@ TOYOTA REPAIR MANUAL 7FBR 10, 13, 15, 18 "(0 ay,FOREWORD This Manual (Volume 2) contains diagnostics service procedures of electrical controller of the TOYOTA ELECTRIC POWERED FORKLIFT 7FBR10 to 18. For maintenance, specifications and repair procedures for the chassis, body and material handling system, refer to Volume 1 (Pub. No. CE318-2) Please use these manuals for providing quick, correct servicing of the corr- sponding forklift models. This manual deals with the above models as of February 2001. Please under- stand that disagreement can take place between the descriptions in the man- ual and. actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. TOYOTA Material Handling Company |ADselon of TOYOTA INDUSTRIES CORPORATIONSECTION INDEX | NAME SECTION _ GENERAL oo | o | BATTERY oe [ CHARGER _ Ea [CONTROLLER Ea _ MULTI-DISPLAY FUNCTIONS | Em TROUBLESHOOTING = [| MOTOR | DRIVE UNIT SUSPENSION & CASTER WHEEL = ee | STEERING | FRONT BRAKE & AXLE REAR BRAKE | BODY MATERIAL HANDLING SYSTEM _ MAST _CYLINDER [ OIL PUMP OIL CONTROL VALVE HYDRAULIC PIPING __ ; | TBC-EPS MULTIFUNCTION LEVER APPENDIX | 21 |GENERAL Page EXTERIOR VIEW... VEHICLE MODELS FRAME NUMBER. OPERATING TIP: GENERAL INSTRUCTIONS... JACKING UP... HOISTING THE VEHICLI WIRE ROPE SUSPENSION ANGLE LIST. SAFE LOAD FOR EACH WIRE ROPE ‘SUSPENSION ANGLE.. TOWING THE VEHICLE.. ELECTRICAL PARTS INSPECTION.. 0-9 0-402 EXTERIOR VIEW0-3 VEHICLE MODELS Batery 31 Tifing height cet for each mast mast standard Model | Controt method | vottage| Quantity | “iting v sv Fv Fsv () |@HSHR)| eign | (om) (om) (rm) (oom) _\ (mm) TFBR10 | Microcomputer] 48 | 201 | 3000 [25000 5000/ 2500 to 5000 [2500 to 4000] 3700 to 6000] 7B || 7FERtS | Microcomputer] 48 | 201 | 3000 [2500 10 6000] 2500 1o 6000 | 2500 to 4000 3700 to 6000 eres |! 7FBRI15 | Microcomputer! 48 280 3000 | 2500 to 6000 | 2500 to 5000 | 2500 to 4000 3700 to 6000 TFBR16 | Microcomputer] 48 | 280 | 3000 | 2500 0 5000| 2500 to 5000| 2500 to 4000] 3700 to 6000 FRAME NUMBER Payload (ton)| Veh | punching format Punching position 1.0 TFBR10 | 7FBR10-10011 1.25 7FBR13 7FBR13-10011 15 7FBRIS | 7FBR15-10011 18 TFBR18 7FBR18-10011 Frame No. punching postion0-4 OPERATING TIPS GENERAL INSTRUCTIONS 1 Skillful oper (1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation. (2) Check the cable color and wiring state before disconnecting any wiring. (3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting a precision part such as the control valve, use clean tools and operate in a clean location. (6) Follow the specified procedures for disassembly, inspection and reassembly. (6) Always replace gaskets, packing, O-rings, self-locking nuts and cotterpins with new ones each time they are disassembled, (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the "standard tightening torque table". Protection of functional parts (battery-operated vehicles) (1). Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection. Failure or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers. Defect status check Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect. Waste fluid disposal Always use a proper container when draining waste fluid from the vehicle, Careless discharge of oll, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposalJACKING UP ‘Always observe the following instructions when jacking up the vehicle: + When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an xd or rough surface. + Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous. + Always support the load of jacked-up vehicle with wooden blocks at specified points. ‘Supporting the vehicle with the jack only is very dangerous. + Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle. = By) gem ‘Wooden stand points06 HOISTING THE VEHICLE ‘When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist by any other attachment section as it is very dangerous.0-7 WIRE ROPE SUSPENSION ANGLE LIST Se=p=n="T Tension [Compression] SWEParsen [SHRPETSON| Tension | Compression | SUeDETON 0° |1.00time} —otime so |14ttime| .008me | | 9 | 30 30° | 1.04time} 0.27 time |. 120° |2.00time | 1.73 time oe 3 a | Pe zr | 60° [1.16 time} 0.58 time om s \ SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit:N (ton:tf) Single-rope Rope diameter Cutng suspension ‘Two-rope suspension Four-rope suspension mm loa oe oO | 3] 6] 9] oO | 30] 6] oO a 21380 | 3040 | 6080 | 5880 | 6200 | 4310 | 12160 | 71770 | 10400 | 8630 (2.18) | (0.31) | (0.62) | (0.60) | (0.53) | (0.44) | (1.24) | (1.20) | (1.06) | (0.88) e 31480 | 4410 | 6830 | 8530 | 7650 | 6280 | 17650 | 17060 | 18300 | 12560 (3.21) | (0.45) | (0.90) | (0.87) | (0.78) | (0.64) | (1.80) | (1.74) | (1.56) | (1.28) 10 49230 | 6960 | 14020 | 13440 | 11770 | 9810 | 27460 | 26480 | 23540 | 19610 (6.02) | (0.71) _| (1.43) | (1.38) | (4.20) | (4.00) | (2.80) | (2.70) | (2.40) | (2.00) ae 76880 | 10980 | 21570 | 21280 | 18630 | 14710 | 43150 | 41190 | 37270 | 2420 (784) | (1.12) | (2.20) | (2.10) | (4.90) | (4.50) | (4.40) | (4.20) | (3.80) | (3.00) a ‘96400 | 13730 _ | 27460 | 26480 | 23640 | 18630 | 54920 | 52960 | 47070 | 37270 (9.83) (1.40) (2.80) | (2.70) (2.40) | (1.90) | (5.60) | (5.40) | (4.80) | (3.80)0-8 Components weights Unit: kg Member Weight ayy [7FBR10-13 340 | TFERI5-16 465 Drive motor ASSY 2 7FER10.13 28 eee 7FBRI5.18 305 [Drive unit ASSY Wdrive wheel ‘7FBR10-18 ‘Approx. 90 Mast ASSY 7FBR10-13 “Approx. 350 Lilift bracket & fork 7FBR15-18 ‘Approx. 360 7FBR1O 2030 Vehicle weight Pesta Laced 7FBRI5 2190 [Zeer en e227 |TOWING THE VEHICLE Tow the vehicle as follows in case of a failure or for loading onto a truck: + In the case of STD vehicle, tow it using the hole in the frame rear guard. + In the case of a vehicle with a bumper weight, tow it using the tapped hole (M12 x 1.25) at the bumper weight. Note: As a rule, do not tow a reach type vehicle. If it is unavoidable, keep the towing distance within the minimum required range. sTD “Toke an action without damaging the costed surtace SST 09510-13000-71 (Up t02001.4) Hole for towing (from 2001.5) ‘WiRear bumper weight without damaging the coated sutace. ® PP vossnssr0070-10 ELECTRICAL PARTS INSPECTION 1. Always disconnect the battery plug before inspecting or servicing electrical parts. 2. Pay sufficient attention when handling electronic parts. a) @) @) Never subject to electronic parts, such as computers and relays, to impact. Never expose electronic parts to high temperature or moisture. Do not touch connector terminals, as they may be deformed or damaged due to static electricity 3. Use a circuit tester that matches the object and purpose of measurement. Analog type: This type is convenient for observing movement during operation and the operating condition. The measured value should be used only for reference or rough judgement. Digital type: movement. A fairly accurate reading is possible. However, it is ficult to observe operation or (1) Difference between results of measurement with analog and digital types * The results of measurements using the analog type and the digital type may be different. Use the circuit tester according to its instruction manual. Differences between the polarities of the analog type and the digital type are described below. 1) Analog circuit tester Reverse Foward Red fester probe Red tester probe Example of measurement result Tester range:k® range Forward direction:Continuity 11 k2 Reverse direction:No continuity 2) Digital circuit tester Forward Reverse —) Ike Black Black teste tester tester Probe] 1 @] |pmbe probe ee Example of measurement result Tester range:2 MQ range Forward direction:Continuity 2 MQ Red | Reverse direction:No continuity 1 probe|CHARGER GENERAL ... ON-VEHICLE CHARGER APPLICABLE CHARGER LIST... SPECIFICATIONS. COMPONENTS.. WIRING DIAGRAM. BEFORE CHARGING TAP CHANGER .. CHARGER PANEL ASSY... TRANSFORMER ASSY... TIMER TEST... TROUBLESHOOTING. OFF-VEHICLE CHARGER APPLICABLE CHARGER LIST GENERAL (GS) .. SPECIFICATIONS. WIRING DIAGRAM BEFORE CHARGING DISASSEMBLY -INSPECTION-REASSEMBLY, SERVICE STANDARDS .. TIMER TEST... TROUBLESHOOTING. 