK SET screen.
CLOCK SET screen
1) Press button (1) to decrease the selected (blinking) value.
2) Press button (2) to increase the selected (blinking) value.
3) Press button (3) to enter the selected (blinking) value and proceed to the next item.
4) Press button (3) when “MINUTES” is selected on the CLOCK SET FUNCTION SELECTION
screen to display the next screen (GENERAL screen).
2. Press button (3) when “NO” is selected on the CLOCK SET FUNCTION SELECTION screen to display
the next screen (GENERAL screen).
Downloaded from www.Manualslib.com manuals search engine
5-15
DIAGNOSIS
1. When diagnosis is activated, the diagnosis ON
indicator comes on and blinks on the screen and a
beep sounds to warn the operator that some
abnormality has occurred on the vehicle.
2. Also, up to three diagnosis error codes are displayed
on the screen. When the number of error codes
exceeds three, up to six are displayed on screens.
3. In order to enable battery level checking, battery
charge indicator is displayed during diagnosis error
codes display.
Wrench symbol
A1
1
A1
2 A1
3
1 2 3 4 5 . Oh
S P H
S P H
MENU
Diagnosis codes
Abnormality detection time
(Key ON hour meter)
■ Diagnosis code list
Displayed code: Code indicated on the display when an abnormality occurs in the vehicle
Diag memory code: Code indicated on the display when mask function DIAG MEMORY is in use P5-30
C/R: Main controller, DCR_LH: Traveling AC driver 1, DCR_RH: Traveling AC driver 2,
PCR: Material handling AC driver
Diag
Displayed
memory
code
code
Faulty
Phenomenon on vehicle
Detection
controller

DCR: Low temperature
Display only
DCR_LH,
DCR_RH

PCR: Low temperature
Restricted material
handling output
PCR
30-1
30-1
DCR_LH: Low voltage
30-2
30-2
DCR_RH: Low voltage
30-3
30-3
PCR: Low voltage
Material handling and
power steering stop
PCR
31-1
31-2
31-1
31-2
DCR_LH: Low starting voltage
DCR_RH: Low starting voltage
Traveling disabled
DCR_LH
DCR_RH
31-3
31-3
PCR: Low starting voltage
Material handling and
power steering stop
PCR
32-1
32-2
32-3
32-1
32-2
32-3
DCR_LH: EEPROM abnormality
DCR_RH: EEPROM abnormality
PCR: EEPROM abnormality
DCR_LH
Operate under the default DCR_RH
PCR
33-1
33-1
Communication abnormality from C/R to
DCR_LH
33-2
33-2
33-3
33-3
61-1
61-1
Communication abnormality from C/R to
DCR_RH
Communication abnormality from C/R to
PCR
Load sensor: Open
61-2
61-2
Load sensor: Short circuit
62-1
62-2
62-1
62-2
Tilt angle sensor: Open
Tilt angle sensor: Short circuit
Downloaded from www.Manualslib.com manuals search engine
Traveling disabled
DCR_LH
DCR_RH
DCR_LH
Traveling disabled
DCR_RH
Material handling and
PCR
power steering stop
·No NL control and forward tilt restriction
C/R
·No automatic leveling
·No forward tilt restriction
C/R
·No automatic leveling
5-16
Diag
Displayed
memory
code
code
Faulty
Phenomenon on vehicle
Detection
controller
63-1
63-1
63-2
63-2
63-3
63-3
64-1
64-2
64-3
65-1
65-2
65-3
64-1
64-2
64-3
65-1
65-2
65-3
Forward and backward tilt SWs:
simultaneously on
Forward tilt SW: Short circuit for more than 2
minutes
Backward tilt SW: Short circuit for more than
2 minutes
Lift solenoid: Open
Lift solenoid: Short circuit
Lift solenoid: Drive circuit abnormality
Tilt solenoid: Open
Tilt solenoid: Short circuit
Tilt solenoid: Drive circuit abnormality
66-1
66-1
Tilt matching abnormality
67-1
67-1
Lifting height switch abnormality
71-1
71-2
72-1
72-2
72-3
72-4
73-1
71-1
71-2
72-1
72-2
72-3
72-4
73-1
73-2
73-2
73-3
73-3
Tire angle sensor: Open
Tire angle sensor: Short circuit
Steering angle sensor: STS1 abnormality
Steering angle sensor: STS2 abnormality
Steering angle sensor: STSC abnormality
Steering angle sensor: Open
Steering knob synchronizer solenoid: Open
Steering knob synchronizer solenoid: Short
circuit
Steering knob synchronizer solenoid:
Drive circuit abnormality
74-1
74-1
Tire angle sensor matching abnormality
Traveling restriction,
C/R
no steering synchronizer
A0-1
DCR main drive circuit overheat
Restricted traveling output
DCR_LH,
DCR_RH
A0-2
PCR main drive circuit overheat
Restricted material
handling output
PCR
C/R
·No forward tilt restriction
·No automatic leveling
C/R
(Forward tilt disabled)
Interruption of lift solenoid output
C/R
Interruption of tilt solenoid output
C/R
·No forward tilt restriction
C/R
·No automatic leveling
·No low lift restriction and
forward tilt restriction
C/R
·No automatic leveling
Traveling stop, no steerC/R
ing knob synchronizer
No steering knob synchronizer
C/R
Steering knob synchroC/R
nizer solenoid output stop
A1-1
A1-1
C/R: High voltage
·Traveling disabled
·Material handling and
power steering disabled
(solenoid off)
A1-2
A1-3
A1-2
A1-3
DCR_LH: High voltage
DCR_RH: High voltage
Traveling disabled
DCR_LH
DCR_RH
A1-4
A1-4
PCR: High voltage
Material handling and
power steering disabled
PCR
Downloaded from www.Manualslib.com manuals search engine
5-17
Diag
Displayed
memory
code
code
Faulty
Phenomenon on vehicle
Detection
controller
A2-1
CPU board overheat
Restricted traveling output
C/R
A2-2
DCR_LH or DCR_RH board overheat
Restricted traveling output
DCR_LH,
DCR_RH
A2-3
PCR board overheat
Restricted material handling output
PCR
A3
A3
Incorrect battery connection
A4
A6-1
A6-3
A6-5
AA-1
AA-2
AA-3
A4
A6-1
A6-3
A6-5
AA-1
AA-2
AA-3
Accelerator switch abnormality
Lift switch abnormality
Tilt switch abnormality
Attachment switch 1 abnormality
CPU board thermo-sensor abnormality
DCR_L board thermo-sensor abnormality
DCR_R board thermo-sensor abnormality
AA-4
AA-4
PCR board thermo-sensor abnormality
AC
AC
AD-1
AD-1
AD-2
AD-2
AD-3
AD-3
AD-4
AD-4
AD-5
AD-5
AD-6
AD-6
Semiconductor switch abnormality
·Traveling disabled
·Material handling and
power steering disabled
·MB not turned on
Traveling disabled
C/R
Material handling disabled
C/R
Restricted traveling output
C/R
DCR_LH
DCR_RH
Restricted material handling output
·Traveling disabled
·Material handling and
power steering disabled
·MB not turned on
Communication abnormality from DCR_L to
Traveling disabled
C/R (1)
Traveling disabled
Communication abnormality from DCR_L to (when AD-4 and AD-6
C/R (2)
occur at the same time,
MB not turned on)
Communication abnormality from DCR_R to
Traveling disabled
C/R (1)
Traveling disabled
Communication abnormality from DCR_R to (when AD-2 and AD-6
C/R (2)
occur at the same time,
MB not turned on)
Communication abnormality from PCR to
Material handling and
C/R (1)
power steering disabled
Material handling and
power steering disabled
Communication abnormality from PCR to
(when AD-2 and AD-4
C/R (2)
occur at the same time,
MB not turned on)
Downloaded from www.Manualslib.com manuals search engine
C/R
PCR
C/R
C/R
C/R
C/R
C/R
C/R
C/R
5-18
Diag
Displayed
memory
code
code
AF-1
AF-1
AF-2
AF-2
AF-3
AF-3
AF-4
AF-4
C1-1
C1-1
C1-2
C1-2
C1-3
C1-3
C1-4
C1-4
Faulty
CPU abnormality (1)
CPU abnormality (2)
CPU abnormality (3)
CPU abnormality (4)
DCR_LH current sensor offset abnormality
DCR_LH: Overcurrent
DCR_RH current sensor offset abnormality
DCR_RH: Overcurrent
C2-1
Drive motor overheat
C2-2
C2-3
C2-2
C2-3
C3-1
C3-1
C3-2
C3-2
C4-1
C4-2
C4-3
C4-4
C7
C8-1
C8-2
C4-1
C4-2
C4-3
C4-4
C7
C8-1
C8-2
Drive motor 1 thermo-sensor abnormality
Drive motor 2 thermo-sensor abnormality
DCR_LH main drive circuit thermo-sensor
abnormality
DCR_RH main drive circuit thermo-sensor
abnormality
Accelerator potentiometer abnormality (1)
Accelerator potentiometer abnormality (2)
Accelerator potentiometer abnormality (3)
Accelerator potentiometer abnormality (4)
Direction switch abnormality
Drive motor 1 rpm sensor abnormality
Drive motor 2 rpm sensor abnormality
CB-1
CB-1
MB contactor abnormality
CB-2
E1-1
E1-2
CB-2
E1-1
E1-2
MB contactor fused
PCR current sensor offset abnormality
PCR: Overcurrent
E2-1
Pump motor overheat
E2-2
E2-2
E3
E3
Pump motor thermo-sensor abnormality
PCR main drive circuit thermo-sensor
abnormality
E8
E8
EE-1
EE-1
EE-2
EE-2
EE-3
EE-3
Pump motor rpm sensor abnormality
Phenomenon on vehicle
Detection
controller
·Traveling disabled
·Material handling disC/R
abled
·Power steering disabled
DCR_LH
Traveling disabled
DCR_RH
Restricted traveling output
Restricted traveling output
Traveling disabled
Display only
Traveling disabled
Restricted traveling output
·Traveling disabled
·Material handling and
power steering disabled
(solenoid off)
Display only
Material handling and
power steering disabled
Restricted material
handling output
Restricted material
handling output
Material handling disabled
DCR_LH
DCR_RH
DCR_LH
DCR_RH
DCR_LH
DCR_RH
C/R
C/R
DCR_LH
DCR_RH
C/R
C/R
PCR
PCR
PCR
PCR
Communication abnormality from display to
C/R (1)
Display only
C/R
Communication abnormality from display to
C/R (2)
Communication abnormality from display to
Operate under the default C/R
C/R (3)
Downloaded from www.Manualslib.com manuals search engine
5-19
Diag
Displayed
memory
code
code
EF-1
EF-1
EF-2
EF-2
EF-3
EF-3
EF-4
EF-1
Faulty
F1-1
F1-1
F1-2
F1-2
FF
H1-1 *1
H1-2 *1
H1-3 *1
H1-4 *1
H1-5 *1
H2-1 *1
H2-2 *1
H2-3 *1
H2-4 *1
H2-5 *1
H3-1 *1
H3-2 *1
H3-3 *1
FF
H1-1
H1-2
H1-3
H1-4
H1-5
H2-1
H2-2
H2-3
H2-4
H2-5
H3-1
H3-2
H3-3
H3-4 *1
H3-4
H3-5 *1
H3-5
H4-1 *1
H4-2 *1
H4-3 *1
H4-1
H4-2
H4-3
H4-4 *1
H4-4
H4-5 *1
H4-5
H5-1 *1
H5-1
EEPROM abnormality (1)
EEPROM abnormality (2)
CPU abnormality
EEPROM abnormality (3)
Communication abnormality from C/R to display (1)
Communication abnormality from C/R to display (2)
D15V overcurrent
Lift potentiometer abnormality (1)
Lift potentiometer abnormality (2)
Lift potentiometer abnormality (3)
Lift potentiometer neutral abnormality
Lift potentiometer matching abnormality
Tilt potentiometer abnormality (1)
Tilt potentiometer abnormality(2)
Tilt potentiometer abnormality (3)
Tilt potentiometer neutral abnormality
Tilt potentiometer matching abnormality
Attachment 1 potentiometer abnormality (1)
Attachment 1 potentiometer abnormality (2)
Attachment 1 potentiometer abnormality (3)
Attachment 1 potentiometer neutral abnormality
Attachment 1 potentiometer matching
abnormality
Attachment 2 potentiometer abnormality (1)
Attachment 2 potentiometer abnormality (2)
Attachment 2 potentiometer abnormality (3)
Attachment 2 potentiometer neutral abnormality
Attachment 2 potentiometer matching
abnormality
Lift b1 (UP) solenoid abnormality (1)
H5-2 *1
H5-2
Lift b1 (UP) solenoid abnormality (2)
H5-3 *1
H5-3
Lift a1 (DOWN) solenoid abnormality (1)
H5-4 *1
H5-4
Lift a1 (DOWN) solenoid abnormality (2)
H5-5 *1
H5-5
Lift solenoid drive circuit abnormality
Downloaded from www.Manualslib.com manuals search engine
Phenomenon on vehicle
Detection
controller
Operate under the default
Operate under the default
C/R
Display only
Operate under the default
Display only
Display
Display off
C/R
Lift operation stop
C/R
Tilt operation stop
C/R
Attachment 1 operation
stop
C/R
Attachment 2 operation
stop
C/R
Lift operation stop
Material handling disabled
Lift operation stop
Material handling disabled
Material handling disabled
C/R
5-20
Diag
Displayed
memory
Faulty
code
code
H6-1 *1
H6-1 Tilt a2 (FRONT) solenoid abnormality (1)
H6-2 *1
H6-2
Tilt a2 (FRONT) solenoid abnormality (2)
H6-3 *1
H6-3
Tilt b2 (REAR) solenoid abnormality (1)
H6-4 *1
H6-4
Tilt b2 (REAR) solenoid abnormality (2)
H6-5 *1
H6-5
Tilt solenoid drive circuit abnormality
H7-1 *1
H7-1
Attachment 1 a3 solenoid abnormality (1)
H7-2 *1
H7-2
Attachment 1 a3 solenoid abnormality (2)
H7-3 *1
H7-3
Attachment 1 b3 solenoid abnormality (1)
H7-4 *1
H7-4
Attachment 1 b3 solenoid abnormality (2)
H7-5 *1
H7-5
Attachment 1 solenoid drive circuit abnormality
H8-1 *1
H8-1
Attachment 2 a4 solenoid abnormality (1)
H8-2 *1
H8-2
Attachment 2 a4 solenoid abnormality (2)
H8-3 *1
H8-3
Attachment 2 b4 solenoid abnormality (1)
H8-4 *1
H8-4
Attachment 2 b4 solenoid abnormality (2)
H8-5 *1
H8-5
H9-1 *1
H9-2 *1
H9-1
H9-2
H9-3 *1
H9-3
Attachment 2 solenoid drive circuit abnormality
Unload valve solenoid open
Unload valve solenoid short
Unload valve solenoid drive circuit abnormality
*1: Only on the vehicle with the mini lever (OPT).
Downloaded from www.Manualslib.com manuals search engine
Phenomenon on vehicle
Tilt operation stop
Material handling disabled
Tilt operation stop
Material handling disabled
Material handling disabled
Attachment 1 operation
stop
Material handling disabled
Attachment 1 operation
stop
Material handling disabled
Material handling disabled
Attachment 2 operation
stop
Material handling disabled
Attachment 2 operation
stop
Material handling disabled
Material handling disabled
Material handling disabled
Detection
controller
C/R
C/R
C/R
C/R
5-21
MASK FUNCTIONS
■ General
In addition to the functions described in the instruction manual for use by general users, the multiple
display provides the following mask functions for use by the service staff for vehicle maintenance and
specification setting.
The mask functions are protected by password to prevent damage of the data by unintentional operation
by users.
Mask function list
When used
Option
set
Vehicle
delivery
Board
replacement
Others
Analyzer
Displays the vehicle’s electrical
system operating status and reads
the error information detected by
controllers.


Upon vehicle
abnormality
detection
Tuning
Makes fine adjustment of traveling
and material handling functions.

{
*2
As requested by
customer
Specification
setting
Sets each vehicle option and other
specifications. *1

{
*2 · *3

Each control
function
enable/disable
Enables or disables each control
function.

{
*2 · *3

Hour meter
start
Starts the hour meter count.
{
{
*3

Demo mode
Enables or disables the demo
mode. (Material handling prohibition during traveling for vehicle
delivery)


Upon new
vehicle
demonstration
Updates voltage values of sensor
signals under the standard vehicle
condition.

{
*2

Makes the speedometer reading
appropriate.

