Toyota 7FBMF 16, 18, 20, 25, 30 Service Manual

ELECTRIC FORKLIFT TRUCKS

7FBMF 16,18 7FBMF 20,25

7FBMF 30,35 7FBMF 40,45,50

< Tillbaka till Servicemanual 7FBMF 16-50

AUGUST 2002

Index

Pub. No. PE313

SECTION INDEX

NAME	SECTION
GENERAL	0
DEVELOPMENT OBJECTIVES	1
CONTROLLER	2
MULTIPLE DISPLAY	3
BATTERY	4
POWER TRAIN	5
STEERING & REAR AXLE	6
TIRES	7
OPERATOR’S COMPARTMENT	8
BODY & ACCESORIES	9
MATERIAL HANDLING & HYDRAULICS SYSTEM	10
SAS	11
MAIN OPTIONS & ATTACHMENTS	12
WIRING DIAGRAM	13

FOREWORD

This manual mainly describes the development objectives of new Toyota forklift 7FBMF16~50 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 September 2002.

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.

GENERAL

	Page
VEHICLE EXTERIOR VIEWS	.................................................. 0-2
MODEL LINE-UP ........................................................................	0-3
STANDARD EQUIPMENTS.....................................................	0-4

0-1

0

0

11

12

13

0-2

VEHICLE EXTERIOR VIEWS

7FBMF16~35

7FBMF40~50

0-3

MODEL LINE-UP

Models

		Capacity	Model (80V or 72 V)
		(Load Center 500 mm)	New	Previous
	1 ton Series	1.6 ton	7FBMF16	FBMF16
						0
		1.8 ton	7FBMF18	—
	2 ton Series	2.0 ton	7FBMF20	FBMF20
		2.5 ton	7FBMF25	FBMF25
	3 ton Series	3.0 ton	7FBMF30	FBMF30
		3.5 ton	7FBMF35	—
		4.0 ton	7FBMF40	—
	4 ton Series	4.5 ton	7FBMF45	—
		5.0 ton	7FBMF50	—

Frame number stamping

Stamping Style

Model Stamping Location

(Starting Number)

	7FBMF16	7FBMF18	10011	Stamp on LH & upper surface of front cross plate
	7FBMF18
	7FBMF20	7FBMF25	10011
	7FBMF25
	7FBMF30	7FBMF35	10011
	7FBMF35
	7FBMF40
	7FBMF45	7FBMF50	10011
	7FBMF50

0

11

12

13

0-4

STANDARD EQUIPMENTS

			: STD P:OPT		—: Not Available
	Standard Equipment	1.6-3.5 ton	4.0-5.0 ton		Note
Electrical	AC Power system for travelling & load handling
System
	AC Power controller for steering	—		1.6-3.5 ton: DC system
	Multiple display (All round model)	P	P
Chassis	SAS (System of Active Stability)
	Wet brake system
	Parking brake system of electric switch type
	Full hydraulic power steering
Body	Overhead guard
	Memory tilt steering column
	ORS seat
	Floor mat
	Battery hood damper
	Assist grip (LH)
	Instrument panel holder
	Paper clamp on battery hood
	Drawbar pin
Load	Wide visible mast (V)			H3300 mm
Handling
	Load bucharest			H1220 mm
System
	Fork			1.6~1.8 ton: L800 mm
				2.0~5.0 ton: L1000 mm
	Mini-lever control system
	3-way valve (A400)
Others	Electric horn
	Headlight	P	P
	Rear-view mirror	P	P

1-1

DEVELOPMENT OBJECTIVES

	Page
DEVELOPMENT OBJECTIVES..............................................	1-2
FEATURES (SELLING POINTS)............................................	1-3
AC POWER SYSTEM................................................................	1-6

1

0

11

12

13

1-2

DEVELOPMENT OBJECTIVES

TOYOTA 1.6 ~ 3.0 ton FBMF 16 ~ 30 counterbalance type electric 4-wheel forklift trucks have had an established reputation as high performance forklift trucks since first their model launched in 1989.