2122 GENERAL A fully automatic microcomputer-controlled on-vehicle charger (OPT) and a fully automatic microcom- puter-controlled off-vehicle charger (OPT) are provided. The on-vehicle charger is not provided on cold storage models. This manual explains mainly the on-vehicle charger. ON-VEHICLE CHARGER ‘Transformer ~\ | Maanete ote _ (Charger operation pane! APPLICABLE CHARGER LIST ‘Applicable vvehicle mode! riz|zl7 Flr Fle Power supp] 8} 5 | 8 | 8 | Transformer eapacty| Battery | Applicable capacty| capaciy |R|R|R|R Transformer madet | Power supply voltage | (50/60 Hz) votage (aise) (oreo He) | 10] 13] 15] 18 TRazec | 2000 2mRT ev 20110225 rion [O[O TRas120 | a 3636 7 28010312 THEA OO TRAG7OC a 45145 7 370 18iBA OOSPECIFICATIONS a Transformer model TRAC Type FW Magnetic ‘switch Rang aon Thermal setting TA Transformer ~~ | Capacity 50/60 Hz 2.7/2.7 KVA (TF) Insulation Type H Diode (Och) Type PT76S8A Fuse (Feh) (Capacity 40A 250V tom Transformer model TRAST2C ; Type FOS Magnetic switch Rating aan Thermal setting 13A ‘Transformer ‘Capacity 50/60 Hz 3.6/3.6 KVA (TF) Insulation Type H Diode (Deh) Type PT100S8 Fuse (Fch) Capacity BOA 250V item Transformer model TRAS7OC Type PWS ae a Rating 26A Thermal setting 2A [Transformer (Capacity 50/60 Hz 4.5/4.5 KVA (TF) insulation ‘Type H Diode (Dechy Type PEGOEN,PFOOEN Fuse (Fch) Capacity GOA 250V24 COMPONENTS 2511 2511-07025 WIRING DIAGRAM © TAP LAYOUT BOXex Ln Traveling / material handling IT DISPLAY controller jones, sok zy 2i0v 20v z0v 2i0v zo0v 210v rv ' , , one 20 2i0v 20v z0v 2i0v 200v 220v 2i0v 200 Primary Secondary -26 BEFORE CHARGING Ifthe ampere capacity at the charging location is insufficient because other electrical appliances are being used, ask an electrical work contractor to provide an exclusive circuit for the charger. See the "On-vehicle charger ls | | r (P2-2) for the AC power supply capacity. TAP CHANGER 1. Measure the power supply voltage to be used for charging. Tester range: AC (250 or 1000 V) Note: Measure the power supply voltage at night (or, if that is impossible, during a time when electrical appliances are not being operated). Set the tap changer. (1). Disconnect the battery plug. (2) Remove the tap cover of each phase corresponding to the power supply voltage measured in step 1 above, (3) Change the taps, (4) Connect the charger to the power supply outlet and Note: press the NORMAL button. (8)_Measure the voltage between the set taps. Tap Measured voltage 200V 799 V or less 210V 200 t0 208 V 220V 210 to 219V + Taps are set to 220 V at the time of shipment. + Be sure to set the tap changer for phases U, V and W. + For about a week after tap changer setting, keep track of the battery charging state (specific gravity and electrolyte level) to make sure the tap setting is appropriate.CHARGER PANEL ASSY REMOVAL - INSTALLATION Removal Procedure 1 Disconnect the battery plug. 2 Disconnect CN61, CN65 and CN68. 3. Remove the charger panel ASSY. Installation Procedure The installation procedure is the reverse of the removal procedure.28 DISASSEMBLY - INSPECTION-REASSEMBLY Disassembly Procedure 1 Remove the charger operation panel ASSY. [Point 1] 2. Remove the plug. 3 Remove the magnetic switch ASSY. [Point 2] Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.Point Operations 29 uP LED NORMAL LED. [Point 1] inspection: Inspect each button in the ON and OFF positions (CN68) Measurement Toy | oFr | ser terminals range NORMAL |” Between aa ~ button 2ands Bal EQUAL Between aa * button 3and 8 a Inspection: Inspect the applied voltage of the LED at CN70 of the display. (CN68 must be connected.) During charging | Charging stopped on (LED on) (LED off) Tester range S Between 9 and 30 EQUALLED| (between Y-B and BR) 5v ov owe NORMAL Between 10 and 30 a 7 LED (between Y-G and BR) Upon end of test | Other state on70 mode (LED on) (LED off) Tester range Between 11 and 30 UP LED (between Y-W and BR) oy ov 40,voCTest switch | Reset switch Reset switch 96 95 6 95 —o | o— Not operating Operating [Point 2] Inspection Inspect the magnetic switch contact continuity. Tester range Oxt Measurement terminals TW, $-V and R-U ey eM ScHION __ 0a MSch OFF ao Inspection Inspect the magnetic switch coil continuity. ‘Tester range ont Measurement terminals AVAZ FWOS 7,300 Standard FW-O 7,300.9 “| FWaAS 5008 Inspection: Inspect the thermal relay contact continuity. Tester range ‘Oxt ‘Measurement terminals 95-96 | Not operating oa Standard a Operating ea Inspection: Inspect the reset switch, Check that the thermal relay is deactivated upon pressing the reset switch while the thermal relay is activated Do not adjust the thermal relay operating current. If charging stops due to thermal relay activation while the charger is in use, always check the thermal relay activating cause and reset after taking corrective action. Press the reset switch lightly to reset the thermal relay. * To test the thermal relay, set the activation state as follows: FW-0S, FW-0: Pull the reset switch. FW-18: Use a thin screwdriver to move the reset switch to the left.2 TRANSFORMER ASSY REMOVAL - INSPECTION: INSTALLATION T=Nem (kgf-cm) [ft-lbf] Le a) Chae T=1322 (19020) [94214] Removal Procedure Disconnect the battery plug Remove the steering wheel and instrument panel. Disconnect CN61 and pull the hamess out. Disconnect the N1 terminal and pull the cable out. [Point 1] Disconnect the P1 terminal. Disconnect the rear speed sensor connecters Remove the transformer ASSY set bolts. Remove the transformer ASSY by hoisting it. [Point 2] @VYoOHroOnA Installation Procedure The installation procedure is the reverse of the removal procedure.242 Point Operations [Point 1] Removal: Tie a string to the N1 terminal and pull the N1 cable out to the transformer side while sending the string gradually toward the transformer. Untie the string when the N1 cable is pulled out to the transformer side, with the string left in the vehicle. Installation Use the string left in the vehicle to pass the N1 cable to the controller side. [Point 2] Inspection Inspect the fuse. Standard: 0.0 Inspection: Measure the insulation resistance. Measuring instrument 500 VDC megohmmeter Measurement terminals | Each coil terminal - Frame Standard Hl TMQ or more Inspection: Measure the primary coil continuity. Tester range ‘Oxt | _ Measurement terminals Ui-Vs, Vie and Wi-Ur ‘Standard oa2-13 TRaRISOTTRASTIO HrRas70c 143700, Inspection: Measure the secondary coil continuity. Tester range axT Measurement terminals | _Uz-V2, V2We and We-U2 ‘Standard oa Inspection: Measure the diode continuity. Inspect the diodes installed on the radiating fin plate and remove only if an abnormality is found. Tester range Deak Measurement | Forward | Anode (-)— Cathode () terminals Reverse ‘Anode (+) — Cathode (-) Standard |_romward Continuity Reverse cot Reassembly: ‘As two diodes with different polarity are used, be sure to avoid incorrect installation. Reassembly: Install each diode by tightening to the specified torque, '=2.620.2 Nem (2642 kgf-cm)INSPECTION AFTER INSTALLATION 4. Inspect each wiring connection. Note: Check each wiring connection by referring to the charger wiring diagram. 2.__Measure the insulation resistance. Measuring instrument 500 VDC megohmeter Measurement terminals [Each coil terminal - Frame ‘Standard {MA or more 3, Measure the no-load secondary voltages. With the battery plug disconnected, connect the charger plug to the power supply, start charging (by pressing the NORMAL button) and measure the following items: Tester range 250 VDC Controller side battery Measurement Between both terminals terminals (+) terminal: (+) probe (terminal: (.) probe Standard | TR4225C,TR4312C and TR4320C:75/79V 50/60 Hz TR4370C and TR4445C:71/74.5VTIMER TEST Operating procedure 1. Connect the power plug to the receptacle on the vehicle. 2. The initial timer test screen appears on the display. 