{
*2

Function
Description
Matching
Tire constant set
*1: This matches the controller and screen control according to the installed options and control functions
equipped on the vehicle; note that this function does not enable or disable the option or control function
itself.
*2: Board: Main controller
*3: Board: Multiple display control board
Downloaded from www.Manualslib.com manuals search engine
5-22
Preparation for the MASK MENU screen
Caution:
When going to the MASK MENU screen from the
general screen, always jack up the vehicle until the
drive wheels (front tires) leave the ground, and
support the vehicle with wooden blocks under the
front frames.
Be sure to fully lower the fork.
1. Check that the battery plug is connected securely and
turn the key switch to ON.
2. Operate mask functions according to Password Input
Procedure. (See page 5-23.)
Downloaded from www.Manualslib.com manuals search engine
5-23
■ Password
Notes on password input
1. Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button
may be damaged.
2. If a mistake is made part of the way through, turn the key switch to OFF and begin again. If the MASK
MENU screen does not appear after several attempts, the system may be faulty.
Password input procedure
Button (1)
3 0 / 9
AM
Button (2)
11 : 00
S P H
S P H
MENU
MASK MENU screen
1. Press buttons (1) and (2) at the same time.
Button (1)
3 0 / 9
AM
Ve
D* . *
T L * . * TR* . *
11 : 00
S P H
S P H
C* .
P * .
S P H
MENU
MENU
2. Within 10 seconds, press button (1)
5. The VERSION screen is displayed for
about 3 seconds.
Button (2)
Button (3)
Button (2)
3 0 / 9
AM
3 0 / 9
11 : 00
S P H
S P H
AM
S P H
S P H
MENU
S P H
MENU
4. Within 10 seconds, press buttons (2) and (3)
at the same time for more than 2 seconds.
3. Within 10 seconds, press button (2)
Procedure
11 : 00
Operation
Response from the vehicle
1
Press buttons (1) and (2) at the same time.
A short beep sounds.
2
Press button (1) (in 10 seconds after pressing button (1) and
(2))
A short beep sounds.
3
Press button (2) (in 10 seconds after pressing button (1))
A short beep sounds.
4
Press buttons (2) and (3) at the same time and hold for 2
seconds or more. (in 10 seconds after pressing button (2), End A short beep sounds.
of password input)
5
The VERSION screen is displayed automatically.
6
After displaying the VERSION screen for 3 seconds, the MASK MENU screen appears automatically.
Downloaded from www.Manualslib.com manuals search engine
5-24
Operation on MASK MENU screen
Caution:
Unlike the analyzer function selection on of previous models, display of test screen does not
prohibit the vehicle’s ordinary operation.
1. Input the password on the general screen (see page 5-23) to display the MASK MENU screen.
2. Press button (1) or (2) to select the desired menu item, and press button (3) (enter) to display the
menu or setting screen for each function.
(1) ANALYZER screen
This screen displays the vehicle’s electrical system operating status and the error code detected by
the controller.
(2) TUNING screen
Performs fine adjustment of traveling and material handling control.
(3) OPTION SET screen
Matches the controller or display control according to the set option or control.
(4) MATCHING screen
This screen is for updating the sensor output voltage stored in the controller (output voltage values
from the SAS function and mini lever function sensors in the standard vehicle condition).
(5) WHEEL DIA screen
Updates the tire information in the controller to correct the speed and trip meter display.
(6) END screen
GENERAL screen can displayed from this screen.
Press button (3) on this screen to display the GENERAL screen.
As an alternative method, turn the key switch to OFF when any screen is displayed to display the
general screen.
Version screen
Button (2)
GENERAL screen
Button (1)
Press Button (3)
= ME NU=
6 . END
= ME NU=
1 . ANAL YZ ER
S P H
S P H
S P H
S P H
MENU
MENU
Button (3)
Press Button (1) or
(2) to switch screen.
Press Button (1) or
(2) to switch screen.
= ME NU=
5 . WH E E L
= ME NU=
2 . T U N I NG
S P H
D I A
S P H
S P H
Press Button (1) or
(2) to switch screen.
= ME NU=
3 . OP T I ON
Press Button (1) or
(2) to switch screen.
= ME NU=
4 . MA T C H I N G
SE T
S P H
S P H
MENU
MENU
S P H
MENU
Downloaded from www.Manualslib.com manuals search engine
S P H
Press Button (1) or
(2) to switch screen.
S P H
MENU
5-25
■ Analyzer
General
1. The analyzer supports inspection and troubleshooting of the control system using the communication
function between the traveling/material handling controller and the display.
2. Setting the display into the ANALYZER screen makes it possible to inspect and detect abnormality in
functions of the operating system and sensors, such as main traveling, material handling, EHPS, SAS
circuits and the accelerator.
3. Utilization of the analyzer functions enables quick, easy servicing.
4. The analyzer has the following functions:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes detected in the electrical system in the past. The
diagnosis memory function displays these error codes.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/Out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors in the traveling, material
handling, EHPS and SAS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(a) I/O MONITOR1
Displays the temperature of each electrical functional part and the analog input voltage
detected by each controller.
(b) I/O MONITOR2
Displays the ON/OFF states of traveling-related switches and the analog input voltage from
related sensors.
(c)
I/O MONITOR3
Displays ON/OFF of switches related to traveling and mast control and the analog input
voltage values from related sensors.
(d) I/O MONITOR4
Displays the ON/OFF states of steering knob synchronizer-related and other switches and
the analog input voltage values from related sensors.
(3) Active test function (ACTIVE TEST)
The controller outputs an operation signal (ON or OFF signal) to the selected item in order to permit
operation check of that function.
(4) One error code at the time is displayed in the upper right-hand portion on both the I/O MONITOR
and ACTIVE TEST screens.
Downloaded from www.Manualslib.com manuals search engine
5-26
Analyzer menu screen list
*Values shown in the 2nd column are display examples and not the standard values.
ANALYZER MENU
screen
1
2
3
DIAG MEMORY
I/O MONITOR1
(Voltage/
temperature)
I/O MONITOR2
(Traveling
system)
Display
1st column
Meaning
2nd column
DIAG-1 to
DIAG-10
Error code and
detection time
Error display
I/O 1-1
THCD: +25/+25
Main drive circuit 1 temperature (heat sink): °C
Main drive circuit 2 temperature (heat sink): °C
I/O 1-2
THCP: +25
Main pump circuit temperature (heat sink): °C
I/O 1-3
TD: +25/+25
Drive motor 1 temperature: °C
Drive motor 2 temperature: °C
I/O 1-4
TP: +25
Pump motor temperature: °C
I/O 1-5
TBD: +25/+25
Traveling AC driver 1 board temperature: °C
Traveling AC driver 2 board temperature: °C
I/O 1-6
TBP: +25
material handling AC driver board temperature: °C
I/O 1-7
TEMP: +25.0
CPU board temperature: °C
I/O 1-8
VB48: 50.0
Battery voltage: V
I/O 1-9
VBKS: 50.0
Key start voltage: V
I/O 1-10
VBSOL: 50
Solenoid voltage: V
I/O 1-11
VBMB: 50
Voltage after MB contactor: V
I/O 1-12
VBBD: 50/50
Traveling AC driver 1 DC_BUS voltage: V
Traveling AC driver 2 DC_BUS voltage: V
I/O 1-13
VBBP: 50
Material handling AC driver DC_BUS voltage:
V
I/O 2-1
POTA: 0.71
SWAC: 0
Accelerator potentiometer voltage: V
Acceleration switch: 0 (OFF), 1 (ON)
I/O 2-2
DSF: 0
DSR: 0
Forward switch: 0 (OFF), 1 (ON)
Reverse switch: 0 (OFF), 1 (ON)
I/O 2-3
LSB: 1
LSD: 1
Brake switch: 0 (OFF), 1 (ON)
Seat switch: 0 (OFF), 1 (ON)
I/O 2-4
SSD1: 3000
[3000]
Drove motor 1 rpm: rpm
[Main controller instruction rpm: rpm]
I/O 2-5
SSD2: 3000
[3000]
Drove motor 2 rpm: rpm
[Main controller instruction rpm: rpm]
I/O 2-6
SPD: 10.0
Main traveling speed: mph or km/h
Downloaded from www.Manualslib.com manuals search engine
5-27
ANALYZER MENU
screen
Display
1st column
I/O 3-1
I/O 3-2
I/O 3-3
I/O 3-4
4
I/O MONITOR3
(material handling
system and mast
control)
Meaning
2nd column
L: −.−− −.−− 1−
Lift switch: 0 (OFF), 1 (ON)
*1
L:0.90 3.50 10
Lift lever angle 1 sensor voltage: V
Lift lever angle 2 sensor voltage: V
Lift raise switch: 0 (OFF), 1 (ON)
Lift lower switch: 0 (OFF), 1 (ON)
L (SOL):−.−−
Unused
*1
L (SOL):0.35
Lift proportional valve current: A
T:−.−− −.−− 10
Forward tilt switch: 0 (OFF), 1 (ON)
Backward tilt switch: 0 (OFF), 1 (ON)
*1
T:0.90 3.50 10
Tilt lever angle 1 sensor voltage: V
Tilt lever angle 2 sensor voltage: V
Forward tilt switch: 0 (OFF), 1 (ON)
Backward tilt switch: 0 (OFF), 1 (ON)
T (SOL):−.−−
Unused
*1
T (SOL):0.35
Tilt proportional valve current: A
A1: −.−− −.−− 1− Attachment 1 switch: 0 (OFF), 1 (ON)
*2
A1:0.90 3.50 01
Attachment 1 lever angle 1 sensor voltage: V
Attachment 1 lever angle 2 sensor voltage: V
Attachment 1 raise switch: 0 (OFF), 1 (ON)
Attachment 1 lower switch: 0 (OFF), 1 (ON)
A1 (SOL):−.−−
Unused
*2
A1 (SOL):0.35
Attachment 1 proportional valve current: A
A2:−.−− −.−− −−
Unused
*3
A2:0.90 3.50 01
Attachment 2 lever angle 1 sensor voltage: V
Attachment 2 lever angle 2 sensor voltage: V
Attachment 2 raise switch: 0 (OFF), 1 (ON)
Attachment 2 lower switch: 0 (OFF), 1 (ON)
A2 (SOL):−.−−
Unused
I/O 3-8
*3
A2 (SOL):0.35
Attachment 2 proportional valve current: A
I/O 3-9
SWTK:0
Tilt knob switch: 0 (OFF), 1 (ON)
I/O 3-10
SSP:2000
[2000]
Pump motor rpm: rpm
[Main controller instruction rpm: rpm]
I/O 3-11
MH:10−
Lifting height switch: 0 (OFF), 1 (ON)
I/O 3-12
POTT:2.50
Tilt angle sensor voltage: V
I/O 3-13
SPL:0.84 (1.7)
Load sensor voltage: V (MPa display)
I/O 3-5
I/O 3-6
I/O 3-7
Downloaded from www.Manualslib.com manuals search engine
5-28
ANALYZER MENU
screen
5
6
I/O MONITOR4
(Steering
control)
ACTIVE TEST
(operation test)
Display
1st column
Meaning
2nd column
I/O 4-1
STS:001
Steering angle sensor pulse: 0 (OFF), 1 (ON)
I/O 4-2
K-POS:159
(150)
Steering angle knob position: Actual (target)
I/O 4-3
K-DIFF:100
SOL:0
Deviation of steering angle knob position
Steering knob synchronizer solenoid:
0 (OFF), 1 (ON)
I/O 4-4
TIRE:2.40
Tire angle sensor voltage: V
ACT-1
FAN: ON/OFF
(48)
Fan output
Fan voltage: V
ACT-2
KSOL: ON/OFF
(0)
Steering knob synchronizer solenoid output
Steering knob synchronizer solenoid check
signal:
0 (normal), 1 (error)
PSOL:−−/−−− (−) Unused
ACT-3
*1
PSOL:
ON/OFF (0)
*1: Mini lever models (OPT)
*2: 3-way and 4-way mini lever models (OPT)
*3: 4-way mini lever models (OPT)
Downloaded from www.Manualslib.com manuals search engine
Unload valve output
Unload valve check signal: 0 (normal), 1 (error)
5-29
Operation procedure
1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Check that “1. ANALYZER” is displayed on the MASK MENU screen and press button (3) (enter) to
display the ANALYZER MENU screen.
3. Select the menu item using buttons (1) and (2) and then press button (3) (enter) to display the set
screen.
Button (1): To the previous menu item screen
Button (2): To the next menu item screen
Button (3): Enter (to the selected menu item screen)
If you select “7. END” on the MENU screen of the analyzer and press button (3), the MASK MENU screen
is displayed.
Button (1) Button (2)
MASK MENU screen
Press button (3)
= ME N U =
1 . A NA L Y Z ER
S P H
S P H
7. END screen
MENU
Button (3)
Press button (3)
= AN L ME NU=
7 . END
S P H
S P H
1. DIAG MEMORYscreen
MENU
Press button (1) or
(2) to switch screen.
= AN L ME NU=
1 . D I AG ME MOR Y
S P H
S P H
MENU
Press button (1) or
(2) to switch screen.
Press button (1) or
(2) to switch screen.
6. ACTIVE TEST screen
= AN L ME NU=
6 . A C T I V E T E S T
S P H
S P H
2. I/O MONITORI screen
MENU
Press button (1) or
(2) to switch screen.
= AN L ME NU=
2 . I / O MON I T OR 1
5. I/O MONITOR4 screen
S P H
S P H
MENU
Press button (1) or
(2) to switch screen.
= AN L MENU =
5 . I / O MON I T OR 4
S P H
S P H
3. I/O MONITOR2 screen
MENU
Press button (1) or
(2) to switch screen.
= AN L ME NU=
3 . I / O MON I T OR 2
S P H
S P H
4. I/O MONITOR3 screen
MENU
= AN L ME NU=
4 . I / O MON I T OR 3
Press button (1) or
(2) to switch screen.
Downloaded from www.Manualslib.com manuals search engine
S P H
S P H
MENU
5-30
Diagnosis Memory Function (DIAG MEMORY)
The controller stores up to 10 of the most recent errors. The DIAG MEMORY screen displays these
diagnosis error codes together with their detection time (as key ON hour meter reading).
The most recent diagnosis error code is displayed as DIAG-1, followed by DIAG-2, DIAG-3 and so on to
DIAG-10.
Operation Procedure
1. Display the ANALYZE MENU screen.
Button (1)
2. Check that “1. DIAG MEMORY” is displayed and
ANALYZER MENU screen Button (2)
press button (3) (enter). Past diagnosis codes are
displayed sequentially starting with the newest one.
3. Functions of buttons on the 1. DIAG MEMORY screen
= AN L ME NU=
are as follows:
1 . D I AG ME MOR Y
S P H
S P H
Button (1): Unused
Button (2): Unused
Button (3): Displays past diagnosis codes
Button (3)
*:
Press button (3)
• Press button (3) on the DIAG-10 screen to display the
ANALYZER MENU screen.
• When no error codes are displayed on the screen and
the hour meter time is “0.0h”, it indicates that no error
I A
1
A1
1
1 2 3 4 5 . 6 h
codes are stored in the memory.
S P H
S P H
• Other screen cannot be displayed from DIAG
MEMORY screen. Display ANALYZER MENU screen
to display other screen.
Key ON hour meter
*: For the details of diagnosis error codes, see
Press button (3)
DIAGNOSIS CODE LIST on P5-15.
MENU
MENU
A1
I A
2
2
1 2 3 4 5 . 6 h
S P H
S P H
MENU
Press button (3)
I A
3
0 . 0 h
S P H
S P H
MENU
No error occurrence
is indicated
I A
Press button (3)
1 0
0 . 0 h
S P H
S P H
MENU
Press button (3)
ANALYZER MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-31
Vehicle Abnormalities Not Stored in Diagnosis Memory
Some abnormalities are not stored in diag memory even when the controller detects it and warn the
operator.
Warning indicators
Warning method
Displayed code
1
Parking brake ON warning:
Warns if the direction switch is turned to the forward or reverse position and the vehicle travels
when the parking brake is on.
• Indication
Parking brake ON
warning indicator
blinks
• Beep
Short beeps
2
Parking brake OFF warning (OPT):
Warns if the operator vacates the seat without
pulling the parking brake lever. (Warns even when
the key switch is OFF)
• Beep
Short beeps
3
Overdischarge warning (lift interrupt):
Warns if the battery discharge exceeds the level
set by the tuning function. (see page 5-45.)
When the warning is activated, material handling
operation while traveling is disabled.
• Indication
Battery charge indicator blinks
• Beep
Short beeps
4
Return to neutral warning:
Warns if the key switch is turned to ON when the
direction switch is in the forward or reverse position.
• Beep
Short beeps
No display
5
Material handling lock (OPT):
When the operator leaves the seat while operating the mini lever and then sits down again, a
buzzer sounds to warn the operator and the material handling operation will be disabled.
• Beep
Short beeps
No display
6
Incomplete matching warning:
(1) Tilt angle sensor at fork in the level position
(2) Tilt angle sensor at the forward tilt restriction
angle
(3) Pressure sensor at no-load state
(4) Tire angle sensor at straight travel position
(5) Lift lever angle sensor at lift lever neutral
position (OPT)
(6) Tilt lever angle sensor at tilt lever neutral
position (OPT)
(7) Attachment 1 lever angle sensor at
attachment 1 lever neutral position (OPT)
(8) Attachment 2 lever angle sensor at
attachment 2 lever neutral position (OPT)
• Indication
Wrench symbol
Downloaded from www.Manualslib.com manuals search engine
No display
5-32
I/O monitor
This function displays the analog input voltage from each
of traveling, material handling and SAS sensors.
Monitoring the displayed values enables the quality of
each circuit/sensor to be judged.
When any abnormality is detected, it is displayed as an
error code on the screen.
Detected error code
at present
Activated
function No
< I / O1
T HCD :
1 >
+ 2 5 /
+ 2 5
S P H
S P H
MENU
Description of activated function
I/O monitor 1
This function displays the temperature of each electrical functional part and the voltage at the respective
terminal.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press button (2).
3. Check that “2. I/O MONITOR1” is displayed and press
button (3) (enter). I/O monitor function (1) is activated
and I/O 1-1 to I/O 1-13 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR1 screen
are as follows:
Button (1): Unused
Button (2): Unused
Button (3): Displays I/O 1-1 to I/O 1-13 screens
sequentially
*: Press button (3) on the I/O 1-13 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from I/O MONITOR1
screen.
Display ANALYZER MENU screen to display other
screen.
(1) I/O 1-1 screen
THCD: Main drive circuit (1) (2) temperature (°C)
Temperatures of the main drive circuit element (1) (2)
are displayed
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
(2) I/O 1-2 screen
THCP: Main pump circuit temperature (°C)
Temperature of the main pump circuit element is
displayed.
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
Downloaded from www.Manualslib.com manuals search engine
Button (1)
ANALYZER MENU screen Button (2)
= AN L ME NU=
2 . I / O MON I T OR 1
S P H
S P H
MENU
Button (3)
Press button (3)
(1) I/O 1-1 screen
I / O1
T HCD
1
+ 2 5 /
+ 2 5
S P H
S P H
MENU
Press button (3)
(2) I/O 1-2 screen
I / O1
T HCP
2
+ 2 5
S P H
S P H
MENU
Press button (3)
I/O 1-3 screen
5-33
(3) I/O 1-3 screen
TD: Drive motor (1) (2) temperature (°C)
Temperatures of the drive motor (1) (2) is displayed.
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
(4) I/O 1-4 screen
TP: Pump motor temperature (°C)
Temperature of the pump motor is displayed.
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
(5) I/O 1-5 screen
TBD:
Traveling AC driver 1/2 board surface temperature
(°C)
Surface temperatures of the traveling AC driver 1/2
board are displayed.
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
I/O 1-2 screen
(3) I/O 1-3 screen
I / O1
T D
3
+ 2 5 /
Button (2)
Button (1)
+ 2 5
S P H
S P H
MENU
Button (3)
Press button (3)
(4) I/O 1-4 screen
I / O 1
T P :
4
+ 2 5
S P H
S P H
MENU
Press button (3)
(5) I/O 1-5 screen
I / O1
T B D :
5
+ 2 5 /
+ 2 5
S P H
S P H
MENU
(6) I/O 1-6 screen
TBP:
Material handling AC driver board surface
temperature (°C)
Surface temperature of the material handling AC
driver board is displayed.
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
(7) I/O 1-7 screen
TEMP: CPU board temperature (°C)
The surface temperature of the main controller CPU
board is displayed.
• Checks if the temperature measurement function is
functioning properly.
• The temperatures at the time of measurement are
displayed.
(8) I/O 1-8 screen
VB48: Battery voltage (V)
The battery voltage is displayed.
Standard: 48 V
Press button (3)
(6) I/O 1-6 screen
I / O1
T B P
6
+ 2 5
S P H
S P H
MENU
Press button (3)
(7) I/O 1-7 screen
I / O1
T E MP
7
+ 2 5 . 0
S P H
S P H
MENU
Press button (3)
(8) I/O 1-8 screen
I / O1
V B 4 8
8
5 0 . 0
S P H
S P H
MENU
Press button (3)
I/O 1-9 screen
Downloaded from www.Manualslib.com manuals search engine
5-34
(9) I/O 1-9 screen
VBKS: Key start voltage (V)
Power source voltage of traveling and material
handling AC drivers are displayed.
Standard: 48 V
(10) I/O 1-10 screen
VBSOL: Solenoid power supply voltage (V)
Solenoid power source voltage is displayed.
Standard: 48 V
I/O 1-8 screen
Button (2)
Button (1)
(9) I/O 1-9 screen
I / O1
VB K S
9
5 0 . 0
S P H
S P H
MENU
(11) I/O 1-11 screen
VBMB: Main battery voltage input (V)
Main controller input voltage after the MB contactor is
displayed.
Standard: 48 V
(12) I/O 1-12 screen
VBBD: Main drive motor circuit (1) (2) voltage (V)
Voltages of the main drive motor circuit (1) (2) are
displayed.
Standard: 48 V
(13) I/O 1-13 screen
VBBP: Main pump motor circuit voltage (V)
Voltage of the main pump motor circuit is displayed.
Standard: 48 V
Button (3)
Press button (3)
(10) I/O 1-10 screen
I / O 1
V BSOL
1 0
5 0
S P H
S P H
MENU
Press button (3)
(11) I/O 1-11 screen
I / O 1
V BMB
1 1
5 0
S P H
S P H
MENU
Press button (3)
(12) I/O 1-12 screen
I / O 1
V B BD
1 2
5 0 /
5 0
S P H
S P H
MENU
Press button (3)
(13) I/O 1-13 screen
I / O 1
V B BP
1 3
5 0
S P H
S P H
MENU
Press button (3)
ANALYZER MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-35
I/O monitor 2
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing
control.
Operation procedure
1. Display the ANALYZER MENU screen.
2. Press button (2) twice.
3. Check that “3. I/O MONITOR2” is displayed and press
button (3) (enter). I/O monitor function (2) is activated
and I/O 2-1 to I/O 2-6 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR2 screen
are as follows:
Button (1)
Button (1): Unused
ANALYZER MENU screen Button (2)
Button (2): Unused
Button (3): Displays I/O 2-1 to I/O 2-6 screens
sequentially
= AN L ME NU=
*:Press button (3) on the I/O 2-6 screen to display the
3 . I / O MON I TOR 2
S P H
S P H
ANALYZER MENU screen.
Other screen cannot be displayed from I/O MONITOR2
screen.
Button (3)
Display ANALYZER MENU screen to display other
Press
button (3)
screen
(1) I/O 2-1 screen
(1) I/O 2-1 screen
POTA: Accelerator potentiometer voltage (V)
A: When the accelerator pedal is released
< I / 0 2
1 >
(SWAC: OFF)
P O T A 0 . 7 1 S WA C 0
S P H
Standard: 0.3 to 2.4 V
S P H
B: Standard voltage when the accelerator pedal is
depressed to its stroke end
Standard: 1.7 to 4.7 V
Press button (3)
B - A = 1.4 V or above
SWAC: Accelerator switch
I/O 2-2 screen
When the accelerator pedal is released
SWAC: 0 = OFF
Standard voltage when the accelerator pedal is
depressed to its stroke end
SWAC: 1 = ON
Operate the accelerator pedal to judge switch ON/
OFF quality.
MENU
MENU
Downloaded from www.Manualslib.com manuals search engine
5-36
(2) I/O 2-2 screen
Direction switch inspection.
DSF: Forward traveling switch
DSR: Reverse traveling switch
Operation
I/O 2-1screen
Indication
DSF
DSR
Forward traveling
1 (=ON)
0 (=OFF)
Neutral
0 (=OFF)
0 (=OFF)
Reverse traveling
0 (=OFF)
1 (=ON)
Button (1)
(2) I/O 2-2 screen
< I / 0 2
0
DS F
2 >
DSR
1
S P H
S P H
MENU
Operate the direction lever to judge switch ON/OFF
quality.
(3) I/O 2-3 screen
• LSB: Brake switch inspection
When the brake pedal is released
LSB: 1 = ON
When the brake pedal is depressed
LSB: 0 = OFF
Operate the brake pedal to judge switch ON/OFF
quality.
• LSD: Deadman seat check
When the seat is occupied
LSD: 1 = ON
When the seat is not occupied
LSD: 0 = OFF
Take or leave a seat to judge switch ON/OFF
quality.
Button (3)
Press button (3)
(3) I/O 2-3 screen
< I / 0 2
L S B 1
3 >
L SD
1
S P H
S P H
MENU
Press button (3)
(4) I/O 2-4 screen
< I / 0 2
4 >
SS D1
3 0 0 0 [ 3 0 0 0 ]
S P H
S P H
(4) I/O 2-4 screen
SSD1: Drive motor 1 rpm [target rpm]
Inspect the rpm sensor while the vehicle is
traveling.The rpm of the drive motor increases
according to the speed increase.
(5) I/O 2-5 screen
SSD2: Drive motor 2 rpm [target rpm]
Inspect the rpm sensor while the vehicle is traveling.
The rpm of the drive motor increases according to the
speed increase.
(6) I/O 2-6 screen
SPD: Traveling speed (km/h)
Check the traveling speed while the vehicle is jacked
up. Gradually depress the accelerator pedal. Check
that the traveling speed increase is almost at the
same rate of the depression of the accelerator pedal
to judge the quality.
Button (2)
MENU
Press button (3)
(5) I/O 2-5 screen
< I / 0 2
5 >
SS D2
3 0 0 0 [ 3 0 0 0 ]
S P H
S P H
MENU
Press button (3)
(6) I/O 2-6 screen
< I / 0 2
S P D
6 >
1 0 . 0
S P H
S P H
MENU
Press button (3)
ANALYZER MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-37
I/O monitor 3
This function displays the ON/OFF status of material handling and mast control switches and analog input
voltages from sensors.
Operation procedure
1. Display the ANALYZER MENU screen.
2. Press button (3) three times.
3. Check that “4. I/O MONITOR3” is displayed and press
Button (1)
Button (2)
button (3) (enter). I/O monitor function (3) is activated
ANALYZER MENU screen
and I/O 3-1 to I/O 3-13 are displayed sequential every
time button (3) is pressed.
4. Functions of buttons on the I/O MONITOR3 screen
= A N L
ME NU=
4 . I / O MON I T OR 3
are as follows:
S P H
S P H
Button (1): Unused.
Button (2): Unused.
Button (3): Displays I/O 3-1 to I/O 3-13 screens
Button (3)
sequentially
Press button (3)
*: Press button (3) on the I/O 3-13 screen to display the
(1) I/O 3-1 screen
ANALYZER MENU screen.
Standard models
Other screen cannot be displayed from I/O MONITOR3
screen.
Display ANALYZER MENU screen to display other
< I / O3
1 >
L :
.
.
1
screen
S P H
MENU
S P H
(1) I/O 3-1 screen
Standard models
L: Lift switch inspection
When the lift lever is in the UP position
L: −.−− −.−− 1− = ON
When the lift lever is in the neutral or DOWN position
L: −.−− −.−− 0− = OFF
Operate the lift lever to judge ON/OFF quality.
Mini lever models (OPT)
L: Lift lever angle 1 sensor voltage (V)
Lift lever angle 2 sensor voltage (V)
Lift raise switch (0=OFF, 1=ON)
Lift lower switch (0=OFF, 1=ON)
Judge the raise and lower input quality by lift lever
operation.
Lift lever angle 1
sensor voltage
Lift lever angle 2
sensor voltage
Raising
1.1 to 2.3 V
2.2 to 3.5 V
Lowering
0.4 to 1.6 V
2.9 to 4.2 V
(2) I/O 3-2 screen
Standard models
L (SOL): Unused
Mini lever models (OPT)
L (SOL): Lift proportional valve solenoid current (A)
Judge the output quality to lift proportional valve
solenoid by lift lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