3. The timer test starts when buttons (1) and (2) are pressed at the same time, and "NOW TESTING!” is displayed on the screen. + The bars indicating charge light up at a rate of one per second as the test proceeds. + When ten bars are lit up after 10 seconds, the test is complete and "TEST COMPLETED" appears on the screen. [TIMER TEST IN PROGRESS] eee The LEDs on the charger operation panel come on in the Soi order of (3)->(4)-»(5).. _S + The magnetic switch turns on when "NOW TESTING!" is displayed, and turns off upon display of "TEST COMPLETED" about ten seconds later. TIMER TEST COMPLETED] nome 4. The initial screen reappears when any of buttons (1) or TT (2)is pressed. [-cHanger ber. ° (a3) & ® _@216 TROUBLESHOOTING WHEN A DIAGNOSIS ERROR CODE |S DISPLAYED F6-1 Safety timer activation tr ection 1 ~ ING ZAC input voltage check on the (GV, abnormal boltage drop or lacking Ihase) AC power supply defect AC put ong power meron "OK (AC200 to 220) y Trpeston 2 Iso Ae poner pug erninal voltage + Power cable delet check (OV, abnormal voltage drop or lacking phase) OK (AC200 to 220V) Y Tepeaton’ Chergr tno teat MS__. bispay detect OK F7 error | rosette noma or EQUAL baton P| and check if the magnetic switch is Cloned and bel ta poston 3K We {Closed and held) + To "The mepetc itch isnot Zooad who he. NORMAL. ot EQUAL buttons pressed” Trpocion (es DC ine fuse continuity check Blown fuse ‘OK OA) ’ + To "Charging completes normally but the charge is insufficientInspection 1 Power supply voltage check Measurement terminals Each power supply terminal Tester range 250 VAC ‘Standard 200 to 220 VV OK (200 to 220 V)-»To Inspection 2 NG (0 V, abnormal voltage drop or lack of phase) -»Power supply defect Inspection 2: Power supply plug terminal voltage inspection Measurement terminals Power plug terminals Tester range ~ 250 VAC ‘Standard 200 to 220 V = OK (200 to 220V)-»To Inspection 3 NG (0 V, abnormal voltage drop or lack of phase) -»Power cable defect298 Inspection 3: Charger timer test See the "TIMER TEST" section (on P2-15). (OK To "Charging completes normally but the charge is insufficient”. NG —Display defect Inspection 4: DC side fuse inspection ‘AC power plug disconnected, charging buttons off and fuse removed Measurement terminals Both terminals of DC fuse Tester range T Oxt ‘Standard on ~ OK (0.2) >To "Charging completes normally but the charge is insufficient" NG (22) Blown fuse2-19 F7 (Charging starting failure inspection 1 NG Connection check INS connection defect OK Y Isthe transformer operating | NG (Not heard) sound heard when the NORMAL or EQUAL button is pressed? [OK (Heard) ‘ NG (<2) Inspection 2 co [NStea) y ‘Transformer fuse check (See tee oal bee! Check compatbilty between |e page 2-12) battery capacity and transformer capacity (See page 2-2.) OK (0) x + Incompatible Y _ Inspection 3 [Inspection 4 <= !— Feet navies [Phat fo wsparapal jchecl (MSch) boltage ‘apenenger check (Se page 2-[NS l = rece 6 (i e os + Tap adjustment defect v + Transtormer defect = Msch defect + Transformer defect Inspection 6 NG| + Charger operation panel ASSY defect “| Gperation button check OK + Display defect Inspection 1: Connection check (1) See that the transformer is correctly connected to the P1 and N1 terminals of the traveling and material handling controllers without looseness. (2) See that CN61, CN6S and CNB are connected correctly (8) Check that the AC and DC plugs are free from contact defect. (No roughness of the terminal or heating during power conduction) (4) Check that the power cable is not damaged, OK Transformer current conduction sound check NG -sConnection defect2:20 Inspection 2: ‘Transformer fuse (Fch) inspection See P2-12. OK (02) >To Inspection 3 NG (00) —>Fuse (Fch) defect Inspection 3: ‘Transformer primary voltage inspection CN61 connector disconnected, AC plug connected and charging buttons on (1) CNST-1(U) — CNGT-2(V) (REC side) Measurement terminals (2) CNG1-2(V) — CN61-3(W) (REC side) @ CN61-3(W) — CN61-1(U) (REC side) Tester range 250 VAC [Standard 200 to 220V ia OK (200 to 220 V)-»Transformer defect NG (Other than standard)-»To Inspection 4. Inspection 4: Magnetic switch voltage inspection ‘AC plug connected, charging buttons on/off operation Measurement terminals Magnetic switch A1-A2 "Tester range 250 VAC ‘Standard ‘Charging button ON:200 to 220 V, charging button OFF:0 V At a2 OK (200 to 220V)-»MSch defect NG (Other than standard)-+To Inspection 62:21 Inspection 5: Tap changer inspection See P2-6. OK-Transformer defect NG->Tap adjustment defect Inspection 6: Operation button inspection ‘CN68 disconnected ‘CN68- Pressed state Released state ‘Tester range (1) NORMAL button’ Between 2 and 8 oom 2 a @ EQUAL button Between 3 and 8 0a 2 co) 4{3{2i4 el7i6l5 OK-Display defect NG-sCharger operation panel ASSY defect FB ‘charging completion failure | spesion + JK magnetic etch (set detect magnetic switch (MSch) voltage check nS y charging button check |» - Display defect a y + Charge operon pel detet Inspection 1 Magnetic switch (MSch) voltage inspection See P2-20. Inspection 2: Operation button inspection See P2-212-22 WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED The vehicle does not move at all. (Charging screen appears even though the power plug is not connected.) + Display defect The charging screen does not appear even though the AC power plug is connected (OK (No movement) Connect the AC power plug andmove [-—"° MOVES p> - Display detect the vehicle ING (The vehicle moves.) vy Inspection 1 NG (@¥, abnormal voltage dip or lacking phase) ‘AC input voltage check on the power [ AC power supply supply side defect + power interruption (OK (ACO0 to 220V) Y Ingpection 2 ING (OV, abnormal voltage drop or lacking phase) AC power plug terminal voltage check (oaes cable detect ~ Tok (AC200 to 220¥) y + Display defect Inspection 1 Power supply voltage inspection ‘See Inspection 1 (P2-17) for diagnosis error code "F6-1" OK (200 to 220 VAC)->To Inspection 2 NG (0 V, abnormal voltage drop or lack of phase)-»Power supply defect or power interruption Inspection 2: Power plug terminal voltage inspection ‘See Inspection 2 (P2-17) for diagnosis error code "F6-1" OK (200 to 220 VAC)-»Display defect NG (0 V, abnormal voltage drop or lack of phase)-»Power cable defect2-23 The magnetic switch is not suctioned when the NORMAL or EQUAL button is pressed ING (No display) Display screen check eee ge + To“The charging screen does not appear even though the AC power plug is connected.” [OK (Charging screen display) Ad Inspection 4 ING Inspection 2 Magnetic switch boltage check || Operation button inspection [OK OK NG us + Magnetic switch (MSch) defect + Display defect + Charger operation panel ASSY defect Inspection 1 Magnetic switch voltage inspection See P2-20. Inspection 2: Operation button inspection See P2-21.24 (Charging completes normally but the charge is insufficient Battery and transformer capacity NG. compatibility check (See page 22) | * Caray incompat OK Y NG “Tap vollage check (Seo page26) |~° _______ . Tap adjustment defect OK ee individual transformer check NG (See page 2-12) [Re __» . transformer defect OK ¥ fANLVOMONITOR { br Battery votage check (Comparision ||NG tm + CPU board detect between displayed value and actually || COE within 22% from the Reccnea aay actualy measured value) OK (win 22% fom the Yactually measured value) Battery electrolyte specific gravity and |NG temperature check ater completion of | | —P « Battery defect charging (See page 1-7.) (Check if corrected by equal charging.) OK + Decreased capacity due to lowering of electrolyte temperature + Decreased capacity due to battery service life2-25 (Charging progress indicator does not proceed during the timer test. + Display defect The LED on the charger operation panel does not come on. tnspection 1 ING (LED on) Charger timer test OK Y NG (OV during charging) inspection 2 ge + Display detect LED voltage check ‘OK BV during