Downloaded from www.Manualslib.com manuals search engine
MENU
Mini lever models (OPT)
< I / O3
1 >
L :
1 . 0 0 3 . 0 0
1 0
S P H
S P H
MENU
Press button (3)
(2) I/O 3-2 screen
Standard models
< I / O3
2 >
L ( SO L ) :
.
S P H
S P H
MENU
Mini lever models (OPT)
< I / O3
2 >
L ( SO L ) :
0 . 3 5
S P H
S P H
MENU
Press button (3)
I/O 3-3 screen
5-38
(3) I/O 3-3 screen
Standard models
T: Forward and backward tilt switch inspection
Operation
Display
Forward
tilt switch
Backward
tilt switch
Forward tilt
T: −.−− −.−− 10
1 (=ON)
0 (=OFF)
Neutral
T: −.−− −.−− 00
0 (=OFF)
0 (=OFF)
Backward tilt
T: −.−− −.−− 01
0 (=OFF)
1 (=ON)
Operate the tilt lever to judge ON/OFF quality.
Mini lever models (OPT)
T: Tilt lever angle 1 sensor voltage (V)
Tilt lever angle 2 sensor voltage (V)
Forward tilt switch (0=OFF, 1=ON)
Backward tilt switch (0=OFF, 1=ON)
Judge the forward and backward tilt input quality by lift
lever operation.
Tilt lever angle 1
sensor voltage
Tilt lever angle 2
sensor voltage
Forward tilt
1.1 to 2.3 V
2.2 to 3.5 V
Backward tilt
0.4 to 1.6 V
2.9 to 4.2 V
(4) I/O 3-4 screen
Standard models
T (SOL): Unused
Mini lever models (OPT)
T (SOL): Tilt proportional valve solenoid current (A)
Judge the output quality to the tilt proportional valve
solenoid by tilt lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
(5) I/O 3-5 screen
Standard models
A1: Attachment 1 lever inspection
When the attachment 1 lever is ON
A1: −,−− −,−− 1− = ON
When the attachment 1 lever is in the neutral position
A1: −,−− −,−− 0− = OFF
Operate the attachment 1 lever to judge ON/OFF
quality.
3-way and 4-way mini lever models (OPT)
A1: Attachment 1 lever angle 1 sensor voltage (V)
Attachment 1 lever angle 2 sensor voltage (V)
Attachment 1 raise switch (0=OFF, 1=ON)
Attachment 1 lower switch (0=OFF, 1=ON)
Judge the input quality by attachment 1 lever
operation.
Attachment 1 lever
angle 1 sensor voltage
Attachment 1 lever
angle 2 sensor voltage
Raising
1.1 to 2.3 V
2.2 to 3.5 V
Lowering
0.4 to 1.6 V
2.9 to 4.2 V
Downloaded from www.Manualslib.com manuals search engine
I/O 3-2 screen
Button (2)
(3) I/O 3-3 screen Button (1)
Standard models
< I / O3
T :
.
3 >
.
1 0
S P H
S P H
MENU
Mini lever models (OPT) Button (3)
< I / O3
3 >
T :
1 . 0 0
3 . 0 0
1 0
S P H
S P H
MENU
Press button (3)
(4) I/O 3-4 screen
Standard models
< I / O3
4 >
T ( SO L ) :
.
S P H
S P H
MENU
Mini lever models (OPT)
< I / O3
4 >
T ( SO L ) :
0 . 3 5
S P H
S P H
MENU
Press button (3)
(5) I/O 3-5 screen
Standard models
< I / O3
A1 :
.
5 >
.
1
S P H
S P H
MENU
3-way and 4-way mini lever models (OPT)
< I / O3
5 >
A1 : 1 . 0 0 3 . 0 0
1 0
S P H
S P H
MENU
Press button (3)
I/O 3-6 screen
5-39
(6) I/O 3-6 screen
Standard models
A1(SOL): Unused
3-way and 4-way mini lever models (OPT)
A1 (SOL): Attachment 1 proportional valve solenoid
current (A)
Judge the output quality to attachment (1) proportional
valve solenoid by attachment 1 lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
(7) I/O 3-7 screen
Standard models, 2-way and 3-way mini lever
models (OPT)
A2: Unused
4-way mini lever models (OPT)
A2: Attachment 2 lever angle 1 sensor voltage
Attachment 2 lever angle 2 sensor voltage
Attachment 2 raise switch (0=OFF, 1=ON)
Attachment 2 lower switch (0=OFF, 1=ON)
Judge the forward and backward tilt input quality by tilt
lever operation.
Attachment 2 lever
angle 2 sensor
voltage
Attachment 2 lever
angle 2 sensor
voltage
Raising
1.1 to 2.3 V
2.2 to 3.5 V
Lowering
0.4 to 1.6 V
2.9 to 4.2 V
(8) I/O 3-8 screen
Standard models, 2-way and 3-way mini lever
models (OPT)
A2 (SOL): Unused
4-way mini lever models (OPT)
A2 (SOL): Attachment 2 proportional valve solenoid
current (A)
Judge the output quality to attachment 2 proportional
valve solenoid by attachment 2 lever operation.
Standard: 0.3 to 0.85 A (Lever operated)
I/O 3-5 screen
Button (2)
(6) I/O 3-6 screen Button (1)
Standard models
< I / O3
6 >
A 1 ( S OL ) :
.
S P H
S P H
MENU
Button (3)
3-way and 4-way mini lever models (OPT)
< I / O3
6 >
A 1 ( S OL ) :
0 . 3 5
S P H
S P H
MENU
Press button (3)
(7) I/O 3-7 screen
Standard models
2-way and 3-way mini lever models (OPT)
< I / O3
A 2 :
.
7 >
.
S P H
S P H
MENU
4-way mini lever models (OPT)
< I / O3
7 >
A 2 : 1 . 0 0 3 . 0 0
1 0
S P H
S P H
MENU
Press button (3)
(8) I/O 3-8 screen
Standard models
2-way and 3-way mini lever models (OPT)
< I / O3
8 >
A 2 ( S OL ) :
.
S P H
S P H
MENU
4-way mini lever models (OPT)
< I / O3
8 >
A 2 ( S OL ) :
0 . 3 5
S P H
S P H
MENU
Press button (3)
I/O 3-9 screen
Downloaded from www.Manualslib.com manuals search engine
5-40
(9) I/O 3-9 screen
SWTK: Automatic fork leveling cancel switch
inspection
0 = OFF
1 = ON
Operate the tilt knob switch to judge ON/OFF quality.
(10) I/O 3-10 screen
SSP: Pump motor rpm [target rpm]
Inspect the rpm sensor during the actual material
handling operation. Check that the pump motor rpm
increases according to the material handling speed
increase.
(11) I/O 3-11 screen
MH: Lifting height switch inspection
Combination of lifting height switch ON/OFF
Lifting
height
Indication
MH1
switch
MH2-1
switch
Low lifting
height
10−
1 (=ON)
0 (=OFF)
High lifting
height
01−
0 (=OFF)
1 (=ON)
Change the lifting height to judge ON/OFF quality.
(12) I/O 3-12 screen
POTT: Tilt angle sensor voltage (V)
Check the input voltage of tilt angle sensor controller
Standard when the mast is in the vertical position:
Approx. 1.3 V
When operating the mast forward from the vertical
position: Input voltage decrease
When operating the mast backward from the vertical
position: Input voltage increase
(13) I/O 3-13 screen
SPL: Load sensor voltage (V) (MPa display)
Check the input voltage of load sensor controller.
Standard without load: Approx. 0.8 V
Input voltage increases according to the load increase
I/O 3-8 screen
Button (2)
Button (1)
(9) I/O 3-9 screen
< I / O3
S WT K : 0
9 >
S P H
S P H
MENU
Button (3)
Press button (3)
(10) I/O 3-10 screen
< I / O3
1 0 >
SS P :
2 0 0 0 [ 2 0 0 0 ]
S P H
S P H
MENU
Press button (3)
(11) I/O 3-11 screen
< I / O3
1 1 >
MH :
1 0
S P H
S P H
MENU
Press button (3)
(12) I/O 3-12 screen
< I / O3
POT T :
1 2 >
2 . 5 0
S P H
S P H
MENU
Press button (3)
(13) I/O 3-13 screen
< I / O3
1 3 >
S P L :V 0 . 8 4 (
1 . 7 )
S P H
S P H
MENU
Press button (3)
ANALYZER MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-41
I/O monitor 4
ON/OFF state of knob steering synchronizer and other switches and the analog input value from each
sensor are indicated.
Operation procedure
1. Display the ANALYZER MENU screen.
Button (1)
2. Press button (2) four times.
ANALYZER MENU screen Button (2)
3. Check that “5. I/O MONITOR4” is displayed and press
button (3) (enter). I/O monitor function (4) is activated
and I/O 4-1 to I/O 4-4 are displayed sequential every
= A N L ME N U =
time button (3) is pressed.
5 . I / O MO N I T OR 4
S P H
4. Functions of buttons on the I/O MONITOR4 screen
S P H
are as follows:
Button (1): Unused
Button (3)
Button (2): Unused
Press button (3)
Button (3): Displays I/O 4-1 to I/O 4-4 screens
(1) I/O 4-1 screen
sequentially.
*:Press button (3) on the I/O 4-4 screen to display the
ANALYZER MENU screen.
Other screen cannot be displayed from I/O MONITOR4
< I / O4
1 >
ST S :
0 1 0
screen.
S P H
S P H
Display ANALYZER MENU screen to display other
screen.
MENU
MENU
Press button (3)
I/O 4-2 screen
(1) I/O 4-1 screen
STS: Steering angle sensor inspection
0 = OFF
1 = ON
< I / O4
1 >
ST S :
0 1 0
S
STS1 STS2 STSC
Turning the steering wheel one round will turn STS1
and STS2 ON, OFF and then ON. STSC turns on only
when the steering wheel is in the standard position.
STSC sensor turns on when the actual value is 80 on
the I/O 4-2 screen.
159
0
1
80
Downloaded from www.Manualslib.com manuals search engine
5-42
(2) I/O 4-2 screen
K-POS: Actual value of knob position (target)
Actual value:
Knob position computed by the controller from the
steering angle sensor signal.
Target value:
Knob position computed by the controller from the tire
angle sensor signal.
I/O 4-1 screen
(2) I/O 4-2 screen
2 >
1 5 9
< I / O4
K POS
Button (2)
Button (1)
1 5 0
S P H
S P H
MENU
Button (3)
Press button (3)
I/O 4-3 screen
Assuming the steering wheel is divided into 160 (0 to
159), the knob position of 80 is as indicated in the
illustration to the left. This value increases when
turning the steering wheel clockwise and decreases
when turning it counterclockwise.
159
0
1
80
(3) I/O 4-3 screen
• K-DIFF: Deviation of steering angle knob position
Difference between target and actual values at I/O
4-2.
• SOL: Steering synchronizer solenoid
0 = OFF
1 = ON
Operate the steering wheel to check that the steering
synchronizer solenoid turns on when there is
deviation of steering angle knob position.
(4) I/O 4-4 screen
TIRE: Tire angle sensor voltage (V)
Operate the steering wheel to check the variation in
voltage.
Standard at tire straight travel position:
Approx. 2.40 V
I/O 4-2 screen
(3) I/O 4-3 screen
< I / O4
K D I FF
Button (2)
Button (1)
3 >
1 0 0 SOL
S P H
0
S P H
MENU
Button (3)
Press button (3)
(4) I/O 4-4 screen
< I / O4
T I RE :
4 >
2 . 40
S P H
S P H
MENU
Press button (3)
ANALYZER MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-43
Active test
This function outputs ON/OFF signals to each switch related to the electrical system and compares
controller input signals with those signals.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press button (2) five twice.
3. Check that “6. ACTIVE TEST” is displayed and press
Button (1)
button (3) (enter). ACTIVE TEST function is activated
and ACT-1 to ACT-3 are displayed sequential every
ANALYZER MENU screen Button (2)
time button (3) is pressed.
4. Functions of buttons on the ACTIVE TEST screen are
as follows:
= AN L ME NU=
6 . ACT I VE TE ST
Button (1): Forced ON
S P H
S P H
Button (2): Forced OFF
Button (3): Displays ACT-1 and ACT-3 sequentially
*:Press button (3) on ACT-3 screen to display the
Button (3)
ANALYZER MENU screen.
Press button (3)
Other screen cannot be displayed from ACTIVE TEST
(1) ACT-1 screen
screen.
Display ANALYZER MENU screen to display other
screen.
< ACT
1 >
MENU
(1) ACT-1 screen
FAN: Fan (Fan voltage (V))
Forcibly output the ON/OFF signal to check the fan
operation and display visually.v
• Press button (1) to select ON.
→ Fan rotates and fan voltage is displayed.
• Press button (2) to select OFF.
→ Fan stops rotating and fan voltage is displayed.
Note:
Be sure to open the battery hood and remove the side
cover to check the fan operation.
(2) ACT-2 screen
KSOL: Steering knob synchronizer solenoid
1: Signal check line ON (error)
0: Signal check line OFF (normal)
Turn the steering wheel slowly to check the deviation
in the rear tire movement.
ON (bypass open) selected: Tires rarely move
OFF (bypass close) selected: Tires normally move
Downloaded from www.Manualslib.com manuals search engine
F AN : ON / O F F
( 4 8 )
S P H
S P H
MENU
Press button (3)
(2) ACT-2 screen
< ACT
2 >
K S OL : ON / O F F
( 0 )
S P H
S P H
MENU
Press button (3)
ACT-3 screen
5-44
(3) ACT-3 screen
Standard models
PSOL: Unused
Mini lever models (OPT)
PSOL: Unload valve solenoid
1: Signal check line ON (error)
0: Signal check line OFF (normal)
• Turn the key switch to ON and operate the material
handling lever.
→If the unload valve turns on normally, material
handling operation is possible.If the unload
valve stays off, material handling operation is
disabled.
• Turn the key switch to OFF and operate the material
handling lever.
→If the unload valve turns off normally, material
handling operation is disabled.If the unload
valve stays on, material handling operation is
possible.
ACT-2 screen
Button (1)
(3) ACT-3 screen
Standard models
< ACT
P SOL :
Button (2)
3 >
(
)
S P H
S P H
MENU
Mini lever models (OPT)
< ACT
3 >
P S O L : O N / OF F
Button (3)
( 0 )
S P H
S P H
MENU
Press button (3)
ANALYZER MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-45
■ Tuning
General
This function performs fine adjustment of traveling and material handling controls.
When the use requests to limit the maximum speed or weaken the regenerative braking force, each setting
can be performed on the TUNING screen in the procedures same as power control level setting.
59 tuning items are prepared including spares.
Tuning items list
Tuning
No.
Level (
Item
1
2
: Initial setting position)
3
4
5
6
7
8
1
Switchback regenerative breaking torque:
Changes the regenerative braking torque at
switchback.
Weak
Strong
2
Acceleration OFF regenerative breaking torque:
Changes regenerative breaking torque when
acceleration is OFF.
Weak
Strong
3
Battery warning setting level:
Changes the activation timings of low remaining
battery charge warning and battery
overdischarge warning. (See page 5-50.)
4
Battery charge indicator correction:
Corrects decreasing rate of battery charge
indicator.
5
Traveling speed limiter:
Adjust the maximum traveling speed.
Low
speed
High
speed None
6
Attachment power control No.1:
Changes the pump motor output for when
attachment switch No.1 is ON.
Low
speed
High
speed
7
Tilt power control:
Changes the pump motor output for when
the tilt switch is ON.
(The SAS function mast control speed is not limited.)
Low
speed
High
speed
8
Attachment power control No.2: *1
Changes the pump motor output for when
attachment switch No.2 is ON.
Low
speed
High
speed
9
Auto-off function activation time:
Sets the time for activating auto-off function.
Short
10
Spare
11
Spare
12
Spare
*1: 4-way mini lever models (OPT)
Downloaded from www.Manualslib.com manuals search engine
Slow
Fast
Slow
decrease
Disabled
Fast
decrease
Long
None
5-46
Tuning
No.
Level (
Item
1
2
: Initial setting position)
3
4
5
6
7
8
20
Lift lowering adjustment (1):
Adjusts solenoid output current at the beginning
of lift lowering operation.
Small
Large
21
Lift lowering adjustment (2):
Adjusts inching speed during lift lowering operation.
Slow
Fast
22
Lift lowering adjustment (3):
Adjusts the maximum solenoid output current during
lift lowering operation.
Small
Large
23
Lift lowering adjustment (4):
Adjusts acceleration during lift lowering operation.
Weak
Strong
24
Lift lowering adjustment (5):
Adjusts deceleration during lift lowering operation.
Weak
Strong
25
Lift raising adjustment (1):
Adjusts solenoid output current at the beginning of
lift raising operation.
Small
Large
26
Lift raising adjustment (2):
Adjusts inching speed during lift raising operation.
Slow
Fast
27
Lift raising adjustment (3):
Adjusts the maximum solenoid output current during
lift raising operation.
Small
Large
28
Lift raising adjustment (4):
Adjusts acceleration during lift raising operation.
Weak
Strong
29
Lift raising adjustment (5):
Adjusts deceleration during lift raising operation.
Weak
Strong
30
Forward tilt adjustment (1):
Adjusts solenoid output current at the beginning of
forward tilt operation.
Small
Large
31
Forward tilt adjustment (2):
Adjusts inching speed during forward tilt operation.
Slow
Fast
32
Forward tilt adjustment (3):
Adjusts the maximum solenoid output current during
forward tilt operation.
Small
Large
33
Forward tilt adjustment (4):
Adjusts acceleration during forward tilt operation.
Weak
Strong
34
Forward tilt adjustment (5):
Adjusts deceleration during forward tilt operation.
Weak
Strong
35
Backward tilt adjustment (1):
Adjusts solenoid output current at the beginning of
backward tilt operation.
Small
Large
Downloaded from www.Manualslib.com manuals search engine
5-47
Level (
: Initial setting position)
Tuning
No.
Item
36
Backward tilt adjustment (2):
Adjusts inching speed during backward tilt operation.
Slow
Fast
37
Backward tilt adjustment (3):
Adjusts the maximum solenoid output current during
backward tilt operation.
Small
Large
38
Backward tilt adjustment (4):
Adjusts acceleration during backward tilt operation.
Weak
Strong
39
Backward tilt adjustment (5):
Adjusts deceleration during backward tilt operation.
Weak
Strong
40
Attachment 1 lowering adjustment (1):
Adjusts solenoid output current at the beginning of
lowering operation of attachment 1.
Small
Large
41
Attachment 1 lowering adjustment (2):
Adjusts inching speed during lowering operation of
attachment 1.
Slow
Fast
42
Attachment 1 lowering adjustment (3):
Adjusts the maximum solenoid output current during
lowering operation of attachment 1.
Small
Large
43
Attachment 1 lowering adjustment (4):
Adjusts acceleration during lowering operation of
attachment 1.
Weak
Strong
44
Attachment 1 lowering adjustment (5):
Adjusts deceleration during lowering operation of
attachment 1.
Weak
Strong
45
Attachment 1 raising adjustment (1):
Adjusts solenoid output current at the beginning of
raising operation of attachment 1.
Small
Large
46
Attachment 1 raising adjustment (2):
Adjusts inching speed during raising operation of
attachment 1.
Slow
Fast
47
Attachment 1 raising adjustment (3):
Adjusts the maximum solenoid output current during
raising operation of attachment 1.
Small
Large
48
Attachment 1 raising adjustment (4):
Adjusts acceleration during raising operation of
attachment 1.
Weak
Strong
49
Attachment 1 raising adjustment (5):
Adjusts deceleration during raising operation of
attachment 1.
Weak
Strong
50
Attachment 2 lowering adjustment (1):
Adjusts solenoid output current at the beginning of
raising operation of attachment 2.
Small
Large
51
Attachment 2 lowering adjustment (2):
Adjusts inching speed during lowering operation of
attachment 2.
Slow
Fast
Downloaded from www.Manualslib.com manuals search engine
1
2
3
4
5
6
7
8
5-48
Level (
: Initial setting position)
Tuning
No.
Item
52
Attachment 2 lowering adjustment (3):
Adjusts the maximum solenoid output current during
lowering operation of attachment 2.
Small
Large
53
Attachment 2 lowering adjustment (4):
Adjusts acceleration during lowering operation of
attachment 2.
Weak
Strong
54
Attachment 2 lowering adjustment (5):
Adjusts deceleration during lowering operation of
attachment 2.
Weak
Strong
55
Attachment 2 raising adjustment (1):
Adjusts solenoid output current at the beginning of
raising operation of attachment 2.
Small
Large
56
Attachment 2 raising adjustment (2):
Adjusts inching speed during raising operation of
attachment 2.
Slow
Fast
57
Attachment 2 raising adjustment (3):
Adjusts the maximum solenoid output current during
raising operation of attachment 2.
Small
Large
58
Attachment 2 raising adjustment (4):
Adjusts acceleration during raising operation of
attachment 2.
Weak
Strong
59
Attachment 2 raising adjustment (5):
Adjusts deceleration during raising operation of
attachment 2.
Weak
Strong
Downloaded from www.Manualslib.com manuals search engine
1
2
3
4
5
6
7
8
5-49
TUNING Screen Operating Procedure
1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Press button (2) to display “2. TUNING” and press button (3) (enter) to display the TUNING MENU
screen.
3. Press button (1) or (2) to display the tuning item desired to be set. Press button (3) (enter) to display
the TUNING screen of the selected item.
Button (1): Display the previous tuning item
Button (2): Display the next tuning item
Button (3): Enter (display the selected tuning item)
* Press button (3) on the TUNING MENU screen, select “6. END” and press (3) to display MASK MENU
screen.
“2.TUNING2 LIFTV” to “5.TUNING5 ATT2V” (tuning No.20 to 59) are not used on the standard models.
They are only used on the mini lever models (OPT).
MASK MENU screen
Button (1) Button (2)
=ME NU =
2 . T UN I NG
S P H
S P H
MENU
Button (3)
Press button (3)
= T UN MENU=
1 . T UN I NG1
Press button (3)
= T UN MENU=
6 . END
S P H
S P H
MENU
S P H
Press button (1) or
(2) to switch screen
MENU
Press button (1) or
(2) to switch screen
Press button (1) or
(2) to switch screen
= T UN MENU=
2 . T UN I NG2
L I F. T V
= T UN MENU=
5 . T UN I NG5
AT T 2 V
S P H
S P H
S P H
MENU
S P H
MENU
Press button (1) or
(2) to switch screen
= T UN MENU=
3 . T UN I NG3
T I L T V
S P H
S P H
Press button (1) or
(2) to switch screen
= T UN MENU=
4 . T UN I NG4
A T T 1V
S P H
MENU
Downloaded from www.Manualslib.com manuals search engine
S P H
Press button (1) or
(2) to switch screen
S P H
MENU
5-50
TUNING 1
Button (1) Button (2)
This function sets the tuning level of the standard
functions.
TUNING MENU screen
Operation procedure
1. Display the TUNING MENU screen.
2. Check that “1. TUNING1” is displayed and press
button (3) (enter) to display TUNING level setting
screen.
3. Press button (3) to display the tuning item desired to
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.12 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
setting screen of TUNING1. Display TUNING MENU
screen to display other screen.
= T U N ME N U =
1 . T UN I NG 1
S P H
S P H
MENU
Button (3)
Press button (3)
< T UN >
1
NO .
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
2
NO .
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 1 2
1
5
8
S P H
S P H
MENU
Press button (3)
TUNING MENU screen
Low Remaining Battery Charge Warning and Overdischarge Warning Set Levels (TUNING No.3)
*: The default is level 7.
Discharge
level
TUNING setting levels
1
2
3
4
5
6
7
8
50 to 59%
60 to 69%
70 to 79%
80%
Low remaining battery
charge warning
Battery charge indicator blinks
81 to 89%
90%
91 to 99%
100%
Downloaded from www.Manualslib.com manuals search engine
Overdischarge warning
Ten segments of battery
charge indicator blink
NO
warning
5-51
TUNING 2 LIFTV
This function changes the tuning level of the lift lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display “2.TUNING2 LIFTV”
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.29 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
setting screen of TUNING2 LIFTV. Display TUNING
MENU screen to display other screen.
Button (1)
Button (2)
TUNING MENU screen
= T U N ME N U =
2 . T UN I NG 2 L I F T V
S P H
S P H
MENU
Button (3)
Press button (3)
< T UN >
NO . 2 0
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 2 1
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 2 9
1
5
S P H
8
S P H
MENU
Press button (3)
TUNING MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-52
TUNING 3 TILTV
This function changes the tuning level of the tilt lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display “3.TUNING3 TILTV”
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to
be set.
4. Functions of buttons on the TUNING level setting
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.39 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
setting screen of TUNING3 TILTV. Display TUNING
MENU screen to display other screen.
Button (1)
Button (2)
TUNING MENU screen
= T U N ME N U =
3 . T UN I NG 3 T I L T V
S P H
S P H
MENU
Button (3)
Press button (3)
< T UN >
NO . 3 0
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 3 1
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 3 9
1
5
S P H
8
S P H
MENU
Press button (3)
TUNING MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-53
TUNING 4 ATT1V
This function changes the tuning level of the attachment 1 lever.
Operation procedure
1. Display the TUNING MENU screen.
2. Press button (1) or (2) to display “4.TUNING4 ATT1V”
Button (1)
and press button (3) (enter) to display TUNING level
Button (2)
TUNING MENU screen
setting screen.
3. Press button (3) to display the tuning item desired to
be set.
= T U N ME N U =
4 . T UN I NG 4 A T T 1 V
4. Functions of buttons on the TUNING level setting
S P H
S P H
screen are as follows:
Button (1): Tuning level down
Button (2): Tuning level up
Button (3)
Button (3): Enter (to the next item screen)
Press button (3)
*: Press button (3) on the TUNING No.49 setting screen to
display the TUNING MENU screen.
Other screen cannot be displayed from each level
< T UN >
1
5
8
NO . 4 0
setting screen of TUNING4 ATT1V. Display TUNING
S P H
S P H
MENU screen to display other screen.
MENU
MENU
Press button (3)
< T UN >
NO . 4 1
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 4 9
1
5
S P H
8
S P H
MENU
Press button (3)
TUNING MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-54
TUNING 5 ATT2V
This function changes the tuning level of the attachment 2 lever.
Operation procedure
1. Display the TUNING MENU screen.
Button (1)
2. Press button (1) or (2) to display “5.TUNING5 ATT2V”
Button (2)
TUNING
MENU
screen
and press button (3) (enter) to display TUNING level
setting screen.
3. Press button (3) to display the tuning item desired to
= T U N ME N U =
be set.
5 . T UN I NG 5 A T T 2 V
S P H
4. Functions of buttons on the TUNING level setting
S P H
screen are as follows:
Button (1): Tuning level down
Button (3)
Button (2): Tuning level up
Press
button (3)
Button (3): Enter (to the next item screen)
*: Press button (3) on the TUNING No.59 setting screen to
display the TUNING MENU screen.
< T UN >
1
5
8
Other screen cannot be displayed from each level
NO . 5 0
S P H
setting screen of TUNING5 ATT2V. Display TUNING
S P H
MENU screen to display other screen.
MENU
MENU
Press button (3)
< T UN >
NO . 5 1
1
5
8
S P H
S P H
MENU
Press button (3)
< T UN >
NO . 5 9
1
5
S P H
8
S P H
MENU
Press button (3)
TUNING MENU screen
Downloaded from www.Manualslib.com manuals search engine
5-55
■ Option set
Option set menu list
No.
Indication
Description
Selection
IndiIndiMeaning
Meaning
cation
cation
OPT-1 DEMO MODE
Enables simultaneous operation of
traveling and material handling before
starting the hour meter.
Y
Enable
N
Disable
OPT-2 H/M START
Starts hour meter count.
Y
Counting
N
No
counting
OPT-3 P/C LOCK
Disables level setting of traveling/material
handling power control, 2-speed travel
speed and overspeed alarm (OPT).
Y
Lock
N
Unlock
OPT-4 DESTI *
Sets the data according to the destination. Changes the display.
J
Japan
I
OPT-5 
Not used.


OPT-6 MPH *
Changes the traveling speed unit to mph.
Y
OPT-7 

OPT-8
Not used
Adjust the charge indicator calculation
BATTERY *
constant.

Not used
Enables/disables operation of the auto
SEAT P-OFF
power-off function in relation to the seat
switch.
Enables/disables parking brake OFF
PARKING ERR
warning.
Enables/disables the active mast front tilt
TILT CONT
angle limit

Not used
Enables/disables the mast forward tilt
TILT F-LIM
speed limit control.
B-TYPE *
Battery type

Not used
A


Set to
mph

Feature
A


Other
than
Japan

Set to
km/h

Feature
B

Y
Enable
N
Disable
Y
Enable
N
Disable
Y
Enable
N
Disable




Y
Enable
N
Disable
1

TYPE1

2

TYPE2

Other
than
2-way
Other
than
4-way

Nondisplay
Disable

OPT-9
OPT-10
OPT-11
OPT-12
OPT-13
OPT-14
OPT-15
OPT-16
N

B
OPT-17 2-WAY VALVE *
Sets specification of 2-way mini lever
models
Y
2-way
N
OPT-18 4-WAY VALVE *
Sets specification of 4-way mini lever
models
Y
4-way
N



Y
Display
N
Y

Enable

N

OPT-19 
OPT-20 WHEEL IND
OPT-21 SAS *
OPT-22 
Not used
Sets the wheel indicator of the all-round
model (OPT) to display/non-display.
Enables/disables SAS function
Not used
*: The specification of the vehicle is selected at the time of vehicle shipment.
Downloaded from www.Manualslib.com manuals search engine
5-56
Caution:
• These functions are used to adjust the controller
and display control according to the options
installed on the vehicle; they do not enable or
disable the actual function of the options.
• When the controller board is replaced, it is
necessary to reset it according to the vehicle
specifications.
• When OPT-12 TILT CONT and OPT-21 SAS are
disabled by option setting, the disabled status is
indicated for 5 seconds on the display upon key
switch ON.
Meaning of indication
T-OFF:
TILT CONT (active mast front tilt angle
control) is disabled.
SAS-OFF: SAS (SAS control) is disabled.
T
OF F
AM
11 : 00
S P H
S P H
MENU
Indication when disable
30/ 9
S AS
AM
OF F
11 : 00
S P H
S P H
MENU
Operation procedure for OPTION SET screen
1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Press button (2) twice to display “3. OPTION SET” and press button (3) (enter) to display the OPTION
SET MENU screen.
3. Press button (3) to display the desired option item to be set on the screen.
4. Functions of buttons on the OPTION SET screen are as follows:
Button (1): N → Y
Button (2): Y → N
Button (3): Enter (to the next item screen)
*: Press button (3) on OPT-22 OPTION SET screen to display the MASK MENU screen.
OPT-4 screen
MASK MENU screen
= ME N U =
3 . OP T I ON
Button (1)
Button (2)
Press button (3)
<OPT
3>
P / C L OCK
S ET
S P H
S P H
Y / N
S P H
MENU
S P H
MENU
Button (3)
Press button (3)
<OP T
D EMO
1>
MOD E
Press button (3)
<OP T
2>
H / M ST ART
Y / N
S P H
S P H
MENU
Press
button (3)
Y / N
S P H
S P H
MENU
OPT-2 (H/M START) hour meter starting method:
Press button (2) while keeping button (1) pressed
for 2 seconds or more.
Downloaded from www.Manualslib.com manuals search engine
5-57
OPT-3 screen
OPT-16 screen
Button (1) Button (2)
<OP T
DES T I
Press button (3)
<OP T 1 5 >
B T YPE
4 >
J / I
S P H
S P H
1 / 2
S P H
S P H
MENU
MENU
Button (3)
Press button (3)
Press button (3)
Not used
<OPT
5 >
B L EVEL
<OPT
T I L T
Y / N
1 4 >
F L I M
S P H
S P H
Y / N
S P H
S P H
MENU
MENU
Press button (3)
<OPT
MPH
Press button (3)
Not used
<OPT
K NOB
6 >
Y / N
1 3 >
CONT
S P H
S P H
Y / N
S P H
S P H
MENU
MENU
Press button (3)
Not used
<OPT
C / CN T
7 >
RE S
Press button (3)
<OPT
T I L T
Y / N
1 2 >
C ON T
S P H
S P H
Y / N
S P H
S P H
MENU
MENU
Press button (3)
<OPT
8 >
B ATT ERY
Press button (3)
<OPT
1 1 >
P A RK I NG E R R
A / B
S P H
S P H
Y / N
S P H
S P H
MENU
MENU
Press button (3)
Press button (3)
Not used
< OP T
S HOU
9 >
T OK U
< OP T
S EAT
Y / N
S P H
S P H
MENU
Downloaded from www.Manualslib.com manuals search engine
10 >
P OF F
Y / N
S P H
Press button (3)
S P H
MENU
5-58
OPT-15 screen
Button (2)
Button (1)
Not used
<OP T
3 6 V
1 6 >
Y / N
S P H
S P H
MENU
Button (3)
Press button (3)
<OPT
1 7 >
2 WA Y V A L V E
Y / N
S P H
S P H
MENU
Press button (3)
<OPT
1 8 >
WA Y V A L V E
4
Y / N
S P H
S P H
MENU
Press button (3)
Not used
<OPT
U SA
1 9 >
Y / N
S P H
S P H
MENU
Press button (3)
< OP T
20 >
WH E E L
I ND
Y / N
S P H
S P H
MENU
MASK MENU screen
Press button (3)
Press button (3)
Not used
< OP T
S AS
<OPT
2 2 >
F I SH ERMA N
2 1 >
Y / N
S P H
S P H
MENU
Downloaded from www.Manualslib.com manuals search engine
Press
button (3)
Y / N
S P H
S P H
MENU
5-59
■ Matching
General
Of the sensors used for SAS, the signal voltage values of the tilt angle, load and tire angle sensors in the
mast vertical position, no load state, and tire straight travel position respectively are stored in the controller
at the time of vehicle shipment to be used as the bases for control. Therefore, if maintenance or parts
replacement related to these sensors is performed, matching (updating sensor signal voltage values of the
vehicle in the vehicle standard state) becomes necessary.
Matching of the tilt angle sensor is also necessary when the vehicle posture is remarkably changed.
Matching of the load sensor is also necessary when the load in the no load state is changed including
removal and addition of attachments.
Each lever angle sensor for mini lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment.Therefore, when maintenance or
parts replacement related to these sensors is required, matching needs to be performed.
SAS Matching Items and Conditions
No. Indication
1
TILTL
2
TILTF
3
LOAD
4
TIRE
Description
Condition
*1 · *2 · *3 · *6
Tilt angle sensor output in the fork level position is stored in the controller.
*7 · *8
Tilt angle sensor output of forward tilt control in the mast vertical position *1 · *2 · *3 · *6
is stored in the controller.
*7 · *8
Load sensor output in the no load state is stored in the controller.
*1 · *4 · *6 · *7
Tire angle sensor output in the straight travel position is stored in the con*1 · *5
troller.
Mini lever Matching Items and Conditions (OPT)
No. Indication
5
LIFT
6
TILT
7
ATT1
8
ATT2
Description
Lift lever angle sensor output in the lift lever neutral position is stored in
the controller.
Tilt lever angle sensor output in the tilt lever neutral position is stored in
the controller.
Attachment 1 lever angle sensor output in the attachment 1 lever neutral
position is stored in the controller.
Attachment 2 lever angle sensor output in the attachment 2 lever neutral
position is stored in the controller.
Meaning of Conditions
*1: When the main controller is replaced
*2: When the tilt angle sensor is replaced
*3: When the tilt angle sensor rod is replaced or its length is changed
*4: When the load sensor is replaced
*5: When the tire angle sensor and sensor cover is removed/installed/replaced
*6: When an attachment is changed
*7: When the mast is replaced
*8: When the tilt cylinder is replaced
*9: When the lift lever angle sensor is replaced
*10: When the tilt lever angle sensor is replaced
*11: When the attachment 1 lever angle sensor is replaced
*12: When the attachment 2 lever angle sensor is replaced
Downloaded from www.Manualslib.com manuals search engine
Condition
*1 · *9
*1 · *10
*1 · *11
*1 · *12
5-60
Before matching
4. Tire straight travel position check
Signal voltage of the tire angle sensor in tire straight
travel position is stored. Tire straight travel position is
the condition in which driving the vehicle 5 meters (16
ft) with the steering wheel fixed causes the center of
the vehicle to stay within 50 mm (2.0 in) to the left and
right of the line.
5 m (16 ft)
100mm
(3.9 in)
Within 50 mm (2.0in)
each on the left and
right sides
Vehicle should be in the “Standard state” for matching.
“Standard state” means the vehicle satisfies the following conditions:
1. Tire pressure check
Make sure that the tire pressure is at the specified
V mast
level. Low pressure and deviation of tire pressure
among the tires may hinder accurate matching.
2. Surface levelness check
Matching on the unleveled or inclined surface may
cause deviation of the standard. Perform matching on
a level surface (inclination below 0.5°).
3. No-load vertical condition check
500 mm
Signal voltage of the load sensor in no-load state is
(19.7 in)
stored. Make sure that the following conditions are
FV•FSV mast
met.
• Raise the fork of the V mast to approx. 500 mm
(19.7 in). Make sure that the mast is in the vertical
position by checking with an angle gauge.
• The rear cylinder rod extension of the FV and FSV
mast should be approx. 100 mm (3.9 in).
Make sure that the mast is in the vertical position by
checking with an angle gauge.
• Tilt the mast from backward tilt position to forward
until it becomes vertical.
Operation procedure for MATCHING screen
1. Input the password on the GENERAL screen (see page 5-23) to display the MASK MENU screen.
2. Press button (2) three times to display “4. MATCHING” and press button (3) (enter) to display the
MATCHING setting screen.
3. Press button (3) to display the desired matching item.
4. Functions of buttons on the MATCHING setting screen are as follows:
Button (1): Unused
Button (2): Starts matching for the selected item
Button (3): Display the next item
Downloaded from www.Manualslib.com manuals search engine
5-61
*: Press button (3) on the ATT2 matching set screen to display the MASK MENU screen.
OK on the display is indicated only after matching (by pressing button (2)).
The value in parentheses is the one stored at present.
The value outside parentheses is the one under the present vehicle condition.
Note:
Matching is necessary when the two values, inside and outside the parentheses are different in the
vehicle standard condition.
Button (1)
Button (2)
MASK MENU screen
= ME N U =
4 . MA T CH I NG
S P H
S P H
MENU
Button (3)
Press button (3)
Press button (3)
< MA T CH I NG >
OK
T I L T L ( 2 . 0 0 ) 2 . 0 0
< MA T CH I NG >
AT T 2
(
.
)
S P H
S P H
.
S P H
MENU
MENU
Press button (3)
Press button (3)
< MA T CH I NG >
OK
T I L T F ( 2 . 0 0 ) 2 . 0 0
< MA T CH I NG >
AT T
(
.
)
S P H
S P H
.
S P H
MENU
Press button (3)
< MA T CH I NG >
OK
L OAD
( 0 . 7 0 ) 0 . 7 0
< MA T CH I NG >
T I L T
(
.
)
S P H
.
S P H
MENU
Press button (3)
< MA T CH I NG >
OK
T I RE
( 2 . 4 0 ) 2 . 4 0
< MA T CH I NG >
L I F T
(
.
)
S P H
MENU
Downloaded from www.Manualslib.com manuals search engine
S P H
MENU
Press button (3)
S P H
S P H
MENU
Press button (3)
S P H
S P H
.
S P H
Press button (3)
S P H
MENU
5-62
■ Tire constant set
General
In order to optimize the speed meter, tire constant that matches the tire outside diameter needs to be input
in the controller.
Although the tire constant is set on a new vehicle at shipment from the factory, adjust it whenever the tire
size is changed or the tires are worn excessively to a degree affecting the speedometer function.
Operation procedure for tire constant setting
1. Input the password on the general screen (see page
5-23) to display the MASK MENU screen.
2. Press button (2) four times to display “5. WHEEL DIA”
and press button (3) (enter) to display the tire constant
setting screen.
3. Press button (1) or (2) to set the desired tire constant
and press button (3) (enter) to display the MASK
MENU screen.
4. Functions of buttons on the tire constant setting
screen are as follows:
Button (1): Decreases the tire constant.
Button (2): Increases the tire constant.
Button (3): Enter and display MASK MENU screen
Button (1) Button (2)
MASK MENU screen
= ME N U =
5 . WH E E L
D I A
S P H
S P H
MENU
Button (3)
Press button (3)
WH E E L
D I A
2 2
S P H
S P H
MENU
Tire constant
Tire constant list
Tire type
Pneumatic shaped
cushion
Pneumatic
Tire size
Applicable model
U lug
J lug
18 × 7-8
7FBEF15 ·16 ·18
White
18 × 7-8
7FBEF15 ·16 ·18
U lug
J lug
White
200/50-10
7FBEF20
18 × 7-8-14
7FBEF15
18 × 7-8-16
7FBEF16 ·18
J lug
Downloaded from www.Manualslib.com manuals search engine
Tire constant
24
25
20
6-1
FRAME AND AUXILIARY EQUIPMENT
Page
BODY FRAME ................................................................. 6-2
INSTRUMENT PANEL AND
ADJACENT PORTION ............................................... 6-8
2
3
AUXILIARY EQUIPMENT ............................................. 6-10
FUSES ............................................................................... 6-13
6
Downloaded from www.Manualslib.com manuals search engine
6-2
BODY FRAME
Frame
■ General
(1)
(4)
(3)
(2)
(1)
Round-type front stay
(3)
Cautions for jacking up
(2)
Side cover
(4)
Cautions for hoisting the vehicle
1. Round-type front stay
• The newly adopted round-type front stay facilitates
ingress/egress.
2. Elimination of side covers
• Side covers on previous vehicles are eliminated and replaced with structural members to strengthen
the lower portion of the frame.
Downloaded from www.Manualslib.com manuals search engine
6-3
3. Cautions for jacking up
• A jack-up point is provided at the bottom of the
frame to the rear of the front tire.
• The jack-up point is provided within a range of 150
mm (5.9 in) from the fender. Jack up the vehicle at
the specified jack-up point.
• Do not attempt to perform service work when the
vehicle is jacked up. Always place wood blocks, etc.
under the vehicle before starting the work.
• For jacking up the rear side, see the WEIGHT
section.
2
3
150 mm
(5.9 in)
4. Cautions for hoisting the vehicle
Hoist the front of the vehicle at the mast and the
rear at the head guard similarly as for previous
models.
6
Weight
■ General
1. Compared with previous models, each new model vehicle has a weight of novel design.
2. Jack up the vehicle at the points illustrated below:
Downloaded from www.Manualslib.com manuals search engine
6-4
Battery hood
■ General
1. A press-integrated hood wholly covers the top of the battery. This hood opens up fully for the ease of
battery maintenance and replacement.
2. Use the notch of the head guard to replace the battery from the right-hand side of the vehicle.
■ Battery hood opening/closing procedure
Caution:
When opening/closing the battery hood, hold the handle on the right-hand side of the hood.
(1) Set the mast in vertical position.
(2) Pull the lock release lever.
(3) Tilt the steering post forward.
(4) Open the battery hood.
(1)
(3)
Lock release
lever
(2)
Downloaded from www.Manualslib.com manuals search engine
(4)
6-5
■ Battery hood locking device
• To fix the battery hood securely for operation, a locking device and a catch are provided on the front end
of the hood.
• The locking device automatically locks the hood when closed as a fail safe locking mechanism. The
catch prevents looseness of the hood by means of cushion rubber.
2
3
Catch
Locking device
Damper stay
1. Damper stay is adopted as a standard part to reduce the hood opening/closing force.
2. When fully open, the stay is automatically locked. To close the hood, release the lock with a finger.
Push this and
release the lock
Side hoods
1. Stamped side hoods are adopted to create a simple and clean product image.
2. Simply open the battery hood only for daily inspection and battery fluid addition.
3. For battery replacement, the side hoods on both sides can be removed or installed in one-touch action
without using a tool.
Downloaded from www.Manualslib.com manuals search engine
6
6-6
Step
1. An open step is adopted for the new model. The step height is much reduced compared to previous
models for easier ingress/egress.
2. The top surface of the step is designed for both slip-resistance and easier cleaning.
Step height
mm (in)
H1
H2
545 (21.5)
Previous model
430 (16.9)
545 (21.5)
H2
H1
New model
Toe board
1.
2.
3.
4.
Toe board is divided into the front and rear sections.
The front toe board is attached with the accelerator pedal and fixed onto the frame with bolts.
The rear toe board allows one-touch installation/removal using a positioning pin.
For hydraulic oil and other daily inspection, simply remove the rear toe board.
Accel pedal
FR Toe boad
RR Toe boad
Positioning pin
Downloaded from www.Manualslib.com manuals search engine
6-7
Floor mat
The new model is provided with a floor mat on top of the toe board.
Seat
■ General
A seat switch function is added to the Grammar seat favorably accepted on the 7FGF25 series.
A fabric seat (Grammar) is adopted optionally.
■ Major Features
1. ORS function
Operator protection system: Decreases critical damage to the upper body of the operator in case of
unexpected rollover of the vehicle.
2. Side wings with holes
• Restrain the operator in an emergency.
• Assist grip function for ingress
3. Seatbelt installation as standard equipment
ELR (emergency lock retractor) type
4. Reclining function
Tilting range: 5 ° each in the forward and backward directions
5. Dial type operator's weight adjustment mechanism
Knob position on the front side of the seat
Operator’s weight adjustment function: 50 to 130 kg
6. Built-in seat switch
7. Bull mark
Downloaded from www.Manualslib.com manuals search engine
6-8
INSTRUMENT PANEL AND ADJACENT PORTION
■ Layout near operator’s seat
(1)
(2)
(7)
(9) (10) (11) (12)
(8)
F
N
R
(13)
(14)
(4)
(3)
(6)
(5)
(17)
Center of vehicle
Center of steering
Pattern of shift
(16)
(18)
Layout of Pedal
(15)
D2 Pedal (OPT)
No.
Name
No.
Name
(1)
Parking lever
(10) Control lever (for tilting)
(2)
Horn SW
(11)
(3)
Direction lever
(12) Control lever (for attachment) (optional)
(4)
Turn signal SW
(13) Brake pedal
(5)
Key SW
(14) Accelerator pedal
(6)
Lamp SW
(15) D2 pedal (optional)
(7)
Steering wheel
(16) Tilt steering lock lever
(8)
Seat
(17) Rear work light SW (optional)
(9)
Control lever (for lifting)
(18) Tilt steering lock release lever
* SW: Switch
Downloaded from www.Manualslib.com manuals search engine
Control lever (for attachment)
6-9
Instrument panel
■ General
1. Novel design is realized with resin molding.
2. The instrument panel consists of 2 halves using sturdy and environmentally friendly polypropylene as
the material.
3. The downsized instrument panel improves the ease of ingress/egress.
LH Instrument panel
Downloaded from www.Manualslib.com manuals search engine
RH Instrument panel
6-10
AUXILIARY EQUIPMENT
■ Direction switch
1. Difference from previous models
The direction switch is the same as that installed on the 7FGF25 series.
2. Direction lever
(1) The direction switch is of the lever type easily operable with fingers as on the 7FGF25 series.
(2) The direction switch is positioned on the left-hand side as a standard component.
(3) Since the D2 pedal (OPT) has a built-in switch, no direction lever is provided.
Direction switch
Forward
Fr
Neutral
F
N
N
R
Backward Rr
Downloaded from www.Manualslib.com manuals search engine
6-11
■ Lights
1. List of lights
Type of light
Specifications
Bulb
(1)
Head light
OPT Same as on the previous model
40W
(2)
Front combination light
OPT Same as on the previous model
10W(Clearance, upper)
25W(Flasher, lower)
(3)
Rear combination light
High-mount, transverse rear combination lights are installed as stanOPT dard components for improved