charging) Y + Charger operation panel ASSY defect Inspection 1 Charger timer test (See P2-15) Inspection 2: LED applied voltage inspection (See P2-9.) Check that CN68 is connected, Charging in progress | Charging stopped N70 (LED on) LED off Tester range Between 9 and 30 NORMAL LED | (setween ¥-B and BR) 5v ov tovoc Between 10 and 30 ae EQUALLED | (tween ¥-G and BR) 5V ov | Upon end of test mode] Other state ‘N70 (LED on) (LED off) Tester range Between 11 and 30 UPLED | (petween ¥-W and BR) 5v ov 10VDC2-26 OFF-VEHICLE CHARGER Yuass APPLICABLE CHARGER LIST Gs i7aeal hal Transformer Power | FFI FI F Power capacity | Applicable supply |B/ 8/8) B Battery | supply (KVA) capacity | Output | capacity |R|R|R|R Manufacturer | voltage | voltage | Charger mode! | (50/60 Hz) | (AH/SH) | plug | (50/60 Hz) | 10/13/15) 18 SGSES45IBY2 | 4978 [20110225] isIA_[O|O 200v [SG3-6060/BV2 [5.4/4.7 — | 260t0 320 207208 oe Japan SG3-69-801BY2 | 7.3165 | 37010 445 ‘30720A ° Storage | 48V * = sB175 Battery SCEES-45IBY2 | 43/38 | 20110225 TOROA [O[O 4oov | S63-6950.8¥2 | 54/47 | 28010 320 TOTO ole SGS-66-8018V2 | 7.3165 | 87010 445 5710A oo Yuasa T TT7]7]7 ‘Transformer Power |F | FF] F Power capacity | Applicable supply 8/8) 8/8 Battery | supply (kVA) capacity | Output | capacity |R|R|R|R Manufacturer | voltage | voltage | Charger model | (50/60Hz) | (AH/SH) | plug | (50/60 Hz) | 10| 13/15/18 - ZICAB4EAD_ | 32132 | 20110226 TOGA [O|OT | 200v | Z7G48-54AD | 45/45 | 260t0 320 TESA oe Zicae 6666 20) Yuasa oy ‘30AD 370 | sears |_ 207208 Battery ZMC48-45AD | 32/32 | 20110225 BBA _[O|O 4oov | ZMC48-54AD | 48/45 | 260t0 320 TOTOA o|6 ZMC4-B0AD_[ 66/66 370 [107108 o[eGENERAL (GS)2:28 SPECIFICATIONS 200 V POWER SUPPLY VOLTAGE Tem SCS-OG-45IBV2 | SGSEOGOIBVD | SE3-69-80/8Y2 Magnetic switch type CuSIT | = CLK20iT (Misch) Rating ‘AG 200 V, 5060 Hz © < Thermal relay Type TH | < 18 THR) Set value @ 6 1 © 8 Trenetormer yess | Copacty, ‘50/60 He (KVA) 4388 | Salar 73065 i) insulation Claes Hie ee = Silicon diode ‘SKR71102 © * 7 | (Och) ‘ype ‘SENTIIOZ © © Sas Microcomputer eet ee aes control 2 2 Timer (AMT) — Microcomputer ee control © © Total timer setting ® 6 © © Fuse Fen) | Capacity ® 30 80 © [AC power supply capacity "50/60 Hz (A) 15/18 [2080 40720 ‘Charger weight ~ kg (Ib) 32 (71) 42 (93) 44 (96) 400 V POWER SUPPLY VOLTAGE Tern SGSEG-ASIBYD | SGSESGOIBYD | SC3-09-80IBY2 Magnetic switch ype CLRASIT = CLRBIT (Sch) Rating ‘AC 400 V, 50/60 Hz © = Thermal retay Type Ti | = < (THR) Set value @ 67 75 i Transformer ~ [Capacity 50/60 Hz (KVA) 4538 BAT 73165 (TF) Traulation Glass H = = ‘Silicon diode Type SKRTA02 < ‘ (Och) SKNTA02 = = Microcomputer ‘Operating vottage setting oa « + Timer (AMT) Microcomputer Timer setting ee « « Total timer setting ®) « Fuse Fen [Capacty CE w [AC power supply capacity ‘S0TBO He (A) Tonto © TSO | Chorus, wolol tener enemenenenenenenenels ©) 32071) 263) 44 G7)229 WIRING DIAGRAM For 200V For 400V Rt -+R2: (Unused)2:30 BEFORE CHARGING Off-vehicle Charger Circuit Set-up Ifthe ampere capacity at the charging location is insufficient because other electrical appliances are being used, a separate circuit exclusively for the charger should be installed. This circuit should be provided with circuit breakers or fuses having the capacities shown on page 2-28. TAP CHANGER 1. Measure with a circuit tester the power supply voltage to be used for charging. Circuit tester range: AC (250 V or 1000 V) Note: Measure the power supply voltage at night (or, if that is impossible, during a time when electrical appliances are not being operated). 2. Set the tap changer (1) Remove the cover of each tap. (2) Select the appropriate tap corresponding to the power supply voltage measured in step 1 above. (3) Manually close the magnetic switch, and measure the voltage at each tap terminal. [For 200 V] [For 400 V] Measured voltage Tap Measured voltage Tap 199 V or less 200 V 339 V or less 340V 200 to 209 V 210V_ | 341 to 359.V | 360V = 210 to 219 V 220V 360 to 379V | 380" 220 to 229.V 230V 380 to 399. V 400 V 400 to 419. V 420V 420 to 439 V 440 V 440 to 458V 460 Note: + Taps are set to 220 V at the time of shipment. + Be sure to set the tap changer for phases U, V and W. + For about a week after tap changer setting, keep track of the battery charging state (specific gravity and electrolyte level) to make sure the tap setting is appropriate.2:31 DISASSEMBLY - INSPECTION-REASSEMBLY 7 Disassembly Procedure a tag indicating the connecting position at the time of disassembly to prevent incorrect connection at the time of reassembly. 1 Remove the charger cover. 2 Perform inspection before disassembly. [Point 1] 3. Remove the magnetic switch ASSY (MSch). [Point 2] 4 Remove the timer ASSY (AMT). 5 Remove the resistor (R1+R2). (Unused) 6 7 8 Remove the fuse (Fch). [Point 3] Remove the diode (Dch). [Point 4] Remove the transformer (TF). [Point 5] Reassembly Procedure ‘The reassembly procedure is the reverse of the disassembly procedure.oe Reset laver Point Operations [Point 4} Inspection: Inspect the magnetic switch contact continuity. Tester range Oxf [Measurement terminals TW, SV and R-U ON 0a ‘Standard GE oa Inspection: Inspect the magnetic switch coil continuity Resistance between At and A2 Tester range [See the Service Standards list. ‘Oxt Inspection Inspect the thermal retay contact continuity Tester range Ox Measurement terminals 95-96 Not operating 0a [Standard eel Operating waa Note: Do not adjust the thermal relay operating current. + If charging stops due to thermal relay activation while the charger is in use, always check the thermal relay activating cause and reset after taking corrective action. + Press the reset switch lightly to reset the thermal relay. Inspection: Inspect the transformer insulation resistance. Measurement terminals | Between each winding and frame ‘Standard 0.2 MQ or more2-33 Inspection: Inspect the transformer continuity. Tester range ‘ax Primary side UV V4 Wry Measurement terminals |____!_ ‘Secondary side UV VzW2 WeU2 Standard on [Point 2} Inspection: Inspect the magnetic switch contact continuity. Tester range ‘axt Measurement terminals TW, S-V and R-U ‘Standard = 7 OFF ee Inspection: Inspect the magnetic switch coil continuity. Resistance between Ai and A2 ‘Tester range ‘See the Service Standards list. Ot Inspection Inspect the thermal relay contact continuity. Tester range axt Measurement terminals 95-96 —— Not operating oa (Operating eaReset Lever Note: + Do not adjust the thermal relay operating current. + If charging stops due to thermal relay activation while the charger is in use, always check the thermal relay activating cause and reset after taking corrective + Press the reset switch lightly to reset the thermal relay. [Point 3] Inspection: Inspect the fuse continuity. Standard: 00. [Point 4] Inspection: Inspect the diodes in installed on the fin and remove only if an abnormality is found. [Tester range TAK Measurement | Forward node (-) — cathiode (4) terminals _| Reverse | Anode (+) — cathode () aaa Forward | See the Service Standards Ist Reverse 02 Inspection ‘As two diodes with different polarities are used, be sure to install in the correct direction. Note: In the case of a charger with a capacity of 320 AH/5 HR or less, the diode mounting direction is the reverse of that shown in the figure.2-35 [Point 5] Inspection: Inspect the transformer insulation. ‘Measurement terminals | Between each winding and frame | Standard 0.2 MQ or more Inspection: Inspect the transformer winding continuity. Primary winding Tester range Qx1 7 oe UV; Measurement terminals VW, WU, [Standard ~ on Secondary winding Tester range on UpVo Measurement terminals V2-W2 We-Ug ‘Standard onInspection after Reassembly 1. _ Inspect each wiring connection. Not Check each wiring connection by referring to the charger wiring diagram. 