visibility, damage prevention and
design.
25W(Flasher, outer)
25W/10W
(Stop/tail, center)
25W(Reverse, RH only
inside)
(4)
Rear working light
The rear working light is of a large
OPT square type.
(red pilot lamp provided)
40W
The new model operates on 48 V and not compatible with engine-driven forklifts.
(2)
Downloaded from www.Manualslib.com manuals search engine
(1)
(3)
(4)
6-12
2. Light switch
Light switch is positioned on the right-hand side of the steering column for improved operability.
Two-stage light switch turns the side clearance lights and taillights ON and OFF in the first stage and
the headlights, side clearance lights and tail lights ON and OFF, in the second stage.
Turn signal switch
Light switch
Switch for rear working
light (OPT)
Turn signal switch (W/ auto return function)
T
R
Neutral
N
L
Downloaded from www.Manualslib.com manuals search engine
H
OFF
OFF
Light switch
6-13
FUSES
■ Installed positions
Fuses F1 and F4 to F6 are installed in the controller box located under the rear right-hand section of the
vehicle. F1 is of the module type while F4 to F6 are of the blade type. Previously independent F1 for
traveling and F2 for material handling are integrated as F1 fuse for traveling and material handling.
F1
A view
F4
F5
F6
A view
■ Name (Applicable function) and capacity
7FBEF15 to 20
F1
For traveling/material handling
500A
F4
For lights
10A
F5
For control circuit
10A
F6
SAS, for solenoid
10A
■ Cautions for fuse replacement
When replacing any fuse, always be sure to disconnect the battery plugs and discharge overall
capacitor by applying a resistance of approx. 100Ω to between P3 and N2.
Downloaded from www.Manualslib.com manuals search engine
6-14
Downloaded from www.Manualslib.com manuals search engine
7-1
MATERIAL HANDLING AND HYDRAULIC SYSTEM
Page
V MAST ............................................................................. 7-2
FV MAST ........................................................................... 7-3
2
3
FSV MAST ........................................................................ 7-4
MATERIAL HANDLING SPEED.................................. 7-5
LOAD BACKREST & FORK ........................................ 7-6
TILT CYLINDER .............................................................. 7-7
OIL PUMP ......................................................................... 7-8
OIL TANK .......................................................................... 7-9
OIL CONTROL VALVE .................................................. 7-10
MATERIAL HANDLING LEVER .................................. 7-19
HYDRAULIC CIRCUIT ................................................... 7-20
MAST INTERCHANGEABILITY.................................. 7-21
A4 PIPING......................................................................... 7-22
Downloaded from www.Manualslib.com manuals search engine
7
7-2
V MAST
■ General
1. The vehicle is installed with the V mast as the standard component.
2. The mast installation method is changed from that for the previous models to reduce the lost load
center (distance from the front axle center to the fork front).
3. A mast for 2.0 tons is newly provided.
■ Major improvements
1. Improved mast durability
Mast durability has been improved by reducing the torsional force applied to the mast rails by changing
the tilt bracket construction. In addition, the outer middle beam is discontinued to reduce the lost load
center while retaining sufficient mast durability.
2. Front visibility
Unique front visibility vision is retained by using the mast rail and finger bars similarly as on previous
models.
3. Chain
The mast chain size for the 1.5- to 1.8-t masts remains unchanged. The size for the 2.0-t mast is the
same (BL634) as on the 7FBMF 20 and 25 models.
4. Lift cylinder
The lift cylinder for the 1.5- to 1.8-t masts is the same as that for the 7FBMF16 and 18. The lift cylinder
for the 2.0-t mast is the same as that for the 7FBMF20 and 25.
5. Lift cylinder piping
The basic structure of the piping for the 1.5- to 1.8-t masts remains unchanged. The safety down valve
is of the same inline type as on the Previous models except for an additional fitting for the pressure
sensor.
The basic structure of the lift cylinder for the 2.0-t mast is the same as that for the 1.5- to 1.8-t masts.
6. Lift roller
The mast rollers for the 1.5- to 1.8-t masts are the same as those for the 7FBMF16 and 18.
The mast rollers for the 2.0-t mast are the same as those for the 7BMF20 and 25.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity
1.0 ton
1.3 ton
1.5 to 1.8 ton
2.0 ton
−
−
355(14.0)
370(14.6)
380(15.0)
385(15.2)
385(15.2)
−
New model
Previous model
Downloaded from www.Manualslib.com manuals search engine
7-3
FV MAST
■ General
1. The FV mast is optionally available.
2. The mast installation method is changed from that on previous models to reduce the lost load center
(distance from the front axle center to the fork front).
3. A mast for 2.0 tons is not provided.
2
3
■ Major improvements
1. High mast durability
Same as that of the V mast.
2. Front visibility
Unique front visibility vision is retained by using the mast rail and finger bars similarly as on previous
models.
3. Chain
Same as that for the V mast.
4. Lift cylinder
The lift cylinder remains unchanged from that for the 7FBMF16 and 18.
5. Lift cylinder piping
The basic lift cylinder piping is the same as that for previous models.
The same in-line type safety down valve as that for the previous models is used except for an addition
of the fitting for a pressure sensor.
6. Lift roller
Same as for the V mast.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity
1.0 ton
1.3 ton
1.5 to 1.8 ton
2.0 ton
−
−
355(14.0)
370(14.6)
380(15.0)
385(15.2)
385(15.2)
−
New model
Previous model
Downloaded from www.Manualslib.com manuals search engine
7
7-4
FSV MAST
■ General
1. The FSV mast is optionally available.
2. The mast installation method is changed from that for the previous model to reduce the lost load center
(distance from the front axle center to the fork front).
3. A mast for 2.0 tons is newly provided.
■ Major improvements
1. High mast durability
Same as for the V mast.
2. Front visibility
Unique front visibility is retained by using the mast rail and finger bars similar to those on previous
models.
3. Chain
The mast chain for the 7FBEF15 to 18 is the same in size as that for previous models. The chain
(BL634) for the 7FBEF20 is the same in size with that for the 7FBMF20,25.
4. Lift cylinder
The mast lift cylinder for the 1.5- to 1.8-t models remains unchanged from that for the 7FBMF16 and
18. The mast lift cylinder for the 7FBEF20 is the same as that for the 7FBMF20,25.
5. Lift cylinder piping
The basic piping structure remains unchanged for the 1.5- to 1.8-t models. The flow regulator position
has been changed to shorten the lost load center (distance between the center of the front axle to the
front edge of the fork).
The pressure sensor piping is connected to the piping between RR cylinders.
The basic lift cylinder piping structure for the 2.0-t model is the same as that for the 1.0- to 1.8-t
models.
6. Lift roller
Same as that for the V mast.
7. Lost load center (distance between the front axle center and the fork front)
mm(in)
Load capacity
1.0 ton
1.3 ton
1.5 to 1.8 ton
2.0 ton
−
−
395(15.6)
415(16.3)
410(16.1)
415(16.3)
415(16.3)
−
New model
Previous model
Downloaded from www.Manualslib.com manuals search engine
7-5
MATERIAL HANDLING SPEED
List of material handling speeds
mm/s (fpm)
V-mast
Vehicle model
7FBEF15
Lift
Lift
Load
No load
Load
No load
Load
H
610 (120)
430 (85)
560 (110)
400 (79)
560 (110)
400 (79)
P
540 (106)
350 (69)
490 (96)
330 (65)
490 (96)
330 (65)
S
480 (94)
280 (55)
430 (85)
270 (53)
430 (85)
270 (53)
550 (108)
500 (98)
450 (89)
480 (94)
420 (83)
480 (95)
H
610 (120)
420 (83)
560 (110)
390 (77)
560 (110)
390 (77)
P
540 (106)
340 (67)
490 (96)
320 (63)
490 (96)
320 (63)
S
480 (94)
260 (51)
430 (85)
250 (49)
430 (85)
260 (51)
550 (108)
500 (98)
450 (89)
480 (94)
420 (83)
480 (94)
H
610 (120)
390 (77)
560 (110)
380 (75)
560 (110)
380 (75)
P
540 (106)
320 (63)
490 (96)
310 (61)
490 (96)
310 (61)
S
480 (94)
250 (49)
430 (85)
240 (47)
430 (85)
240 (47)
550 (108)
500 (98)
450 (89)
480 (94)
420 (83)
480 (94)
H
500 (98)
340 (67)
470 (93)
320 (63)
−
−
P
450 (89)
280 (55)
420 (83)
270 (53)
−
−
S
400 (79)
220 (43)
360 (71)
210 (41)
−
−
500 (98)
500 (98)
450 (89)
480 (94)
−
−
Lower ALL
7FBEF18
Lift
Lower ALL
7FBEF20
Lift
FV-mast
No load
Lower ALL
7FBEF16
FSV-mast
Lower ALL
Downloaded from www.Manualslib.com manuals search engine
2
3
7
7-6
LOAD BACKREST & FORK
LOAD BACKREST
■ General
1. The backrest is installed as standard equipment.
2. The same flat steel type backrest as on the 7FBMF25 series is adopted.
3. The backrest-less option is selectable for all masts.
7FBEF15 to 18
Outside width of load backrest
mm (in)
970 (42.1)
1070 (42.1)
1220 (48.0)
1520 (59.8)
Forkbar width
mm (in)
920 (36.2)
1020 (40.2)
1170 (46.1)
1470 (57.9)
STD
−
−
−
Height of
load backrest
mm (in)
1220 (48.0)
STD: Standard, − : Not available
7FBEF20
Outside width of load backrest
mm (in)
970 (42.1)
1070 (42.1)
1220 (48.0)
1520 (59.8)
Forkbar width
mm (in)
920 (36.2)
1020 (40.2)
1170 (46.1)
1470 (57.9)
−
STD
●
●
Height of
load backrest
mm (in)
1220 (48.0)
STD: Standard, ●: Available as option, − : Not available
FORK
■ General
1. The fork is the same as that for the 7FBMF25 series.
2. The standard fork color is black. Orange color is provided optionally.
3. The forkless option is provided for all masts as on the Previous models.
Fork width
mm (in)
Fork thickness
mm (in)
7FBEF15 to 18
80 (3.2)
7FBEF20
100 (3.9)
Vehicle model
800
(31.5)
1000
(39.4)
1100
(43.3)
1200
(47.2)
1400
(55.1)
40 (1.6)
STD
●
●
●
●
40 (1.6)
−
STD
●
●
●
STD: Standard, ●: Available as option, − : Not available
Downloaded from www.Manualslib.com manuals search engine
Fork length mm (in)
7-7
TILT CYLINDER
„ General
1. The tilt cylinder is newly provided for the 7FBEF series.
2. The screw type front joint is changed to a welded rod type.
3. The front pin for fixing the mast to the tilt cylinder is changed to an eccentric pin. It allows fine
adjustment of the backward tilt angle and uneven lifting.
4. FR and RR installation points use clevis structure.
5. The internal structure is the same as that for the 7FBMF25 series.
Downloaded from www.Manualslib.com manuals search engine
7-8
OIL PUMP
■ General
1. The external gear pump is the same in basic structure as that on previous models.
2. The conventional double gear pump is replaced with a single gear pump for noise reduction.
3. To improve the lifting speed, the pump capacity has been increased.
Vehicle model
7FBEF15 to 20
Oil pump name
Single gear pump
Oil pump type
TMG1A21A3H5-L (Shimadzu)
Drive system
Direct motor drive
Delivery
(at a pumping rate of 1,500 rpm)
Theoretical delivery
Downloaded from www.Manualslib.com manuals search engine
l (US gal) /min
30.8 (8.14)
cm3 (in3) /rev
21.9 (1.34)
7-9
OIL TANK
■ General
1.
2.
3.
4.
An independent resin tank is separately bolted on to the frame.
It is installed on the front frame.
The oil injection and level can be checked easily by removing the toe board.
The return filter is located under the front toe board.
Breather
Level gauge & cap
Return filter
Oil tank
■ Other hydraulic parts
1. Oil tank cap
• A rubber male-female type cap is adopted.
• A separate breather is adopted for downsizing.
• Check the oil level by holding the cap end in contact with the retainer opening as illustrated.
Retainer
2. Breather
To ensure prevention of oil leakage from the breather, an off-cap structure is adopted. (40-µ mesh)
Downloaded from www.Manualslib.com manuals search engine
7-10
OIL CONTROL VALVE
■ General
Mast control valves are provided anew.
They are as follows:
• A check valve and a solenoid valve are installed in the tilt circuit to control mast tilting operation.
• A check valve and a solenoid valve are installed in the lift circuit, and a key-lift interlock function is
added to prevent the fork from lowering when the lift lever is erroneously moved to the down side while
the key is in the OFF position.
• The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt.
■ Appearance
Forward tilt switch
Backward tilt switch
Lift look release bolt
Tilt solenoid
Lift solenoid
The newly installed check valve for locking the lift circuit enables lowering when unlocked at key
ON. The tilt circuit locking check valve is unlocked to enable tilting only when the tilt lever is
operated in the forward tilt direction with the key switch in the ON position.
■ Specifications
Unit: MPa (kgf/cm2) [psi]
Relief pressure
Downloaded from www.Manualslib.com manuals search engine
Lift
17.2 (175) [246]
Tilt
13.7 (140) [195]
7-11
■ Functional description
General
1. This vehicle is equipped with the key-off lift lock function using a solenoid valve provided in the lift
circuit similarly as on the 7FB10-J35 series.
2. Since tilt lock is electrically controlled by the solenoid valve installed in the forward tilt circuit, the
conventional tilt lock valve has been discontinued.
3. Since the flow is controlled by pump motor revolution similarly as on the 7FB10-J35 series, no solenoid
valve is provided on the control valve side.
Lift circuit
1. During lifting (lift solenoid valve: ON)
(1) When the lift lever is operated in the lifting direction, the lift spool moves to the left in the figure.
Then, the pump pressure compresses the spring at the lift load check valve to open the valve.
(2) The pump pressure is led to the lift logic valve. The pressure compresses the spring at the lift logic
valve to open it.
(3) As the result, the pump pressure is led to the C1 port to extend the lift cylinder and raise the fork.
Check valve
Solenoid valve
C1
Logic valve
Lift spool
Lift cylinder
Pump port
Downloaded from www.Manualslib.com manuals search engine
Lift load check valve
7-12
2. During lowering (lift solenoid valve: ON)
(1) When the key switch is turned ON, the lift solenoid valve is turned on. The poppet moves to the
right side in the figure to open the check valve. Then the hydraulic oil at the lower portion of the lift
cylinder flows through the C1 port to the lower side of the logic valve and the solenoid valve, and to
the upper side of the logic valve and the lift spool.
(2) Therefore, the relation of the pressures when the spool is stationary with the key switch ON will be
as follows: C1 pressure = Logic valve upper side pressure = Logic valve lower side pressure.
(3) Then operating the lift lever to the lowering side pushes the lift spool to the right in the figure and
opens the circuit between the C1 and tank ports. Since part A of the logic valve has an orifice, the
hydraulic oil between the lower side of the logic valve and the spool flows to the tank port.
Meanwhile, the hydraulic oil at the C1 port does not flow down quickly because it is choked by the
logic valve orifice.
Part A
Logic valve upper side
Check valve
Orifice
Poppet
Solenoid valve
C1
Logic valve
Logic valve lower side
Tank port
Lift spool
Lift cylinder
Pump port
Downloaded from www.Manualslib.com manuals search engine
Lift load check valve
7-13
(4) From the result of (2), differential pressure relations stand as follows when the lift lever is operated:
C1 pressure > Logic valve upper side pressure = Logic valve lower side pressure.
(5) Then the C1 port pressure acts on the logic valve to move it downward in the figure because of the
difference in area between a and b of logic valve part A. The pressure opens the logic valve and the
main circuit of the C1 port and the tank port to cause the fork to be lowered.
Part A
a
b
Logic valve upper side
Check valve
Solenoid valve
C1
Logic valve
Tank port
Lift spool
Lift cylinder
Pump port
Downloaded from www.Manualslib.com manuals search engine
Lift load check valve
7-14
3. Lowering operation with key-OFF (key-off lift lock)
Operating the lift lever to the lowering side when the key is turned OFF, the lift spool moves to the right
side. Since the solenoid valve is OFF then, the hydraulic oil in the lower part of the logic valve does not
flow to the tank port because of the check valve in the solenoid valve. Thus no pressure difference is
generated between the C1 port and the lower part of the logic valve. Consequently, the logic valve
remains closed. Since the C1 port and the tank port circuits are cut off, the fork does not go down even
when the lift lever is operated in the downward direction when the key switch is turned OFF.
Check valve
Solenoid valve
C1
Logic valve
Tank port
Lift spool
Lift cylinder
Pump port
Downloaded from www.Manualslib.com manuals search engine
7-15
4. Emergency circuit (emergency lowering circuit)
(1) The emergency circuit is provided in consideration of a circumstance where for some electrical
reason the solenoid valve fails to function. This refers to bypassing the hydraulic circuit that links
the lift logic valve lower side to the lift spool. This bypass circuit is provided with a needle valve,
which is normally shut off with the needle pushed in with a bolt. This bolt is locked with a lock nut.
(2) The lowering operation is as follows:
1) Loosen the lock nut.
2) Turn the hexagonal bolt to loosen it. (A turn is sufficient.)
3) Operate the lift lever toward the lowering side to lower the fork. The lowering speed is set at
approximately the same rate as for normal lowering.
4) When the lowering is completed, tighten the bolt and the nut according to the instructions given
in the repair manual.
(3) When the lift is manually lowered, hydraulic oil in the lower part of the cylinder, which is led to the
lower side of the lift logic valve, is also led to the needle valve on the emergency circuit. When the
lowering is manually operated, the hydraulic oil led to the needle valve is now led to the tank port,
generating a differential pressure between C1 port and the logic valve lower side same as in
normal circumstance. This causes the logic valve to open. It also opens the main circuit from C1 to
the tank port, allowing the hydraulic oil in the lower part of the cylinder to flow to the tank port.
Bolt
Solenoid valve
Nut
C1
Needle valve
Logic valve
Emergency circuit
Tank port
Lift spool
Lift cylinder
Pump port
Downloaded from www.Manualslib.com manuals search engine
7-16
Tilt circuit
1. Mast backward tilting (Solenoid valve: OFF)
(1) When the key switch is turned ON and the tilt lever is operated to the backward tilting direction, the
tilt spool is pulled and moves to the left side in the figure.
(2) Then the hydraulic oil in the pump port flows through the spool and compresses the tilt logic valve
spring to open the valve.
(3) As the result of (2), the circuit connecting the pump port and the C3 port is opened. Since the C3
port is connected to the RH chamber of the tilt cylinder, the pump pressure is applied to contract the
tilt cylinder.