2. Measure the transformer insulation resistance. Measurement terminals | Between each winding and frame [Standard 0.2 MQ or more 3. Measure the no-load secondary voltages. Connect the charger plug to the charger receptacle and start the timer, AC voltage Taster range ‘AC 250 V-AG 500 V UpV2 Measurement terminals Vo-We We-Us [Standard See the Service Standards list. DC voltage Tester range BC 250V Both terminals of charger piug Measurement terminals (#) terminal — probe (+) () terminal — probe (-) [Standard ‘See the Service Standards list.2.37 SERVICE STANDARDS Item Service Standard For200V"_| 20016 230 Power supply voltage Vi—Ferad0V—} 340 t0 460, No-load secondary voltage SGS-6845JBY2 | ___ Approx. 56 (The values are the same for 200 V and 400 V.) | SG3-69-60JBY-2 | Approx. 55. AC V|"SG3-69-80JBY-2 ‘Approx. 57 Battery for 24V ‘Approx. 37 Battery for 36 V ‘Approx. 56 No-load secondary voltage Dev Ll Tae TE ‘Battery for 80V" | ‘Approx. 127 | a CLK-15JT | For 200 V: 1300 For 400 V: 5700 MSch coil re tance Q| CLK-20JT For 200 V: 900 Och resistance in forward Q ‘Approx. 25 [Deh resistance in reverse _ Q B Dch tightening torque Nem (kg-cm) [ft-ibf] | SKR71+SKN7 1/02 4 (40) (2.89) Insulation resistance (500 V megohmmeter) MQ 0.2 or more: TIMER TEST 1, Main timer inspection (1) Turn on the AC power switch. (2) Disconnect the battery plug (to unload the charger and operate the voltage relay). (3) Close the magnetic switch (MSch) forcibly by using an insulating bar and press the NORMAL button (black-blue) or EQUAL button (black-biue) for 5 seconds or more until the TEST LED (red) and CHARGING PROGRESS INDICATOR LEDs (three LEDs excluding the uppermost one) light up. Release the button as soon as they light up, and measure with a stop watch the time until the uppermost LED comes on. (4) Ifthe UP LED lights up within the following period of time after the TEST LED lights up and all LEDs then immediatelly go out, the main timer is functioning normally. When NORMAL button is pressed: UP LED lights up in about 6 seconds When EQUAL button is pressed: UP LED lights up in about 18 seconds 2. Total timer inspection (1) Tum on the POWER switch (2) Connect the battery in discharged state (as the main timer is operated first because of voltage relay operation in the fully charged state). (3) Press the NORMAL or EQUAL button for 5 seconds. The TEST LED lights up and charging starts. Release the button when the TEST LED lights up and measure with a stop watch the time until the CHECK LED lights up. (4) If the CHECK LED lights up within the following period of time after the TEST LED lights up, the total timer is functioning normally. (The UP LED does not light up.) CHECK LED lights up in 90 to 100 seconds (6) The LEDs go off when the battery plug is disconnected. Note: If the NORMAL, EQUAL or STOP button is pressed when a fully charged battery is connected, the main timer operates first to light the UP LED and not the CHECK LED. This does not indicate a total timer defect. Inspect again as described above after replacing the battery with a discharged one.2:38, TROUBLESHOOTING Probable cause Trepecton method Sandard Tonective acon Fhe thermal relay onthe AG sides tipped as soon as charging Sas. 1. Short creut of MSch [Cy MSch col coninuly inspection OK: Several hundred’ [Replace WSch Measurement terminals NG: Abnormally low resis Ayand Az tance ZTE salon detector |() TF insulation napecion OK 02 Niner more Replace TF short creut between. |" Measurement terminals: Between each _[NG: Less than 02M@. windings winding end fame OK: 0.2 Mi or more (2) Inspection fr short circuit between TF pr- |NG: Less than 02M mary and secondary windings ‘Measurement terminals: Between primary and secondary winding terminals 3. Deh defect Gy Bch resistance inspection in forward and JOR: Forward — Several 107 | Replace Boh reverse directions ormore Measurement terminals: Both terminals Reverse — 20 (anode and cathode) of Deh NG: Forward —00 ‘Anode —Pt— Cathode Reverse—02 | Forward: Anode (-) Cathode (+) Reverse: Anode (+) Cathode (-) [‘Giher shor ercatin [Ay napect the short cea by separating 63ch 7 aateaive main rut reuit Charging does not start aiough operated coredly for starting charging 7. Interruption or missing |(1) Voltage measurement at main outlet for OK: 200 to 220V In case of missing phase ofinput power | power supply (Charger for 200 ¥) | phase, repair after supply Measurement terminals: Between outlet 38010 440 checking the cause terminals (Charger for 400 V) NG: OV |2--AG plug disconnection | (i) Votage measurement between R, SandT [OK 200% 220 Repair the plug? terminals of MSch (charger fer200v) | any phase fs missing 38010440 forno voltage is (charger for 400) {detected No: OV Blown fuse on DG (7) DC ade fuse continuity inspection ac) Repiace fase side Measurement terminals: Both terminals of |NG: 22 fuse [_MSGh col dsconnes- (i) Mah call coninay apedton TOK Ov Replace Meh tion Measurement terminals: Between Meh |NG: 200 terminals At and A2 (charger for 200 V) 400V (Charge for 400 V) 5. ANT defect AT inepecton OK OV Replace ANT Measurement terminals: Between AMT. |NG: 200V terminals and 8 in wring diagram (charger for 200 ¥) 400 (charger for 400 V) THR contact defect] Gy THR contact inepecton OK Not operating Reset THR by Measurement terminals: Between THR ter-| 00 operating ever or minal 95 and 96 Operating replace MSch ASSY of NG: Not operating =n2:39 Probable cause Inspection method ‘Standard Corrective action [Charging completion failure 1. TF tap charger defect [(1) AC input voltage measurement ~ ‘Change the wiring to Measurement terminals: Between TF tap - ‘match the input volt- changer terminals age [2 Missing phase in input |(7) Voltage measurement at mains outlet for [OK: 200 to 220 V In case of a missing power supply power supply (charger for 200 V) phase, repair after Measurement terminals: Between mains | 3800 440 V checking the cause outlet terminals | _ (charger for 400 v) 3. TAR tipping (THR continuity inspection OK: Not operating Reset lever opera- ‘Measurement terminals: Between THR on tion after checking terminals 95 and 96 Operating the THR tripping 22 ‘cause NG: Not operating <2 '4. Deh defect (open cir- (1) Inspection of Deh resistance in forward [OK; Forward —Several ten | Replace Dch cuit) and reverse directions ‘or more ‘Measurement terminals: Both terminals Reverse — att (anode and cathode) of Dch NG: Forward — cen Anode —H— Cathode Reversa— eof Forward: Anode (-) Cathode (+) Reverse: Anode (+) Cathode (-) ‘5. TF winding discon- | (1) Measurement terminals: Between TH (OK: Continuity Replace TF nection winding terminals NG: an ‘6. MSch contact defect |(1) MSch secondary voliage measurement _ [OK: 200 to 220V. Repair MSch contact Measurement terminals: Voltage measure-| (charger for 200V)__|or replace MSch_ ment between MSch terminals U, Vand W| 380 to.440V ASSY (charger for 400 V) NG: 189Vorless (charger for 200 V) 369 V or less (charger for 400 V) 7. TF terminal tighteness |(1) Inspection of each TF terminal tightenness | No looseness of each terminal | Retighten each ter- defect ‘minal [&. Timer setting at short | (1) Setting time check in test mode ‘See Timer Test section, Replace AMT time | [9. Other contact defect | (7) Inspection of tighteness and connector | No looseness at each portion | Repair or retighten in charging cireuit state at each portion defective portion 10.Lowered batiery (1) Inspection of battery fluid specific gravity. [NG (Measurement after Replace battery charge battery voltage and fluid level charging) If the battery voltage is less than the stan- | Specific gravily: 1.150 or less dard, inspect the voltage per cel. Voltage per cal: 1.75 V or less ‘Total voltage of whole cells 48 V battery: 42.5 V or less 80 V battery: 68 V or lessCONTROLLER GENERAL .. SPECIFICATIONS COMPONENTS... CONTROLLER... EPS CONTROLLER ASSY (FOR EPS AND TBC)......... 3-9 TRAVELING/MATERIAL HANDLING CONTROLLER ASS" BOARD INSPECTION DISASSEMBLY. REASSEMBLY. DISPLAY... ACCELERATOR BOX ASSY. REMOVAL- INSTALLATION. DISASSEMBLY - INSPECTION - REASSEMBLY, BRAKE SWITCH ADJUSTMENT... MATERIAL HANDLING LEVER SWITCH ADJUSTMENT... 