(4) On the other hand, when the tilt spool moves to the left side in the figure, the circuit connecting the
C2 port and the tank port opens. C2 port is jointed to the LH chamber of the tilt cylinder.
(5) The action in step (3) applies the pump pressure to the RH chamber of the tilt cylinder.
Consequently, the hydraulic oil in the LH chamber of the tilt cylinder is led from the C2 port to the
tank port through the control valve spool as if pushed by the piston inside the tilt cylinder.
Tilt cylinder
C2
C3
Check valve
Tilt spool
Solenoid valve
Tank port
Tilt logic valve
Pump port
Downloaded from www.Manualslib.com manuals search engine
7-17
2. Mast forward tilting (solenoid valve: ON)
(1) When the key switch is turned ON and the tilt lever is operated in the forward tilting direction, the tilt
spool is pushed and moves to the right side in the figure.
(2) Then, the circuit connecting the pump port to the C2 port opens. Since the C2 port is connected to
the LH chamber of the tilt cylinder, the pump pressure is applied to the LH chamber of the tilt
cylinder through the C2 port.
(3) Meanwhile, the tilt solenoid valve is turned ON when operated for forward tilting. The poppet in the
solenoid valve moves to the right side in the figure to open the check valve. Then the hydraulic oil in
the RH chamber of the tilt cylinder flows through the C3 port, right side of the logic valve, the
solenoid valve, the left side of the logic valve and the tilt spool to the tank port.
(4) Then, part A of the logic valve forms an orifice. Therefore, the hydraulic oil is led from the right side
of the logic valve to the spool and then to the tank port, and the hydraulic oil at the C3 port flows
gradually to the right side of the logic valve because of restriction by the orifice at logic valve part A.
Tilt cylinder
Part A
Logic valve right side
C2
C3
Check valve
Poppet
Orifice
Tilt spool
Logic valve right
side
Solenoid valve
Tilt logic valve
Tank port
Pump port
Downloaded from www.Manualslib.com manuals search engine
Tilt spool constriction
7-18
(5) As the result of (4) above, differential pressure relations stand as follows when the tilt lever is
operated for forward tilting: C3 pressure > Logic valve left side pressure = Logic valve right side
pressure.
(6) Here, because of the difference in area between a and b of the logic valve, the pressure at the C3
port generates a greater force that pushes the tilt logic valve to the right side in the figure. It opens
the logic valve and the main circuit is connected from the C3 port to the tank port.
(7) The choke valve at the tilt spool prevents abrupt forward tilting caused by a load to the mast
forward tilting side when the tilt lever is operated.
Tilt cylinder
b
a
Part A
C2
C3
Logic valve right side
Check valve
Poppet
Logic valve right
side
Tilt spool
Solenoid valve
Tilt logic valve
Tank port
Pump port
3. Forward tilt operation at key-OFF (key-OFF tilt lock)
Operating the tilt lever to the forward tilting side when the key switch is turned OFF, the tilt spool moves
to the right in the figure. The hydraulic oil at the C3 port is led to the right side of the tilt logic valve, but
it is cut off by the check valve in the solenoid valve ahead because the tilt solenoid valve is OFF.
Therefore, no pressure difference is generated between the C3 port and the right side of the logic
valve. Consequently, the logic valve does not open. Thus the mast does not tilt forward if it is
attempted while the key switch is OFF because the circuit between the C3 port and the tank port is
closed.
Tilt cylinder
Logic valve right side
C2
Tilt spool
C3
Check valve
Logic valve right
side
Solenoid valve
Tilt spool constriction
Tank port
Pump port
Downloaded from www.Manualslib.com manuals search engine
7-19
MATERIAL HANDLING LEVER
■ Differences from previous models
1. To improve serviceability, cotter pins are replaced with β pins for installing the control valve lever rods,
control levers and the control valve spool.
2. Tilt knob switch is arranged on the knob of the tilt lever.
4th
Automatic fork leveling switch
3rd
Tilt
Lift
-pin
Downloaded from www.Manualslib.com manuals search engine
7-20
HYDRAULIC CIRCUIT
■ Hydraulic circuit
1. Resin tank is adopted to reduce contamination, and the standard adoption of the return filter promotes
protection of hydraulic devices.
2. The return filter is arranged under the front toe board.
3. The following figure shows the function of the hydraulic circuit:
Downloaded from www.Manualslib.com manuals search engine
7-21
MAST INTERCHANGEABILITY
■ Mast interchangeability by vehicle model
1. Interchangeability within new model series
Vehicle model
Mast type
V
FSV
FV
7FBEF15 to 18
❍
❍
❍
7FBEF20
❍
❍
×
❍: Mast interchangeable between respective model groups
×: Not available
2. Interchangeability with previous models
No interchangeability
3. Interchangeability with 7FBMF25 series
No interchangeability
Downloaded from www.Manualslib.com manuals search engine
7-22
A4 PIPING
■ A4 Piping setting list
Mast
Type of
piping
Oil control valve
Piping number
7FBEF15 to 18
7FBEF20
V
FSV
FV
V
FSV
A405
Four valves
0
❍
❍
❍
❍
❍
A410
Three valves
2
❍
❍
❍
❍
❍
A430
Four valves
2
❍
❍
❍
❍
×
A450
Four valves
4
❍
❍
❍
❍
❍
❍: Available
×: Not available
FV mast is not available for the 7FBEF20.
■ A4 Piping layout
1.
Following the discontinuation of outer mast middle beam, the piping for the outer mast portion has
been modified.
2. The piping of inner and middle masts remains basically unchanged from 7FBMF25 series.
■ Free lift
The free lift of the FV mast without backrest decreases as indicated in the table when the A4 piping is
installed. This is because the pulley for the A4 piping is installed on the front cylinder.
mm (in)
Vehicle model
Mast
FV
7FBEF15 to 18
7FBEF20
-125 (-4.9)
−
■ Termination Types
The termination and piping at the lift bracket are the same as on the 7FBMF25 series.
Piping type
A405
A410
A430
A450
7FBEF15 to 18
7FBEF20
Mast
Mast
V
FSV
FV
V
FSV
STD
NONE
NONE
NONE
NONE
NONE
STD
CTR
RH SIDE
RH SIDE
CTR
RH SIDE
OPT
−
CTR
CTR
−
CTR
STD
CTR
RH SIDE
RH SIDE
CTR
RH SIDE
OPT
−
CTR
CTR
−
CTR
STD
CTR
RH & LH SIDE
RH & LH SIDE
CTR
RH & LH SIDE
OPT
−
CTR & LH SIDE
CTR & LH SIDE
−
CTR & LH SIDE
CTR: center termination
RH SIDE: right-hand side termination
CTR & LH SIDE: center and left -hand termination
RH & LH SIDE: right-hand and left-hand side termination
−: nonavailable
Downloaded from www.Manualslib.com manuals search engine
8-1
SAS CONTROL SYSTEM
Page
SAS CONFIGURATION ................................................. 8-2
MAST CONTROL............................................................ 8-5
2
3
STEERING SYNCHRONIZER FHPS ......................... 8-8
8
Downloaded from www.Manualslib.com manuals search engine
8-2
SAS CONFIGURATION
■ General
The SAS (System of Active Stability) has been developed with the following concepts:
(1) To develop forklift trucks that can be clearly distinguished by customers from other makes in
respect to both “safety” and “engineering”.
(2) To pursue “carefree material handling”.
■ Targets of sas control
Active Mast Function Controller
(1) Longitudinal stability is improved by adopting
the mast forward tilt angle control.
(2) Mast backward tilt angle speed control is
adopted to prevent load from falling.
(3) Automatic fork leveling control is adopted to
improve operating efficiency.
(4) Key-lift interlock is adopted.
Active Steering Synchronizer
with FHPS
Characteristics of turning and straight traveling is
improved by developing FHPS
FHPS:Full Hydraulic Power Steering
■ SAS System configuration
Sensors are installed in various places on the vehicle to detect the vehicle movement and send signals to
the controller. Signals are controlled by the controller and output to respective actuators for action.
Input
control
T
K
Lifting height switch
T
Integral control valve
K
Steering synchronizer
solenoid
T•K
LCD display
• Diagnosis
Backward tilt limit switch
Tilt knob switch
Load sensor
Traveling speed sensor
Steering angle sensor
Tire angle sensor
T:Active mast function controller
K:Active steering Synchronizer
Downloaded from www.Manualslib.com manuals search engine
Controller
Tilt angle sensor
Forward tilt limit switch
Output
Actuator
8-3
■ Names and functions of respective parts
1. Names of parts
2
3
(1)
(5)
(2)
(10)
(3) • (4)
(11)
(12)
(13)
(6)
(8)
(7)
8
(9)
(1)
Lifting height switch
(8)
Tire angle sensor
(2)
Tilt angle sensor
(9)
Integral control valve
(3)
Forward tilt switch
(10)
LCD display
• diagnosis
(4)
Backward tilt switch
(11)
Steering angle sensor
(5)
Tilt knob switch
(12)
Steering synchronizing solenoid valve
(6)
Load sensor
(13)
Main controller
(7)
Traveling speed sensor
Downloaded from www.Manualslib.com manuals search engine
8-4
2. Functions of respective parts
Input side (to the controller)
Name
(1)
Lifting height switch
(2)
Tilt angle sensor
(3)
Forward tilt switch
(4)
Backward tilt switch
(5)
Tilt knob switch
(6)
Load sensor
(7)
Traveling speed sensor
(8)
Tire angle sensor
(11)
Steering angle sensor
Functions
Detects whether the signal is for low or high lifting height. The limit
switch provided on the outer mast side detects the height of inner
mast.
Detects the mast tilt angle. This sensor at the front protector on the
upper side of RH tilt cylinder detects the mast tilt angle from the tilt
cylinder that rotates around the rear pin as the axis of rotation.
Detects the forward tilt operation of the tilt lever. The limit switch
provided to the tilt spool of the oil control valve detects forward tilting
movement when the tilt lever is operated.
Detects the backward tilt operation of the tilt lever. The limit switch
provided to the tilt spool of the oil control valve detects backward tilting movement when the tilt lever is operated.
A switch for automatically leveling the fork when it stops and for
slowing down the backward tilt speed at a low lift.
Detects the load with a pressure sensor provided to the lift cylinder
hydraulic circuit.
Detects the traveling speed from the motor revolution with a sensor
provided to the drive motor.
Detects the tire angle based on the center shaft turning angle with
the sensor at the top of the rear axle center shaft.
Detects the steering wheel position with the sensor provided under
the steering wheel.
Output side (of the controller)
Name
(9)
Integral control valve
(10)
LCD display
(12)
Steering synchronizing
solenoid valve
Downloaded from www.Manualslib.com manuals search engine
Functions
Two solenoids are provided to the integral control valve.
• The heck valve and the solenoid valve installed to the tilt circuit
control the tilting action of the mast.
• The check valve and the solenoid valve on the lift circuit add the
key-off lift lock function to prevent the fork from lowering if the lift
lever for lowering is actuated by mistake while the key is turned
OFF.
If SAS function has any error, wrench symbol mark on the display
blinks, simultaneously buzzing alarm. In addition, an error code indicates abnormal point.
SAS system always requires an initialization (matching) when an
SAS function-related service is provided. In this case, initialize the
system using the display. (See the section for the display)
The solenoid valve is installed to the correcting valve. The solenoid
valve is actuated by a command sent from the controller to open/
close the correcting valve. Opening-closing of the correcting valve
adjusts the hydraulic oil flow rate to the rear axle cylinder to correct
offset of the knob position.
8-5
MAST CONTROL
■ General
Mast control includes the following functions:
1. Mast forward tilt angle control
Mast forward tilt angle control automatically controls the possible forward tilt angle of the mast
according to the state of the load and lifting height. It reduces the hazards of falling cargo or vehicle tipover if the tilt lever is carelessly operated for forward tilting.
2. Mast backward tilting speed control
Automatically reduces the mast backward tilting speed to prevent the load from breaking loose when
the lifting height is high [about 2 m (6.6 ft) or above.] For low lifting height, tilting speed can be reduced
by tilting the mast backward while keeping the tilt lever knob switch pressed.
3. Automatic fork leveling control
When operated for forward tilting with the tilt lever knob switch pressed, the fork automatically stops in
level position (with the mast in vertical position). This function is convenient for connecting/
disconnecting fork during cargo loading/unloading.
4. Key-off lift lock
The fork does not lower if operated for lift lowering (the lift lever is operated to the lowering side) when
the key switch is turned OFF. This function sharply reduces natural drop or forward tilting.
2
3
■ Schematic diagram of control block
Lift lever
Key-switch
Lifting height switch
Tilt konb switch
Tilt angle
sensor
Tilt limit switch
Oil control valve
Tilt cylinder
Tilt solenoid
Load sensor
PS
Lift solenoid
Controller
Pump motor
Downloaded from www.Manualslib.com manuals search engine
8
8-6
■ Descriptions of activation
Mast forward tilt control (forward tilt angle control)
(1) Possible forward tilting angle varies as shown in the figure below according to the lifting height and
load:
Possible forward tilt angle
Light load (no load)
High lift height
Intermediate load
Heavy load
No restriction for
forward tilt angle
Low lift height
No restriction for front tilt angle
Low lift height
Maximum
Forward tilt
angle 5°
High lift height
Forward tilt
(Approx 1°)
Mast vertical
Load
Heavy
(2) If cargo is raised tilted forward for low lifting height, the stop position may come to the forward tilt
side than the control angle. Do not raise the cargo with the mast tilted forward same as previous
model.
(3) When the low load cargo is at the fully raised position, residual pressure from relief stop is detected
by the pressure sensor as high load, subsequently controlling the forward tilt angle. To enable
further forward tilting, lower the cargo slightly from the fully raised position and relief the pressure.
(4) When installing a heavy attachment to a specialty model, etc., the mast forward tilt control may not
be provided.
Caution:
• Don’t place overconfidence with the mast forward tilt control function.
• Although the forward tilt angle is reduced according to the load and lifting height, this does not
guarantee that the cargo does not fall or vehicle does not tip over under any conditions.
• Never tilt the mast forward from the vertical position with the cargo raised same as previous
model. Or the longitudinal stability will be degraded to cause the hazard of falling even under
allowable load.
• Never use the forward tilt control for any work.
Backward tilting speed control
(1) Controls (delays) backward tilting speed for high lifting irrespective of the load. In addition,
controlled speed continues if the cargo reaches the low lifting height from the high lifting height
while backward tilting is actuated.
(2) For low lifting height, the tilting is in full speed without any control irrespective of the load. Actuating
backward tilt with the tilt lever knob switch pressed controls (delays) the backward tilting speed as
long as the switch is pressed.
(3) When the lifting height enters low level from high level during backward tilting, the tilting speed is
controlled (delayed) as long as the tilt knob switch is pressed. Tilting reaches full speed (no speed
limit) when the tilt knob switch is not pressed.
Downloaded from www.Manualslib.com manuals search engine
8-7
Automatic fork leveling control
Operating the fork for forward tilting from the backward tilt position with the tilt lever knob switch pressed
stops the fork automatically in level position (with the mast in vertical position). The conditions vary as
follows depending on the lifting height and the load.
Actuation will be as indicated below when the mast is operated for forward tilting from the backward tilted
position with the tilt lever knob switch pressed:
Not loaded
Loaded
High lifting height (Approx. 2m or
more)
Stops with the mast held in
vertical position
Does not tilt forward
Low lifting height (Less than approx.
2m)
Stops with the mast held in
vertical position
Stops with the mast held vertical or tilted backward by about
1 degree depending on the
load.
• Pressing the tilt lever knob switch during forward tilting with high lifting height and load stops
forward tilting, but the hazard of falling is present depending on the conditions of the road
surfaces, etc. Never use this function for the purpose of any work.
• In the case of a vehicle with attachment, automatic fork leveling control poses a hazard if the
lever stroke is set to maximum during high lifting.
• In the case of a specialty model installed with heavy attachment, etc., the automatic fork leveling
control may not be provided.
Key-off lift lock
1. Integral control valve has been newly designed for mast control, and the lift hydraulic circuit is modified
accordingly.
2. Lowering is disabled if the lever is operated for lowering when the key switch is turned OFF.
3. Since the lift lock solenoid valve is provided to the lift hydraulic circuit, the solenoid valve remains
closed while the key switch is turned OFF, preventing the lowering if the lift lever is operated for
lowering. To lower the fork, turn the key switch ON and operate the lever for lowering.
Possible vehicle weight for installing the mast control
When installing a heavy attachment, etc. to a specialty model, the mast forward tilt angle is set to approx.
1 degree. No automatic fork leveling control is provided for high lifting height.
Upper limit of additional ATT weight (kg)
Vehicle model
Lifting height
3000 mm or
below
Lifting height
3300 to 4000
mm
Lifting height
4300 to 5000
mm
Lifting height
5500 to 6000
mm
7FBEF15
700
550
500
400
7FBEF16
700
550
500
400
7FBEF18
700
550
500
450
7FBEF20
800
700
600
500
Downloaded from www.Manualslib.com manuals search engine
8-8
STEERING SYNCHRONIZER FHPS
■ General
1. The steering angle sensor located at the lower side of the steering wheel and the tire angle sensor
provided to the upper part of the center shaft turning detect the steering angle and the tire angle
respectively and correct offset relation, if any, of both angles by opening the solenoid valve.
2. To correct the offset relation, the controller sends command to the solenoid valve to form a bypass
circuit to return part of hydraulic oil to be supplied to the PS cylinder to the tank. This system retains
relation between the steering knob position and the tire angle at a prescribed level.
3. Correction may not be made for safety reason depending on the traveling speed and other conditions.
4. If the knob position should be offset after maintenance service, etc., the steering position will be
automatically corrected by turning the key switch ON and turning the steering wheel to lock-to-lock.