3132 GENERAL ‘The 7FBR series is installed with a traveling / material handling controller that controls the traveling and material handling systems and an EPS controller that controls the EPS-TBC system. Each is a multifunctional controller utilizing a microcomputer. The traveling / material handling controller has @ commmunication circuit with the EPS controller and display. It provides diagnosis (by self-diagnosis function) to automatically detect any abnormality in the main drive and pump circuits, accelerator, EPS circuit, TBC function and other sensors, and displays the corresponding error code while short beeps sound. At the same time, an action such as disabling traveling, disabling material handling or restriction of traveling speed is automatically taken to ensure safety. Faulty section detection and functional check of the main drive and pump circuits, each control system and ‘sensors are possible by setting the display into the ANALYZER (fault analysis) mode. ‘See page 4-14 in the "MULTI-DISPLAY FUNCTIONS" section for the diagnosis. ‘See page 4-22 in the "MULTI-DISPLAY FUNCTIONS" section for the analyzer. EPS contolerSPECIFICATIONS a 7FBR10,13 TFBRI5,18, F1 (for drive and pump circuits) 360A 410A F3 (for PS circuit) 30A © F4 (for lights) TOA = Fuse F5 (for control circuit) T0A ra FE ~ Y (ecm) 104 < F7 (for TBC circuit) TOA - TMD (for traveling) 100 i480 A = TMP Transistor | fo¢ material handling) 100 V/560 A 100 Vie40 A TMPS (for PS) MG50J2¥S50 < Diode [DFS (for material handling) 700 Vi560 A 100 Vi640 A ‘CSeart (for power supply) ‘S3CM7-800/4QG < Current |CSDa-CSDe sensor _| (for traveling) eee a CSP (for material handling) ‘S3CM7-800/4QG = ‘CO (for traveling and material || Capacitor | naling) 100 V, 2700pF x12 pes. | 100 V, 2700UF x 14 pcs. Contactor | MB (for power supply) ‘Type ME251 <34 COMPONENTS 2401 2401-2392401 3:8CONTROLLER EPS CONTROLLER ASSY (FOR EPS AND TBC) REMOVAL -INSTALLATION 3.9 Removal Procedure 1 2 3 4 5 Disconnect the battery plug Remove the front panel. Disconnect CNS1 and CN140. Remove the EPS controller set bolts. Disconnect CN141, CN142 and CN143, and remove the EPS controller ASSY. Installation Procedure The installation procedure is the reverse of the removal procedure,310 Inspection ‘Some components can be inspected after they are removed from the vehicle, while others can only be inspected as installed on the vehicle. ‘The CPU board must be inspected as installed on the vehicle since the battery voltage be applied. The explanation here is mainly for inspection of the EPS controller ASSY as removed from the vehicle. 4, TMPS1,2 and TMPS3,4 (transistors for PS) (1) Inspection method ‘TMPS wiring disconnected Portion to be inspected Measurement terminals Standard Tester range [CET (-) probe - C1 (*) probe Continuity Ze rere (C2ET (¥) probe = C7 () probe C2ET (-) probe - E2 (+) probe c2et-£2 [a POE VE? | 3ET () probe [Gt () probe - E1 (# crer [St probe Et (+) probe TMPS1,2 [Gi () probe- ET © probe ontk TMPS3,4 © probe ib x GaEp S20) Probe - E2 (#) probe C164 C2E1-62 TwPs34 2 i 7 I) fol || fo]| fo! 1 jes aici Rice lo} | [o]| flo 2 my f =f €1 ae de toch et Note: + When shifting to check G2E1-E2 from G2-E2, short circuit G2-E2 before checking C2E1-E2 in order to avoid the possibility of continuity in both directions. + Never touch the G2 terminal with your bare hand, as static electricity may damage the transistor element.3.11 2, SH1, 2 (shunt 1, 2) (1) Inspection method SH wiring disconnected Portion to be inspected Measurement terminals Standard Tester range ‘SHi SH Both terminals of SH Continuity Qx4 (ott => a Oo e le 3. MPS (power steering contactor) (1) Inspection method Each MPS wiring disconnected oe Measurement terminals Standard Tester range MPS Both terminals of MPS col ‘Approx. 68 axt3.12 TRAVELING/MATERIAL HANDLING CONTROLLER ASSY REMOVAL - INSTALLATION Caution: Before starting the job, measure the voltage between P4 and N14; if there is any voltage, insert a resistor at approx. 1000 between P4 and N1 to discharge the capacitor. } i i | re1se2 130820) (9481.4) T=Nem (kgf-om) [ft-lbf] Removal Procedure Disconnect the battery plug Remove the front panel. Remove the steering wheel and instrument panel. Remove the EPS controller ASSY. Disconnect the connectors and terminals from the traveling/material handling controller ASSY. Remove the controller ASSY. Oakona Installation Procedure The installation procedure is the reverse of the removal procedure.3-13, Inspection ‘Some components can be inspected after they are removed from the vehicle, while others can only be inspected as installed on the vehicle. Inspect the CPU board and DC/MD board as installed on the vehicle since the battery voltage must be applied. The explanation here is mainly for inspection of the traveling/material handling controller as removed from the vehicle. 1. Insulation resistance measurement (Always measure before inspecting the traveling/material handling controller.) (1) Disconnect the battery plug and measure the insulation resistance between the battery plug and body. Measurement terminals | Controller side of battery plug — Body [The higher the resistance the better, but it varies greatly with the vehicle operating condition, place and weather. (Approx. 1 MQ or more) Standard 2. MB (power supply contactor) (1) Inspection method Disconnect CN134, and measure the resistance of the MB coil. Portion to be ] inspected Measurement terminals Standard Tester range i ‘Approx. 200 MB coil Both terminals of CN134 ‘azo | ax43-14 3. CO (overall capacitor) (1)_ Inspection method Confirm complete discharge of CO before inspection Portion to be z inepected Measurement terminals Tester range co Both terminals on the rear side of CO Qx 1k Standard: Bring tester probes into contact with both terminals of CO. The pointer once reflects to the 00 side. Then it gradually returns to «> and finally indicates «. (probe [—Connecta pn No. Connector No. t No. Conditions Standard Remarks GRTOET | GNTOTBE-| a ste OFF and DSF ON | Aprox OV vel No. Condon for measurement Traveling/material handling controller CPU board CN101 basic conditions (battery plug connected, key switch ON) Connector No.Connector No. Conditions ‘Standard Remarks CNIOATT | Unused — Gee) | NEN open OV Gece) | (NZNO). | Poona (GIGS TS | ERICA IT Ney auton OFF momo bv ‘ONTO 18 | CNIORTT 5 etch OFF aay taveen | (Nana), romney | cannes I Immeasurable faven) i “NNO Approx. 48 V CN104-19 CN104-17 | 8 (78, THCD) (N2,N2)__|Key switch OFF 1to4V ‘cNi04-20_—T Unused CN105 basic conditions (battery plug connected, key switch ON, drive motor cable disconnected) Tonnector No.cConnedtor No. Conditions andar Remarks CNTO5-T _" CNT04-17 (33, FAN4) | (N2,N2) Approx.b V CNTOE-2 CNiO4T7 (38, FAN4) | (N2,N2) eee CNi05-3' CN104-17 [Whenthefanisoff_ [Approx 5V— (36, FANCD) | (N2,N2)___ [When the fan is on Approx. OV’ CNTO5-4 CNIO4T7 (19, 20VNO.20n)! _(N2, N2) ae Nat connected = CNTOATT (39,pc) | (N2,N2) Approx. 4V ‘CNTO5-7 CNI04-17 (40,Ppc) | — (N2,N2) oa CNI05-8 cnt0s-6 |Whenthe fanison_ | Approx 05 V_ (94, CKFAND#) | (97, CKFAND-) |When the fan is off Approx. 0V CNTOE-S (@7,OKFANDS | immeasurable = CNTO5-10 CNIOHTT a (13, 20V NO.10N)! _(N2, N2) PPO) CN105-17 ~CN104-47 (37, ck20v) | (N2,N2) ero3.21 ‘Connector No.<>Connector No. Conditions ‘Standard Remarks. CNT05-12 | Not connected CNI05-13__ Not connected CNT05-14_T Not connected CN106 basic conditions (battery plug connected, key switch ON, drive motor cable disconnected) Connector No.e»Connector No. Conditions ‘Standard Remarks cNI06-T Unused = ‘CN106-2 i er. core) | immeasurable = CN106-3— | "[Unused ~ CNIO64 | Unused = CN106-5—T Unused a : : cni0E-6 Unused = CNT06-7 2, TuPaD, | immeasurable = CNI06-8 | CN104-17 (33, TMPD+) | (N2,N2) Approx. SV CN106-9 | CN104-17 (5, CKPV) .; — (N2,N2) ‘Approx. 10.V CNTOETO 1 Not connected = CNi06-11—T Not connected = CN107 basic conditions (battery plug connected, key switch ON, drive motor cable disconnected) ‘Connector No.=Gonnector No. Conditions: Standard Remarks ‘CN107-1 CN104-17 : z == (26, Tus) | (N2,N2) epee as CNI07-2 CNI04-17 (20, TMDAU-) | _(N2,N2) Approx. 6 V CN107-3 CNI04-17 (21, TMDBU-) | (N2,N2) peed NTO7-4 _, _ ONT04-17 (22, TMDCU-) | _(N2, N2) epron ov CNIO7-5 | CNT0417 (23, TMDAD-) | _ (N2, N2) eee CNTO7-6 | CN104-17 (24, TMDBD-) ; —_(N2, N2) pera CNTO7-7 1 ON104-17 (25, TMDCD-) | —_(N2, N2) EpTOe EI, CNi07-8 1 CN10417 (26, TMDD+) | (N2, N2) pee GNiO7-S 1 —GNI04-17 (4,CKDV)_ 1 (N2,N2) ay cNto7-10 7 Unused =3:22 DC/MD board CN111 basic conditions (battery plug connected, key switch ON, drive and pump motor cable disconnected) ‘Connector No.<>Connector No. ‘Conditions T___ Standard Remarks: CNTIT-AT CNTI2-18 : (41, Bag) | (N2,N2) Approx. 50 V CNTT2 ‘Unused CNIS | Unused = CNITi-4 | ONTH1-12 - (11, $20V+) | (7, FAND#) Approx. 20 V | cNtT-S 1 CNTT-13 (16,15) | (@, FAND-) 140 15V CNIS 1 ONTIZ-18 (43, VBKY) | _(N2,N2) ‘Approx. 50 V cuit Unused = — NTS Unused = CNTH-9 CNT ' (339, B20V-)_| (339, B20V-) Approx. 0V CNIT-10 —; _CNIT1-9 (338, B20V+) | (339, B20V-) Approx. 20V CNIT-11 | CNT12-18 (44, VBMB) | —_(N2,N2) Approx. 50 V CNTT-12 1 CNI12-12 - (12, $20V-)_|__ (7, FAND+) Approx. 0V CN111-13——-‘TCN112-18 (14,GNDD) | (N2,N2) ‘Approx. 0V cnt! Unused = CN112 basic conditions (battery plug connected, key switch ON, drive and pump motor cable disconnected) ‘Connector No.Connector No. Conditions ‘Standard } Remarks CNTIeA1 CNTID2 — (162, TMPAD2+) | (N2, TMPAD-SD) 13 to 15V ONTI2-2 (N2, TMPAD-SD) ! Immeasurable = | CN112-3 CN112-2 a (153, TMPAD-G) i (N2, TMPAD-SD) 1310 15V CNTI2-4 CNTI22 (153, TMPAD1#) | (N2, TMPAD-SD) 13to 15V CNTI2-5 CNET _ (15,c15v) | (6,N2) 1410 15V CNTI2-6 CNTIZ-16 (41,B4av) | 6,N2) | Approx. 50 V CN112-7 7 CN112-48 | ae (43, vBKY) | @,N2)3.23 Connector No.=sConnector No Conditions Srandard Remarks CNTI28 CNTI2-18, (4, veMB) | _(N2,N2) Approx. 50.V CNTI2o Unused = CNTI210 | CNTIZAT (1,MB+) | (2, MB) Approx. 11.V GNTIZ-1T 1 GNT12-10 [Battery plug disconnected (2,MB-) | (1,MBs) Resistance measurement Approx. 20.0 ena immeasurable : (7,FAND*) | aa extn immeasurable (@,FAND-) | i” CN112-44 CN112-18 | (#4, GNDC) | (N2, N2) Approx. OV CONTI2-18 Unused = CNII246 1 Unused = CNT? 1 ; 7 ene immeasurable _ et none immeasurable i CN113 basic conditions (battery plug connected, key switch ON, drive and pump motor cable onnected) Connector No. Connector No. Conditions Bandara Remarks nie eta] ona (asa, TuDaD1+) | ya, TMDBUSO) 1310 15V (154, THDBUt+) I coches 13 to 15V (151 MDAU.G) | Camnen ttotev (186; TMDBU-<) | P5: TMDBU-SD) 1810 15V (187, THD30-6) | (N2TMDBDSD) ‘Bio 16 (159, THDGU-G) | @7 TMOG SD) 1310 15V enMoeaS) i (ast MDD SD) 13 to 15V cnTis-10_ [Unused —3:24 Connector No--sConnector No- Conditions Standard Remarks (is, THD8D1+)| (42, TMDSD-SD) Bio t5v (158, TMDCUts) | 7, TMDCU-SD) : 13t0 15V a 60 TMOCD1+) | a TMC $0) 1310 15V Sa ! Immeasurable OT oe 7 = 51 TMDBUSD) i immeasurable : _ (450, TMDAU2S) | (3, MMDAU-SD) 1310 15V a Sev ear tay ox ASS [enw (195, THMDBD2) | (\2,THDEO-S0) 131018 (158, HBGU2 | @7, THDCU-SD| 131018 (165 THDED2) i (na TMDeD-S0)| 13to 15V CN113-23 Unused —_ far aceoen| Immeasurable pO erstneu30)! immeasurable - = ue Inmeasirobie =3-25 EPS controller CN141 basic conditions (battery plug connected, key switch ON) Connector No.=Connector No. Conditions nda Remarks (ase, 820v4) | @s0, 820%) Approx. 20V cszove) | 2,520) Approx. 20 osteanes Immeasurable = Gisou) | “Nanay Approx. 48 V ae souscs)! (NEN) | Approx. 48 CNi47-6 | ONT41-17_ [Key switch OFF _ tv (360, VBBTS) | (N2,N2)__ [Key Switch ON ‘Approx. 48.V j aiaae I Unused = feneii | ay Battery plug connected ‘Approx. 48 V - eee) I Unused _ cua a - Geo) | we.n) fopion V GM) | Geol) [pecntrecraronrent | APPm% 100 oe gee ee (932, SOLES.) | _(N2.N2) nopron 48 (852 S0i8S) | GOT SOLBS) [Resslarce mensurewent_ | A7RO% 108 ear souse) | (N2,N2) Approx. 48 (628,50.8) | (N21) Approx 48 eS, | es, REE | wea CNI4-16 1 CNIAT-A7 (330, SOLBC-) | (N2, N2) ov eT (22 SoHo) | ao SoLace) |Restuncenesoueent_ | APRO% 100 CNI41-17 CNTATA7 (N2, N2) (N2, N2) ov ae Tad3-26 CN142 basic conditions (Battery plug connected, key switch ON) [_ Connector No.=CTonnector No. Conditions [_Standard Remarks | cNta2-1 CNT42-22 (68, SPL+)_| (300, BPOT-) Approx 15 | cNtazz + CNtaz22 I: Approx 0.7 Vor} (334, SSFL-)_| (300, BPOT-) H: Approx. 1.4 V |—_cnTaz3 : ( SPAD+) | [Unused — | — cntaza 1 = CSPAD) | lUnused 7 CNT42-5 1 —CNTAEZE = (ai) 0, BPOT) [Fully lowered position Approx. 0V NTA2-6 —T—_CNTAZ: 7 Ger Mie’) | 00, BPOT) [lly lowered postion ‘Approx. 5 V | cNTaZ-7 7 CsPIN) | Unused _ | — cNTaz8 | ane (,SPIN2) | muses a CN129 | 1 (295, SATBK) | immeasurable — Sta ie \ immeasurable _ Coan + Aorccene immeasurable = s H arena | immeasurable _ | 607, \ a Pratesiuay I immeasurable a i CNTA2-14 CNTAEZ: (333, SSF+) | (300, BPOT-) Approx. 15. V CNTA2-15 CNTAR: IL: Approx. 0.7 Vor (335, SSFR-)_| (300, BPOT) Ht Approx. 1.4 V CNT42-16 —t~ CNTAZZ 2 (316, POTH+) | (300, BPOT-) _ Approx. 5 V CNIAET7 1“ CNTAZ-Z - (176, 1) _|_ (300, BPOT:) aoe | “CNTa218—1—CNT4Z a (59, SPL) | (300, BPOT-) 03t045V T Upon change rom clockwise CN142-19 N142-22 Lig el al alicbod ne (71,82) | (00, BPOT) {tend to countercociwise | 0:3t029V NAT lWhen the steering wheel is: (317, POTH) | (00, BPOT.)_ltumed 05t04.5V CNTAEZT CNT4Z-22 (301, BLS)! (300, BPOT-) ov CNTA2: CNT42-22 (300, BPOT-) | (300, BPOT-) ov3-27 Connector No.=sConnector No. Standard Remarks N142-23 *CN142-22 au (178, $3) | (300, BPOT-) CN142-24 7 (297, SBTAK) Immeasurable - CN142-25 7 (gon sure) | Immeasurable = CNT42-26 @10,sem™Kg | Immeasurable = CN143 basic conditions (battery plug connected, key switch ON) ‘Connector No.Connector No. Conditions Standard Remarks Se, | Se, | oe ws font [umised = ruee Ve ees | Approx. 68.2 28) 2S S| ea ~~ CN145-5 i (-, CHK-20)3:30, DISASSEMBLY Control panel disassembly is rarely needed. In most cases, it is performed to replace defective parts after the source of the problem is detected by inspection Therefore, perform correct operation by referring to the components and assembly drawings. Notes for parts replacement + Tighten bar and harness set nuts and screws to the specfied torque levels, Looseness or tightening failure will cause new problems. + Accurately record the installation location or attach a tag showing the location before disconnecting each bar or harness. At the time of reassembly, check the record or tag to avoid incorrect assembly or wiring, Incorrect assembly or wiring will cause new problems. + Always apply silicone grease to parts that have been applied with it Failure to apply it may cause overheating, + After completing reassembly, check non-contact portions of bars and wiring for undesirable contact. Before installation on the vehicle, use a circuit tester to check continuity at specified points. (See P3-32 for the points requiring inspection with the tester.) + Always replace the TMD and TMP for each arm unit. ‘Always check the part number for identification.3:31 REASSEMBLY Traveling/Material Handling Controller Control Panel Reassembly Drawing T=Nem (kgf-cm) [ftlbf] T=O822(10082017281.4) ——_To9.942(100220)(7 241.4} Tesai0 885) es004 ra raz 421) peso 1512190320) 342090449) \ ae B00 as Teisia(soam ( senso ci esa Enz) (750 CHO 840.071 fast 4 : Toate) \ ener \cura Sana _/ Tra 40594512 52008 ~\ ¥ oO PS oe ar ek S 3 f Te9.12098420) 7284) a fg ove 28 oy ontst we é chtss ents is fetan\ Nee chaos Sur T-98:2,100520 ale Tbaid sus ee) asta peo roast Ters:2150:20 Tea at0 545) 130281.) (2820.04 7 " Caution: Be sure to install insulating sheets without fail. + Failure to install the insulating sheet for the TMD or TMP will damage the TMD and TMP. + Failure to install the insulating sheet under the MB contactor will cause a critical failure. + Check the insulation resistance between the bracket and each P terminal after controller reassembly. Standard: 3 MO or more3-32 Continuity Checks after Reassembly of Control Panel ASSY (1) Inspection method Always disconnect the drive and pump motor cables. Tester range:2 x 1 i Tol Soo ° = ae Pte P16. < C iO why AZ re 7 o ° ° (a) _ Motor cable terminal inspection Motor cable te 7 Ni Pa jotor cable terminal o oy _ = Capacitor char- ° = acteristic Approx. 