■ Schematic diagram of control block
Steering knob
Vehicle speed sensor
Steering wheel angle sensor
DM
P
R
T
L
DM
Solenoid valve
Main controller
Tire angle sensor
Downloaded from www.Manualslib.com manuals search engine
9-1
OUTLINE OF MAJOR OPTIONS
Page
FISHERMAN SPECIFICATION ................................... 9-2
MASTLESS ...................................................................... 9-3
2
3
ATTACHMENT LIST ....................................................... 9-4
DRIVE-IN RACK SPECIFICATION ............................. 9-8
MINI LEVERS................................................................... 9-9
BATTERY ROLL-OUT SPECIFICATION .................. 9-23
9
Downloaded from www.Manualslib.com manuals search engine
9-2
FISHERMAN SPECIFICATION
■ General
1. The fisherman specification improved in rust prevention as compared with standard vehicles is
provided anew. Please recommend it for such cases shown below.
• For use in marine product industry
• For frequent use on wet ground
• For use in a humid environment
• For transportation of salty or other water tanks involving water splashing onto the vehicle
• For use in an environment where ground surface is constantly wet with salty water
• For use in an environment involving splashing of oxidizing fluid (such as hydrogen peroxide or
sodium hypochlorite)
• For use in an environment where a snow-melting agent such as calcium chloride is used
2. Since the fisherman specification has poorer heat radiation because of the waterproof structures of the
drive and pump motors, the rate of operation should be kept at about 60% compared to standard
vehicles.
Depending on the type of operation (such as continuous heavily loaded operation), the vehicle
performances may be temporarily reduced for protecting the controllers and motors from overheating.
The motor current limiting function that is activated upon detection of the specified temperature by the
sensor built in each controller or motor causes this. This is not an abnormality. Since an alarm
indication is given on the monitoring display, suspend operation for some time and restart after
disappearance of the alarm indication.
■ Items and contents
The following items have been changed from those on the standard vehicles.
Item
Content
Drive/Pump motor
Waterproof type
Brake switch
Waterproof type
Covers
Under the Front-Protector cover
Tilt cylinder hole cover
Mast
Anti-rust roller
Fully oil charged lift cylinder
Tilt cylinder
Tilt cylinder boot
Bolt
Rust preventive treatment
(Covers, Tilt pin)
Downloaded from www.Manualslib.com manuals search engine
9-3
MASTLESS
■ General
Mastless vehicles are available optionally.
• These are without the mast ASSY, lift bracket, backrest and fork.
• The high-pressure hose from the mast to the control valve is not provided. The control valve fitting is
attached with a blind plug.
• The tilt cylinder is for the FSV mast. The pin for fixing the tilt cylinder on the mast is not provided.
• The name plate punched with the model, frame No., manufacturing year, front tread, tire size, tire
pressure, voltage, battery weight and rated load is riveted in the same position as on the standard
model.
• A spare nameplate punched with the model, frame No., manufacturing year, voltage, battery weight and
rated load is supplied with the vehicle.
Note:
• Always install the 7FBEF series mast for SAS manufactured by Toyota as described on the
repair manual.
• SAS matching is a must after mast installation.
• Refer to the table in the mast specification section for the allowable load to be punched on the
nameplate (except when the side shifter is installed).
2
3
9
Downloaded from www.Manualslib.com manuals search engine
9-4
ATTACHMENT LIST
SIDESHIFTER
ATT
NAME
E811
E811A
E811B
E911
E911A
E911B
OPT
CODE
D910
D911
D912
D900
D902
D903
INTEGRATED
INTEGRATED
+A430
INTEGRATED
+A450
HOOKED ON
HOOKED ON
+A430
HOOKED ON
+A450
7FBEF15
●
●
●
●
●
●
7FBEF16
●
●
●
●
●
●
7FBEF18
●
●
●
●
●
●
7FBEF20
●
●
●
●
●
●
MODEL
●: Provided
Note:
The sideshifter includes center termination.
Hooked on sideshifter (CASCADE)
■ General
•
•
•
•
A detachable sideshifter (Cascade) is provided.
The basic structure remains unchanged from that for previous models.
It can be installed on the V, FSV and FV (1-t series) masts.
The shifter fork bar width is the same as the fork bar width on the vehicle.
Front view of detachable sideshifter
Downloaded from www.Manualslib.com manuals search engine
9-5
■ Specifications
STD: Standard ●: Available as option
7FBEF15 to 18
Fork bar width
mm (in)
Catalog No.
Assembly weight
920 (36.2)
kg (lb)
50.3 (111)
Effective thickness mm (in)
59.0 (2.32)
Max. sideshift
200 (7.87)
mm (in)
Series
STD
STD: Standard ●: Available as option
7FBEF20
Fork bar width
2
3
55F-SS-A890
mm (in)
1020 (40.2)
1170 (46.1)
1470 (57.9)
55F-SS-A891
55F-SS-A930
55F-SS-A932
53.5 (2.11)
59.0 (2.32)
88.3 (3.48)
Effective thickness mm (in)
59.0 (2.32)
←
←
Max. sideshift
200 (7.87)
←
←
STD
●
●
Catalog No.
Assembly weight
kg (lb)
mm (in)
Series
■ Others
1. Fork & Backrest
The fork and backrest are the same as those of the standard vehicles. Series options can be used as
they are.
2. A4 Piping
The E9 attachment includes the A4 piping as shown in the table below.
E9-code
A4-type
E911
A410
E911A
A430
E911B
A450
3. Control Lever Layout
The control lever layout remains unchanged. The operating directions are also the same.
Downloaded from www.Manualslib.com manuals search engine
9
9-6
Integral sideshifter
■ General
•
•
•
•
The sideshifter integrated with the lift bracket is provided.
The basic structure remains unchanged from that for previous models.
It can be installed on V, FSV and FV (1-t series) masts.
The allowable load and load center are the same as those on standard vehicles.
Rear view of integral sideshifter
Stroke
Stroke
Fork bar width
■ Specifications
7FBEF15 to 18
STD: Standard
Fork bar width
mm (in)
920 (36.2)
Max. sideshift
mm (in)
200 (7.87)
Series
STD
STD: Standard ●: Available as option
7FBEF20
Fork bar width
mm (in)
1020 (40.2)
1170 (46.1)
1470 (57.9)
Max. sideshift
mm (in)
200 (7.87)
←
←
STD
●
●
Series
Downloaded from www.Manualslib.com manuals search engine
9-7
■ Others
1. Fork & Backrest
The fork and backrest are the same as those of the standard vehicles. Series options can be used as
they are.
2. A4 Piping
The E8 attachment includes the A4 piping as shown in the table below.
E8-code
A4-type
E811
A410
E811A
A430
E811B
A450
3. Tire chain installation
There is no optional tire chain installation structure.
4. Control lever layout
The control lever layout and operating directions are the same as on previous models.
Downloaded from www.Manualslib.com manuals search engine
9-8
DRIVE-IN RACK SPECIFICATION
■ Structure (Differences from Standard Model)
The head guard, front stay and rear pillar shapes are different, and the seat position is moved by 36 mm
toward the center of the vehicle.
D
LOAD
B
C
A
mm (in)
A
B
C
D
780 (30.7)
1156 (45.5)
1883 (74.1)
780 (30.7)
■ Unallowable Optional Attachments
Lights (FR·RR combination lamps, etc.)
4-way control valve, piping, etc.
■ Others
The assist grip and headlamps are not installed.
The mast backward tilting angle is up to 5°.
Downloaded from www.Manualslib.com manuals search engine
9-9
MINI LEVERS
■ General
The electromagnetic oil control valves for mast control with mini levers are newly provided as options.
They are as follows:
• A check valve and an electromagnetic proportional valve are installed in the tilt circuit to control the mast
tilting operation.
• A check valve and an electromagnetic proportional valve are installed in the lift circuit for key-off lift
interlock to prevent the fork from lowering in case the down lift lever is touched erroneously while the
key is OFF.
• The check valves in the lift and tilt circuits greatly reduce natural drop and natural forward tilt.
■ Appearance
Connection with actual machine components
Port P
Hydraulic pump
(hydraulic fluid supply source)
Port C2
Tilt cylinder bottom side
Port T1
Tank
Port C3
Tilt cylinder rod side
Port T2
Tank
Port C4
Actuator
Port C1
Lift cylinder bottom side
Port C5
Actuator
G2
Pressure reducing valve static
pressure detection port
Pressure detection port
Port P static pressure detection
port
G1
C1
G2
C3
P
C5
C2
C4
T1
G1
T2
■ Specifications
Unit: MPa (kgf/cm2) [psi]
Mini rever
Relief pressure
Downloaded from www.Manualslib.com manuals search engine
Lift
17.2 (175) [246]
Tilt
−
9-10
■ Explanation of Operation
Material handling valve
1. Pressure compensation mechanism
When pressure compensation mechanism is ON
When solenoid C1 is euergized and non-leak valve is closed, the pressure compensation mechanism
operates as follows:
Pressure oil flowing from port P flows from chamber (a) through orifice A to chamber (b), then flows
through orifice B to chamber (c).
The opening aperture of oil passage E is determined by the equilibrium of chamber (b), chamber (c)
and spring 1.
This controls the oil pressure of chamber (a) at a fixed pressure higher than the oil pressure in
chamber (c).
Pressure oil that has flowed through the pressure reducing valve flows to chamber (f), then flows
through orifice D to chamber (e).
The pressure oil in chamber (c) flows into chamber (d) and the pressure compensation valve is
operated by the equilibrium of chamber (c), chamber (d) and spring 2.
This controls the oil pressure of chamber (d) at a fixed pressure higher than the oil pressure in
chamber (e).
Chamber (d) and chamber (c) are connected by orifice C, so they have the same oil pressure, and the
pressure differential between chamber (a) and chamber (f) is kept constant by operation of the unload
valve and the pressure compensation valve.
This pressure differential is detertimed by spring 1 and spring 2.
When the oil pressure in chamber (a) becomes high, the oil drains from the pilot relief valve of the
unload valve.
Accordingly, the maximum oil pressure of chamber (a) is detertimed by the installation load of spring 3.
Pressure compensating function (sectional view of inlet section)
Main flow/excess flow
Pilot flow
Unload valve
Spring 1
E
A (a)
Port T1
B
Port P
(c)
When the pilot relief valve is opened
(b)
When the pilot relief valve is closed
(f)
Spring 3
(e)
C
Solenoid C1
(d)
Non-leak valve
Pressure compensation valve
Spring 2
Downloaded from www.Manualslib.com manuals search engine
9-11
When pressure compensation mechanism OFF
When solenoid C1 is not energized and the non-leak valve is open, the pressure oil from chamber (c)
flows through orifice Q, then returns to the tank via chamber (g). Now chamber (c) has the same
pressure as the tank, so all the pressure oil from port P returns to the tank via part E.
When the pressure compensating mechanism is inactive (sectional view of inlet section)
Main flow/excess flow
Pilot flow
E
Port T1
Port P
(c)
(g)
Solenoid c1
Q
Downloaded from www.Manualslib.com manuals search engine
Non-leak valve
9-12
2. When material handling is not operated (spool in the neutral position)
When a pressure is applied from the port P
The pressure compensating mechanism is inactive because solenoid c1 is not activated.
When the pressure compensating mechanism is inactive (sectional view of inlet section)
Main flow/excess flow
Pilot flow
E
Port T1
Port P
(c)
(g)
Solenoid c1
Q
Downloaded from www.Manualslib.com manuals search engine
Non-leak valve
9-13
Backpressure leak reduction mechanism
Port C1 of the lift cylinder is connected to the bottom of the lift cylinder, and port C3 of the tilt cylinder is
connected to the rod side of the tilt cylinder.
When load pressure from port C1 and port C3 is applied, leakage to chamber (i) and chamber (j) is
controlled by H and I on the seat.
Leakage of pressure oil that flowed to the lift lock check valve and pressure oil that flowed to the tilt
lock check valve is controlled by land part J and land part K respectively.
This reduces natural drop and natural forward tilt.
Backpressure leak reduction mechanism (sectional view of lift section)
Pilot flow
H
Port C1
J
(i)
Tilt lock check valve
Backpressure leak reduction mechanism (sectional view of tilt section)
I
Pilot flow
Port C3
K
(j)
Tilt lock check valve
Downloaded from www.Manualslib.com manuals search engine
9-14
3. Hydraulic pressure mechanism for solenoid proportional valve
The pressure oil that has had its pressure reduced by the pressure reducing valve flows to chamber
(h), then flows through passage 4 and the filter to become the pilot pressure to each solenoid.
The pressure of the oil is determined by the set load on spring 4.
Hydraulic pressure mechanism for solenoid proportional valve
Pilot flow
Electromagnetic proportional valve
Electromagnetic proportional valve
Tilt section
4
Lift section
Filter
(h)
Inlet section
Spring 4
Downloaded from www.Manualslib.com manuals search engine
Reducing valve
9-15
4. Load sensing mechanism
The pressure compensation valve, unload valve and sensing circuit are part of pressure compensation
operation.
When the spool strokes, chamber 7 connects to each cylinder port.
Sensing pressure is the cylinder pressure, which gives feedback to the pressure compensation valve.
When sensing pressure + pressure of spring (2) = pressure of chamber (d) and chamber (c), the
pressure compensation valve moves to the equilibrium position.
The pressure differential between the sensing pressure and chamber (d) and chamber (c) becomes
the pressure of spring (2).
The pressure of chamber (d) and chamber (c) is applied to the unload valve, then the unload valve
moves to the equilibrium position, when pressure of chamber (e) and chamber (c) + pressure of spring
(1) = P port pressure.
The pressure differential between chamber (d) and chamber (c) and P port pressure becomes the
pressure of spring (1).
The force of spring (1) and spring (2) is now constant, so the pressure differential is constant, and
sensing pressure + force of spring (1) +force of spring (2) = P port pressure.
Load sensing mechanism
Main flow/excess flow
Pilot flow
Lift spool
Tilt section (2nd spool)
Lift section (1st spool)
Tilt spool
Attachment section (3rd spool)
Inlet section
Attachment spool
LS check valve
Downloaded from www.Manualslib.com manuals search engine
7
9-16
5. Lift UP operation
When the lift lever is pushed to the UP side, solenoid b1 is energized and the solenoid proportional
valve moves to the right. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (k) on the left side, and the lift spool moves to the right side.
The volume of oil that flows to chamber (k) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check, then flows
through part L and chamber 7 to move the lift lock check valve, and then flows to the port C1 and the
bottom of the lift cylinder.
The select valve does not operate at this time, so the select valve becomes simply a check valve.
The pressure differential between chamber (a) and chamber 7 is kept constant by the pressure
compensation mechanism and the load sensing mechanism, so the volume of pressure oil supplied to
port C1 is determined by the opening aperture of part L irrespective of the load.
Lift UP operation (lift section)
Main flow/excess flow
Pilot flow
Inlet section
Load check
Lift logic valve
Tilt section
(a)
Section S-S
Port C1
L
Lift spool
(k)
Logic selection valve
S
S
Spring 5
Solenoid b1
Electromagnetic proportional valve
Downloaded from www.Manualslib.com manuals search engine
Solenoid a1
7
8
10
Electromagnetic proportional valve
9-17
6. Lift DOWN operation
When the lift lever is pushed to the DOWN side, solenoid a1 is energized and the solenoid proportional
valve moves to the left. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (m) on the right side, and the lift spool moves to the left side.
The volume of oil that flows to chamber (m) is proportional to the distance the lever is operated.
The pressure oil from chamber (m) flows through 11 into chamber (o) and shifts the select valve to the
left.
Then the pressure oil operating on port C1 flows through orifice F and enters the select valve.
The circuit is configured with the select valve and chamber (u) connected, so the pressure oil of the
select valve flows through part M and then flows from chamber (g) to the tank.
Accordingly, C1 holding pressure opens the lift lock check valve and the oil flows from C1 to the tank.
Lift DOWN operation (lift section)
Main flow/excess flow
Pilot flow
Lift logic valve
M
Port C1
F
Lift spool
5
Logic selection valve
Spring 6
(o)
11
(m)
(g)
Solenoid a1
Solenoid b1
Electromagnetic proportional valve
Electromagnetic proportional valve
If, due to a malfunction, you want to lower the mast without moving the lift spool, opening the
emergency DOWN valve will configure the circuit as shown in the diagram and the mast will descend.
Lift emergency down (lift section)
Main flow/excess flow
Port C1
Emergency down valve
(g)
Downloaded from www.Manualslib.com manuals search engine
9-18
7. FORWARD tilt operation
When the tilt lever is pushed to the FORWARD side, solenoid a2 is energized and the solenoid
proportional valve moves to the left. Then the pressure oil controlled by the pressure reducing valve
flows to chamber (p) on the right side, and the tilt spool moves to the left side.
The volume of oil that flows to chamber (p) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check, then flows from
port C2 to the bottom of the tilt cylinder.
Pressure oil flowing to chamber (p) enters chamber (n), and shifts the select valve to the left.
The circuit is configured so that oil from the tilt cylinder rod side flows from port C3 through the tilt lock
check valve and chamber (y) to chamber (g).
This generates a pressure differential before and after orifice G, and the shifting of the tilt lock valve to
the right causes the oil on the tilt cylinder rod side to return to the tank.
FORWARD tilt operation (tilt section)
Main flow/excess flow
Pilot flow
Tilt section
Load check
Attachment section
(a)
Section T-T
Port C2
(y)
G
Lift logic valve
Port C3
Tilt spool
Spring 7
Logic selection valve
T
T
(n)
(g)
(p)
Solenoid b2
Electromagnetic proportional valve
Downloaded from www.Manualslib.com manuals search engine
Solenoid a2
Electromagnetic proportional valve
9-19
8. REAR tilt operation
When the tilt lever is pushed to the REAR side, solenoid b2 is energized and the solenoid proportional
valve moves to the right. Then the pressure oil controlled by the pressure reducing valve flows to
chamber (w) on the left side, and the tilt spool moves to the right side.
The volume of oil that flows to chamber (w) is proportional to the distance the lever is operated.
Pressure oil flowing from chamber (a) in the inlet section pushes down the load check and shifts the tilt
lock check valve, then flows from port C3 to the tilt cylinder rod side.
The select valve does not operate at this time, so the select valve becomes simply a check valve.
The pressure differential between chamber (a) and chamber 7 is kept constant by the pressure
compensation mechanism and the load sensing mechanism, so the volume of pressure oil supplied to
port C3 is determined by the opening aperture of part O irrespective of the load.
REAR tilt operation (tilt section)
Main flow/excess flow
Pilot flow
Tilt section
Load check
Attachment section
(a)
Section U-U
O
Port C2
Lift logic valve
Port C3
Tilt spool
Logic selection valve
(w)
U
U
Spring 8
Solenoid b2
Electromagnetic proportional valve
Downloaded from www.Manualslib.com manuals search engine
Solenoid a2
7
Electromagnetic proportional valve
9-20
9. Attachment operation
When you operate the attachment lever, solenoid b3 is energized and the solenoid proportional valve
moves to the left. Then the pressure oil controlled by the pressure reduction valve flows to chamber (r)
on the left side and the spool moves to the right side.
Now the oil from chamber (s) drains out from 10 via the solenoid proportional valve.
The flow of the pressure oil after this is the same as for tilt operation.
Attachment operation (attachment section)
Main flow/excess flow
Pilot flow
Tilt section
Load check
Outlet
Section V-V
Attachment spool
(a)
Port C4
Port C5
(s)
(r)
V
V
Spring 9
Solenoid a3
Solenoid b3
Electromagnetic proportional valve
Downloaded from www.Manualslib.com manuals search engine
10
Electromagnetic proportional valve
9-21
■ Mini Lever Structure
Mini levers strongly desired in the US market are provided as options.
• The material handling levers positioned above the instrument panel on previous models are installed on
the right front side of the seat and the lever stroke and operating force are decreased for easier
operation with less fatigue.
• Since they are single-axis levers independent for the forward and backward directions like the manual
levers on previous models, previous model operators can easily handle new models.
• The automatic fork leveling switch is installed behind the tilt lever. When the button is pressed once, the
operated state is stored mechanically by the lock mechanism in the switch for automatic leveling of the
fork at the time of stopping. Pressing it again releases locking to return to the original state without
automatic leveling. (See the mast control section for further details of the function.)
• The lever box position can be adjusted in the longitudinal direction. Loosen the lever box fixing knob, set
the box in the position desired by the operator, and tighten the knob for fixing.
• Levers are guarded all around.
• Material handling operation is disabled while the operator leaves the seat.
Arm pad
Fork automatic
leveling switch
Tilt lever
Lift lever
Guard
Att lever
Downloaded from www.Manualslib.com manuals search engine
9-22
■ Armrest Structure
• An armrest is provided for alleviating the right arm fatigue during traveling and material handling lever
operation.
• The arm pad to be in contact with the arm and palm are made of soft urethane foam to fit the arm and
palm softly.
• The armrest is fixed on the battery hood to be independent from seat sliding operation. A tall operator
with long arms and legs can obtain the best operating position by sliding the seat backward, and an
operator with short arms and legs by sliding the seat forward.
• The armrest height can be adjusted. Loosen the armrest fixing knob, set the armrest at the desired
height and tighten the knob again.
• Every operator can select the best position for lever operation.
Driver’s position
Large operator
Medium operator
Small operator
Armrest fixing knob
Front-to-rear adjusting knob
Downloaded from www.Manualslib.com manuals search engine
Height adjusting knob
9-23
BATTERY ROLL-OUT SPECIFICATION
■ General
• Provided for all models.
■ Structure
Battery roll-out vehicles have different frame structure from the standard vehicle as they replace battery
from the RH side.
The batteries are the same as those for standard vehicles.
The following indicate main structure:
A
Battery stopper
Part A
Metal roller guide and rollers can be installed under the battery. They enable battery replacement with
ease without using the tool.
Roller guide (steel)
Rollers
FR
RH
Downloaded from www.Manualslib.com manuals search engine
9-24
■ Battery replacement procedure
Follow the steps below when removing the battery:
(1) Open the battery hood.
(2) Raise the battery stopper to unlock.
(3) Turn the battery stopper. Slide the battery to remove it.
Installation procedure is the reverse of the removal procedure.
Open/close the battery hood following the same steps as the standard vehicle.
(1)
(3)
(2)
Downloaded from www.Manualslib.com manuals search engine
10-1
APPENDIX
Page
CAUTIONS FOR RECEIVING ORDERS................... 10-2
MAJOR SPECIFICATIONS .......................................... 10-3
2
3
FRAME NUMBER ........................................................... 10-5
TWO-PLANE DRAWING OF THE VEHICLE ........... 10-6
ELECTRIC WIRING DIAGRAM (VEHICLE
INSTALLED WITH OPTIONAL PARTS) ................ 10-9
10
Downloaded from www.Manualslib.com manuals search engine
10-2
CAUTIONS FOR RECEIVING ORDERS
■ Cautions for selling forklifts to customers in the marine product industry
1. Selling the standard vehicles to customers who handle fresh fish, pickles or tanned hides involving
possible salt water splashing onto vehicles may result in troubles of electrical parts such as motors.
Please sell the fisherman specification vehicles to a customer whose working conditions apply to any
of the following:
Conditions
• Transportation of salty or other water tanks involving possible water splashing onto the vehicle
• Vehicle being washed with salty water after the operation
• For use in an environment where the ground surface is constantly wet with salty water
• For use in an environment where the vehicle is possibly wetted with oxidizing fluid (such as
hydrogen peroxide or sodium hypochlorite)
• For use in an environment where calcium chloride or other snow-melting agent is used
2. Attention should be paid for use in such industrial sectors as marine product processing, pickling,
leather tanning and fertilizer production.
■ Cautions for Vehicle Modification
1. Note
These forklifts use high-precision electronic devices. It is, therefore, necessary to pay sufficient
attention to prevent adverse influence on electronic devices when any auxiliary electric equipment not
specified by the manufacturer is to be installed.
2. Caution
When selecting any auxiliary electric equipment of other than the specified manufacturers for
installation on your forklift, check for abnormal surge* or noise generation beforehand and also pay
attention to the installation method.
If it is unknown whether the auxiliary equipment generates any surge, please consult with the auxiliary
equipment manufacturer.
*: Surge refers to local application of a high voltage instantaneously in a part of an electrical circuit due
to a sudden change in the current flowing in the circuit.
3. Other general supplementary advice
(1) Precautions for each type of auxiliary electric equipment are as follows:
1) Auxiliary equipment with built-in inductive load such as a motor or solenoid
Connect a reflux diode across the inductive load.
Connect a surge absorber across the ON/OFF switch.
2) Auxiliary equipment such as a buzzer or chime that generates sound
Use an electronic buzzer instead of a contact-type buzzer or chime.
3) Auxiliary equipment including a high voltage discharge circuit such as an igniter
Since this type is likely to generate a noise, always install after confirming no noise generation.
(2) Precautions about wiring are as follows:
1) Lay the harness for the auxiliary equipment as far from each vehicle harness as possible.
2) Do not branch a power or signal line from any portion in the vehicle harnesses. Connect the
power line for example from an option connector terminal or directly from the battery terminal.
3) The power supply for auxiliary equipment should be provided independently if possible.
(3) Others
1) Install the static straps when installing the non-marking or smooth non-marking tires.
Downloaded from www.Manualslib.com manuals search engine
10-3
MAJOR SPECIFICATIONS
7FBEF15, 7FBEF16
Vehicle model
Item
Standard lifting height
Free lift
Mast tilt angle
Overall length
Forward / Backward
Body length (to the front of fork)
Main
dimensions
Total width
Total
height
Mast raised
Mast lowered
Wheel base
Tread
Front wheel
Rear wheel
Ground clearance
Vehicle weight (without battery)
Minimum turning radius
Rated load
Load center
Performance
Traveling speed
No load
(forward)
Load
Traveling speed
No load
(reverse)
Load
Raising speed
Lowering
speed
Travel
device
Tire size
No load
Load
No load
Load
Front wheel
Rear wheel
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
kg (lbs)
mm (in)
kg
mm (in)
km/h (mph)
km/h (mph)
km/h (mph)
km/h (mph)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)
Foot brake
Parking brake
Battery (STD)
Battery (High)
Drive
unit
mm (in)
mm (in)
Drive motor
Pump motor
Voltage
Capacity
Voltage
Capacity
Type
Output
Control device
Type
Output
Control device
Downloaded from www.Manualslib.com manuals search engine
V
Ah/5HR
V
Ah/5HR
kW
kW
7FBEF15
3000 (118)
7FBEF16
3000 (118)
150 (5.9)
5 / 6.5
2695 (106.1)
150 (5.9)
5 / 6.5
2795 (110.0)
1895 (74.6)
1995 (78.5)
1070 (42.1)
1070 (42.1)
3920 (154)
3920 (154)
1980 (78)
1980 (78)
1400 (55.1)
1505 (59.3)
915 (36.0)
915 (36.0)
175 (6.9)
175 (6.9)
85 (3.3)
85 (3.3)
1885 (4156)
1775 (3914)
1540 (60.6)
1640 (64.6)
1500
1600
500 (24)
500 (24)
16.5 (10.2)
16.0 (9.9)
15.0 (9.3)
15.0 (9.3)
16.5 (10.2)
16.0 (9.9)
15.0 (9.3)
15.0 (9.3)
610 (120)
610 (120)
430 (85)
420 (83)
550 (108)
550 (108)
500 (98)
18×7−8/4.33
15×4.1/2-8/3.00
Mechanical
Manual
48
550
48
600
AC induction type
4.9×2
Transistor inverter
AC induction type
9.2
Transistor inverter
500 (98)
18×7−8/4.33
15×4.1/2-8/3.00
Mechanical
Manual
48
660
48
720
AC induction type
4.9×2
Transistor inverter
AC induction type
9.2
Transistor inverter
2
3
10
10-4
7FBEF18, 7FBEF20
Vehicle model
Item
Standard lifting height
Free lift
Mast tilt angle
Overall length
Forward / Backward
Body length (to the front of fork)
Main
dimensions
Total width
Total
height
Mast raised
Mast lowered
Wheel base
Tread
Front wheel
Rear wheel
Ground clearance
Vehicle weight (without battery)
Minimum turning radius
Rated load
Load center
Performance
Traveling speed
No load
(forward)
Load
Traveling speed
No load
(reverse)
Raising speed
Lowering
speed
Travel
device
Tire size
Load
No load
Load
No load
Load
Front wheel
Rear wheel
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
kg (lbs)
mm (in)
kg (lbs)
mm (in)
km/h (mph)
km/h (mph)
km/h (mph)
km/h (mph)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)
mm/s (fpm)
Foot brake
Parking brake
Battery (STD)
Battery (High)
Drive
unit
mm (in)
mm (in)
Drive motor
Pump motor
Voltage
Capacity
Voltage
Capacity
Type
Output
Control device
Type
Output
Control device
Downloaded from www.Manualslib.com manuals search engine
V
Ah/5HR
V
Ah/5HR
kW
kW
7FBEF18
3000 (118)
7FBEF20
3000 (119.5)
150 (5.9)
5 / 6.5
2800 (110.2)
125 (4.9)
5 / 6.5
3080 (121.3)
2000 (78.7)
2080 (81.9)
1070 (42.1)
1125 (44.3)
3920 (154)
3920 (154)
1980 (78)
1980 (78)
1505 (59.3)
1505 (59.3)
915 (36.0)
915 (36.0)
175 (6.9)
205 (8.1)
85 (3.3)
85 (3.3)
1895 (4178)
2215 (4884)
1645 (64.8)
1710 (67.3)
1750
2000
500 (24)
500 (24)
16.0 (9.9)
15.5 (9.6)
14.5 (9.0)
14.0 (8.7)
16.0 (9.9)
15.5 (9.6)
14.5 (9.0)
14.0 (8.7)
610 (120)
500 (98)
390 (77)
340 (67)
550 (108)
500 (98)
500 (98)
18×7−8/4.33
15×4.1/2-8/3.00
Mechanical
Manual
48
660
48
720
AC induction type
4.9×2
Transistor inverter
AC induction type
9.2
Transistor inverter
500 (98)
200/50-10/6.50
16×6-8/4.33
Mechanical
Manual
48
660
48
720
AC induction type
4.9×2
Transistor inverter
AC induction type
9.2
Transistor inverter
10-5
FRAME NUMBER
■ Frame number punching location
2
3
Frame No. punching
position
■ Frame number punching format
Vehicle Model
Punching format
Vehicle Model
Punching format
7FBEF15
7FBEF15 10011
7FBEF16 to 20
7FBEF20 10011
Downloaded from www.Manualslib.com manuals search engine
10
10-6
E
H
D
C
B
A
TWO-PLANE DRAWING OF THE VEHICLE
F
G
Fr
Rr
T
L
M
R
K
J
I
S
P
N
Downloaded from www.Manualslib.com manuals search engine
Q
O
10-7
mm (in)
Position
Vehicle model
7FBEF15
7FBEF16
7FBEF18
7FBEF20
A
1070 (42.1)
1070 (42.1)
1070 (42.1)
1125 (44.3)
B
900 (35.4)
900 (35.4)
900 (35.4)
990 (39.0)
C
915 (36.0)
915 (36.0)
915 (36.0)
915 (36.0)
D
180 (7.1)
180 (7.1)
180 (7.1)
225 (8.9)
E
80 (3.1)
80 (3.1)
80 (3.1)
100 (3.9)
F
1670 (65.7)
1720 (67.7)
1730 (68.1)
1825 (71.9)
G
1540 (60.1)
1640 (64.6)
1645 (64.8)
1710 (67.3)
H
175 (6.9)
175 (6.9)
175 (6.9)
205 (8.1)
I
3920 (154.3)
3920 (154.3)
3920 (154.3)
3920 (154.3)
J
3000 (118)
3000 (118)
3000 (118)
3000 (118)
K
1970 (77.6)
1970 (77.6)
1970 (77.6)
1970 (77.6)
L
150 (5.9)
150 (5.9)
150 (5.9)
125 (4.9)
M
40 (1.6)
40 (1.6)
40 (1.6)
40 (1.6)
N
800 (31.5)
800 (31.5)
800 (31.5)
1000 (39.4)
O
1895 (74.6)
1995 (78.5)
2000 (78.7)
2080 (81.9)
P
355 (14.0)
355 (14.0)
355 (14.0)
370 (14.6)
Q
1400 (55.1)
1505 (59.3)
1505 (59.3)
1505 (59.3)
R
1980 (78)
1980 (78)
1980 (78)
1980 (78)
S
5°
5°
5°
5°
T
6.5°
6.5°
6.5°
6.5°
Downloaded from www.Manualslib.com manuals search engine
10-8
Downloaded from www.Manualslib.com manuals search engine
10-9
ELECTRIC WIRING DIAGRAM (VEHICLE INSTALLED WITH OPTIONAL PARTS)
CPR
(P2,G)
F6
MB
P2
ACCEL
VRAD
P3
F1
-
SW AC
P1
+
TILT
VRAT
SW K
F5
(41,BR)
F4
(101,Y)
-
VRAL1
+
-
LIFT
LEVER
VRAL2
+ -
TILT
LEVER
VRAT2
VRAT1
+
-
+ -
ATT1
LEVER
VRAAT12
VRAAT11
+
-
+ -
ATT2
LEVER
VRAAT22
VRAAT21
+
-
+ -
SW MH1
SW TK DS F DS R
LS B
LS PB LS D
+
SPL
OPTO
MH1
D15V
(91,GR)
(90,O)
MH2-1
GNDD
LSL+
LSTF+
LSTR+
LSAT2+
LSAT1+
(67,L)
(66,R)
LSD
LSPB
SWLE
(45,W)
(65,Y-G)
(46,G-Y)
DSR
LSB
(70,BR)
DSF
SWTK
(31,P)
(27,Y-G)
(51,R-L)
LS-
LEDTK
POTAT22
POTAT21
POTAT2+
(30,O)
(26,B-Y)
(25,G-W)
POTAT1+
(24,P-W)
POTAT12
(23,B-R)
(29,W-R)
POTAT11
(28,B-W)
(22,G-R)
POTT2
POTT+
P16
L F-R
(81,B-W)
(80,BR)
(79,G-R)
(88,W-G)
TD2+
SSD22
SSD21
SSD2+
CANL
CANH
CANTRD
CANGND
KEYSTART
CUDID1
CUDON
SSD2
P71
(U)
P81
STMD1
(V)
P9
(W)
CUP
AMD1
SSD2-,TD2-
P8
(V)
CUDID0
(82,P)
(77,B-W)
SSD12
SSD11
(76,BR)
(75,G-R)
(87,W-G)
TD1+
SSD1+
CANGND
CANL
CANH
SSD1
P7
(U)
STMP
STMD2
P91
(W)
CUD1 (LH)
AMD2
(W)
CUD2 (RH)
N2
N1
N1
FAN, EXHAUST, CONTROL UNIT
MB
CONTACTOR, BATTERY
VRAD
VARI-OHM, ACCEL, DRIVE
VRAT
VARI-OHM, TILT
DS F
DIRECTION SWITCH, FORWARD
VRAH
VARI-OHM, TIRE(HANDLE)
DS R
DIRECTION SWITCH, REVERSE
DS FO
DIRECTION SWITCH, FORWARD OPTIONAL
MSCH STT
SLL
GNDD
AC-R
+15V
AC-S
LS L
LS TF
LS TR
SMTDK
SDTMK
LCD
DISP
LS AT1 LS AT2
SDTMA
LAMP, STOP LH
SOLL
SOLENOID, LIFT
SWL
SWITCH, LIGHT
L ST-R
LAMP, STOP RH
SOLT
SOLENOID, TILT
CPR
RESISTOR, CURRENT PROTECT
SWF
SWITCH, FLASHER
SOLLa1
SOLENOID, LIFT, a1(DOWN)
RT
TERMINATING RESISTANCE
SWH
SWITCH, HORN
L BU-R
LAMP, BACK-UP RH
SOLLb1
SOLENOID, LIFT, b1(UP)
SST
SENSOR, STEERING
SWTK
SWITCH, TILT KNOB
HR Y
RELAY, HEAD LAMP
SOLTa2
SOLENOID, TILT, a2(FRONT)
SPL
SENSOR, PRESSURE LIFT
SWMH1
SWITCH, HEIGHT NO.1
TR Y
RELAY, TAIL LAMP
SOLTb2
SOLENOID, TILT, b2(REAR)
SOLATa3
SOLENOID, ATTACHMENT, a3
SSD1
SENSOR, SPEED, DRIVE 1
L H-L
LAMP, HEAD LH
BZ
BUZZER
SOLATb3
SOLENOID, ATTACHMENT, b3
SSD2
SENSOR, SPEED, DRIVE 2
L H-R
LAMP, HEAD RH
SOLATa4
SOLENOID, ATTACHMENT, a4
SSP
SENSOR, SPEED, PUMP
L C-L
LAMP, CLEARANCE LH
SA
SURGE ABSOBER
SOLATb4
SOLENOID, ATTACHMENT, b4
STMD1
SENSOR, TEMPRETURE, DRIVE 1
L C-R
LAMP, CLEARANCE RH
H
HORN
SOLP
SOLENOID, PRESSUR
STMD2
SENSOR, TEMPRETURE, DRIVE 2
L T-L
LAMP, TAIL LH
FR Y
RELAY, FLASHER
STMP
SENSOR, TEMPRETURE, PUMP
L T-R
LAMP, TAIL RH
LSAT1
CHGLED4
CHGLED3
CHGLED2
CHGLED1
CHGSW3
CHGSW2
POTL2
POTL+
POTT2
POTT+
POTAT12
POTAT1+
POTAT21
POTAT22
POTAT2+
LSAT2+
SOLP-
L ST-L
SOLb4
LAMP, FLASHER RH
SWITCH, KEY
SOLP+
L F-R
SWK
SOLa4
SWITCH, ACCEL
PRINT BOARD, COMPUTER
SOLb3
SWAC
PB CPU
SOL4+
CONTROL UNIT, PUMP
SOLENOID, STEERING
PB CPU
SOLa3
CU P
SOLST
LSL+
LS-
CONTROL UNIT, DRIVE 2
SOLL+
CU D2
FOR D2 PEDAL
51(R-Y)
43(B-Y)
(4,B-R)
MOTOR, PUMP
(3,W-R)
AM P
N1
48V
(63,P-W)
LAMP, FLASHER LH
CONTROL UNIT, DRIVE 1
LSAT1+
LAMP, FLASHER RH (REAR)
L F-L
CU D1
SOL3+
LAMP, FLASHER LH (REAR)
L F-RR
MOTOR, DRIVE 2
(63,P-W)
LAMP, WORKING
L F-LR
LIMIT SWITCH, DEADMAN
AM D2
(62,B-R)
LW
LIMIT SWITCH, PARKING BRAKE
LS D
MOTOR, DRIVE 1
(62,B-R)
LIMIT SWITCH, BRAKE
LS PB
AM D1
(61,G-R)
LS B
LSTF
VARI-OHM, ATTACHMENT2, NO.2
LCD DISPLAY
LSTR
LIMIT SWITCH, STOP LAMP
VRAAT22
LCD DISP
LSTR+
LIMIT SWITCH, ATTACHMENT NO2
LS ST
SOLa1
LIMIT SWITCH, ATTACHMENT NO1
LS AT2
VARI-OHM, ATTACHMENT2, NO.1
SOLb2
LIMIT SWITCH, TILT RR
LS AT1
VARI-OHM, ATTACHMENT1, NO.2
VRAAT21
SOLT-
LS TR
VARI-OHM, ATTACHMENT1, NO.1
VRAAT12
SOL L
(7,B-G)
VARI-OHM, TILT, NO.2
VRAAT11
FUSE, FAN&SOLENOID
(61,G-R)
VRAT2
FUSE, CONTROL CIRCUIT
F6
LSTF+
FUSE, LAMP
F5
SOLT+
F4
NOTE)
THIS DRAWING SHOWS
CASE OF FULL OPTION.
(6,R-G)
LIMIT SWITCH, TILT FR
(60,W-G)
LIMIT SWITCH, LIFT
LS TF
(60,W-G)
DIRECTION SWITCH, BACK-UP
LS L
VARI-OHM, TILT, NO.1
LSL
DS BU
VARI-OHM, LIFT, NO.2
VRAT1
SOLL-
VARI-OHM, LIFT, NO.1
VRAL2
FUSE, DRIVE
(51,R-Y)
VRAL1
BATTERY
F1
CHGSW1
SMTDA
BATT
Downloaded from www.Manualslib.com manuals search engine
N1
FOR STD(MINI LEVER LESS)
FANEX
DS BU
DS FO
DS F
DS R
SOL T
103(R-W)
120(Y-R)
45(W)
46(G-Y)
SMTDA
SDTMA
SDTMK
SMTDK
SOL P
R
(141,W-R)
(16,R)
(14,B-W)
(142,R-B)
(143,R-G)
(144,G-R)
FANR-
FANR+
SOLP-
SOLP+
(13,R-Y)
SOLb4
(12,P)
(36,G-W)
SOLa4
SOLb3
SOL4+
(35,B-L)
(34,G-Y)
(11,G-B)
SOLa3
SOLb2
SOL3+
(10,R-L)
SOLa2
(8,P-G)
(7,B-G)
(9,Y-B)
SOLa1
SOL2+
SOLb1
(5,Y)
(6,R-G)
SOL1+
(4,B-R)
(3,W-R)
(330,GR)
SOLST-
SOLST+
(329,B-O)
LS-
(51,R-L)
STSC
STS2
STS1
CUDON
CUDID0
(78,P)
AMP
(V)
SSD1-,TD1-
P15
CUDID1
(U)
CANTRD
P14
H
KEYSTART
(84,W-R)
(85,R-L)
SSP
SSP2
SSP1
(83,B-R)
(86,P-G)
(89,Y-G)
TP+
SSP+
CANL
CANH
SSP-,TP-
CUPON
CUPID1
-RR
KEYSTART
-LR
CUPID0
BZ
LF
CANTRP
(108,R-Y)
(109,G-Y)
-R
L F-L
SOL Ta2 SOL Tb2 SOL ATa3 SOL ATb3 SOL ATa4 SOL ATb4
SWF
L BU
LF
SOL La1
RT
CANGND
SA
SOL Lb1
SOL ST
(120,Y-R)
(103,R-W)
(110,GR)
SWH
(314,L)
(312,G-W)
SST
VRAH
TIRE ANGLE
FR Y
(313,R-Y)
(316,R-Y)
(317,G-Y)
(51,R-W)
POT-
POTH
POTH+
CANGND
CANL
(147,Y)
(146,W)
CANH
KEYSTART
FAN(39,B)
(42,GR)
(145,B)
FAN6
FAN4
FAN5
(135,Y)
(134,Y)
(133,Y)
FAN3
(132,Y)
-R
FAN
FAN
EX
EX
(48,P)
POTT1
(57,L)
(21,P-G)
POTL2
POTL+
(20,W-G)
POTL1
(56,G)
(51,R-L)
POT-
(58,BR)
POTTA
(59,Y-R)
SPL
SPL+
(52,GR)
(53,R-G)
POTA
POTA+
(2,R)
(1,V)
(64,R)
(51,R-W)
MB-
MB+
POT-
SWAC
CPR
(18,O)
(55,W-G)
(44,Y-G)
(44,Y-G)
B48V
(41,BR)
-L
L ST
FAN2
L ST
LW
(39,Y)
L H-R
(131,Y)
L H-L
L T-R
(N2,W-B)
L T-L
L C-R
FAN-
N2
L C-L
FAN1
N2
DS FO
(130,Y)
(111,R-L)
(107,R-B)
(102,R-G)
(104,G-R)
PB CPU
DS BU
+
BATT
48V
HM
POTTA+
HS
VBBT
VBKY
SWL
T
VBMB
(115,P)
SWL
-
(116,LG)
LS ST
HR Y
VBMB
TR Y
(43,B-Y)
+
MB
-
(P1,B)
Published by
TOYOTA Material Handling Company
A Division of TOYOTA INDUSTRIES CORPORATION
1st Printing: May 2003
Pub. No. CE335-CD
Printed in JAPAN
I
Downloaded from www.Manualslib.com manuals search engine