500 eee Capacitor | © cma = characteristic _ Capacitor char- ° — acteristic = ‘Approx. 502 mere Capacitor | ue fee = characteristic _ (b) _P4-N1 inspection Bal eeNuC) Capacitor characteristic ray MO) ‘Approx. 500 4 \r characteristic: The pointer deflects to the 00 position once, then it gradually returns to 2. dicates «00 Capaci Finally3:33 Drive motor input voltage measurement If traveling does not seem to be normal or after overhauling the traveling/material handling controller, measure the drive motor input voltage to accurately judge whether the controller functions normally. Drive motor input voltage measuring method Procedure 1 Disconnect the battery plug. 2 Remove the EPS controller. 3 Jack up the drive wheel. 4 Connect the (-) probe of an analog voltmeter to the N1 terminal. 5 Connect the (+) probe of the voltmeter to P7 (P8, P9). Connect the battery plug. 7 Tum the key switch to ON. 8 Operate the accelerator lever fully for forward (reverse) traveling, and record the voltmeter reading then. 9 Measure in the same way for P8 and P9. 10 Compare the voltage measured between N1 and each of P7, P8 and P9. See that the dif- ference is as specified below. Difference between input voltages to P7, P8 and P9 Standard: 2 V or less fol ol Texto —lo To © ye U / Pe. Pr. T Material Handling Circuit OCL Value Measurement In the material handling system, the relief valve in the control valve is actuated at the stroke end of each cylinder. The OCL value of the material handling circuit is set higher than the current at the relief value set pressure. Because of relief from the hydraulic circuit before the current of the material handling circuit reaches the OCL value, the OCL value cannot be measured.334 EPS Controller Reassembly drawing T=Nem (kgf-em) [ft-lbf] Ta3.420,5(045) (2520.04) T=2.510.5(2545) (7.820.05) contes vaaeano /OB)S \— % =a . 6 im onwo —4 T=3.420 563485) oxst YRS Caution: Always apply silicone grease to parts that have been applied with it. Failure to apply it may cause overheating. Continuity Checks after Reassembly of EPS Controller ASSY (1) Inspection method Always disconnect the CN140 and N51. Tester range: 2.x1K Pat Measurement terminals P24 P23 ‘Standard P21(+)—N22(-) 2 P21) N22) =f P22)—N220) Several dozen KO P22(-)—N22(+) =o P21,P22,P23,P24,N22—Frame_ eo3.35 DISPLAY Ifthe cause of trouble is judged to exist in the display, apply the battery voltage and measure the voltage at ‘N70. N70 basic condition (battery plug connected) Connector No.<»Gonnector No. Conditions Srandard Remarks ON70-14 ‘CN70-30 (78, D18v)_ | (14, GNDD) | eee o CN70-1 ' CN70-15 | ‘Approx. 48V Q wy | (43, 48V)3.36 ACCELERATOR BOX ASSY REMOVAL - INSTALLATION 4 Removal Procedure 4 Disconnect the battery plug. 2 Remove the steering wheel and instrument panel. 3. Remove the arm pad. 4 Remove the accelerator box ASSY. Installation Procedure The installation procedure is the reverse of the removal procedure.3.37 Point Operations [Point 1] Inspection: Inspect microswitches (DSF, DSR, DSro, and DSsv). Portion to be Deseeed Measurement terminals DSF ‘CN26-2 — CN26-7 DSR ‘CN26-4 — CN26-7 DSro ‘CN26-6 — CN26-5 Sav CN26-7 — CN26-5 [When the lever is operated: ON (09) Standard _|When the lever is not operated: OFF ) Inspection: Inspect the variable resistor. Weasurement terminals ee [CN26-9 — CN26-10 |” 25k CN26-8 ~ CN26-9 CN26-8 - CN26-10 ‘Changes from 0 2 to 2.5 kQ as the accelerator lever is operated. ‘Changes from 2.5 kG to 0 Qas the accelerator lever is operated.3:38 DISASSEMBLY + INSPECTION: REASSEMBLY Disassembly Procedure 1 Remove the cover and gasket. 2 Remove the microswitch and variable resistor. [Point 1] 3. Remove the accelerator lever. Reassembly Procedure ‘The reassembly procedure is the reverse of the diassembly procedure. Point Operations [Point 1] Reassembly. ‘Connect connector pins according to the illustration and S{4}3i2ii cable colors in the table. jo} 9] 81716 3] BY [4] 6 [3] - [2] W ]t, oR io) RB |[9| LR [8] GR |7{Rw]/e| yR3:39 BRAKE SWITCH ADJUSTMENT 1. Adjust the brake pad clearance and brake pedal height. (See the BRAKE section.) 2. Adjust the mounting position so that the switch is turned ‘on between 1/3 and 2/3 of the brake stroke (A). MATERIAL HANDLING LEVER SWITCH ADJUSTMENT 1, Adjust the front limit switch mounting position so that itis turned off in the range of B between 10 and 20 mm from the fully pulled position. 2. Adjust the rear limit switch mounting position so that itis, turned on in the range of C between 5 and 10 mm from the position where the lever play is eliminatedMULTI-DISPLAY MULTI-SCREEN DISPLAY... GENERAL... SPECIFICATIONS... DISPLAY INDICATION LIST... ABBREVIATIONS DISPLAYED ON THE SCREEN GENERAL FUNCTIONS... GENERAL SCREEN... DIAGNOSIS... DIAGNOSIS CODE LIST.. MASK FUNCTIONS... GENERAL PASSWORD. ANALYZER... TUNING.... 4-35 OPTION SET... MATCHING ..42 MULTI-SCREEN DISPLAY GENERAL 1. The multi-screen display indicates various types of vehicle information by switching the screen according to need. 2. On the cold-storage model, a display heater is provided to prevent worsening of visibility at cold temperatures. Note: Be sure to operate buttons for the display with your finger. If a sharp-edged tool is used, the button may be damaged. When ” ‘stopped @ ® “ 1 «ty a During traveling o ® © 2) Upon error occurrence ‘9 No. Trem No. Tem (1) [Swing lock indicator (7) |Multi-screen display area (@ [2 speed travel speed indicator (8) | Front brake on indicator (3) [Diagnosis ON indicator (@) [Traction control on indicator (4) |Overheat waming indicator (10) |2-speed travel speed control | 6) Battery charge indicator (1) Hour meter selector button (6) Power select indicator (2) Power select button(1) Swing lock indicator ‘Comes on upon swing lock operation, and goes out upon unlocking (2) 2-speed travel speed indicator This indicator comes on and goes out each time the 2-speed travel speed control is pressed. When this indicator is on, 2-speed travel speed is on to limit the maximum vehicle speed to the set level Speed setting can be performed on the 2-SPEED TRAVEL SPEED LEVEL SETTING screen. (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 a 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 Ona vehicle without matching performed for the EPS and TBC functions, 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 controller or drive rts Overneat warning indicator rises beyond the specified level, the overheat warning indicator blinks and a buzzer sounds to warn the operator. ‘When overheated, vehicle operation is restricted and the overheat section indication blinks. Displayed messageC/R :Travel/mate ‘overheat section indication (abbreviation) handling controller PSCR:EPS controller DM :Drive motor (6) Battery charge indicator The battery charge level is indicated in ten stages. A: Low remaining battery charge warning The battery charge indicator blinks when the remaining battery charge drops below the set level. When the key switch is tumed from OFF to ON in this state, a buzzer sounds for § seconds to warn the operator. B: Battery overdischarge warning (lift interrupt function) ‘When the remaining battery charge drops further from the low remaining battery charge warning level to the set level’, all bars of the battery charge indicator start blinking and a buzzer sounds to warn the operator. In this case, material handling during traveling cannot be performed. *:The level can be set using TUNING function of the mask function. {Low remaining battery charge warning Battery overdischarge warning sea ‘amber of egrets covesonding ieee the remiig bate charge