There have been rising demands for clean electric forklift trucks with relevant to environmental concern; and further the market wants higher capacity forklift than 3.0 ton beside the existing capacity models.

Keeping these points in mind, the design concepts were established, as follows:

1. AC induction motor

Making best use of the advantages of AC induction motor drive system to respond to customer's needs for the most suitable load handling system.

2. SAS - System of Active Stability

In order to gain better stability, SAS has been developed. SAS, adopted by 7 series, has already won high confidence from the industrial truck markets.

This same level of stability will be incorporated into the new 7FBMF 16 ~ 50 models.

3.Introducing larger capacity models of 3.5 ton and over in addition to new 1 ~ 3 ton capacity models to enhance the product range.

Creation of over 3.5 ton capacity models has been undertaken together with the model changes launched for 1 ~ 3 ton capacity models.

Most of all, the AC induction drive motor system has been a pioneering endeavor having rallied our technological powers for a successful introduction in our products. Excellent features inherent to AC induction motor have been used to its full advantages with success.

Furthermore, varied demands for additional features have been implemented. Emphasis has been placed on system design development such as the mini-lever system and the wet brake system, etc.

The 7FBMF 16 ~ 50 models certainly have outstanding features compared to other forklift models. On operation, the differences are so obvious in fundamentals, performance, comfort, etc. New 7FBMF 16 ~ 50 models are commendable as an epoch in new era.

1-3

FEATURES (SELLING POINTS)

Table of selling points

				mfr: manufacturer
					: Newly adopted, : Improved
				S: STD, P: OPT, –: Not available
Selling point		Function or Item	Objective			1.5 ~	4.0 ~	mfr A	Relative
						3.5t	5.0t		page
		Improved performance
Improvement in operation		Power keep function	Better performance at a low
hours and work cycles without			battery level			S	S	—	1-8
an operator noticing a decline									2-2
in performance
Availability of different power		Power select function	A touch on a switch selects
modes for different needs:			optimum power mode.
H mode: High power mode
P mode: Power mode						S			1-11
S mode: Standard mode							S	—
									2-2
Other customized modes are
available as well.
		Load handling power				S
		control
		Improvement on operator comfort
Improvement in ease of		The entry area has been	Ease of getting on and off
getting on and 0ff		widened by installing the	equivalent to the engine-			S	S	—	1-10
		battery under floor	powered model
Increased leg space			Expansion of foot space			S	S	—	1-10
		Improved serviceability
Improved serviceability		AC motor	Need for servicing motor			S	S	—	1-7
			brushes is eliminated.
		Overheat protector	Power is reduced						2-5
			automatically when motor is			S	S	—
									5-2
			overheated.
		AC controller	Need for servicing contactor			S	S	—	2-2
			is eliminated.
		Thermal protector	Output is reduced						2-5
			automatically when			S	S	—
									5-2
			controller is overheated.
Reduced need for servicing		Wet brake system	Service life of brake system			S	S	S	5-10
brake			is prolonged
		Regenerative system	Service life of brake system			S	S	S	2-5
		(accelerator off)	is prolonged.
Higher safety during servicing		Jacking points under the	Jacking points indicated for			S	S	—	9-2
		counter weight and frame	higher safety

1

0

11

12

13

1-4

Selling point			Function or Item	Objective	1.6 ~	4.0 ~	mfrA	Relative
					3.5t	5.0t		Page
			Safety
Improved turning stability			SAS-active control rear	Rear wheel ground grip
			stabilizer	force increased when	S	S	—	11-6
				required
Improved material handling			SAS-active mast function	Controls front tilt angle for
stability			controller (front tilt angle	high lifting, etc.	S	S	—	11-10
			control)
Load collapse reduction			SAS-active mast function	Controls rear tilt speed for
			controller (rear tilt speed	high lifting, etc.	S	S	—	11-10
			control)
Operation error prevention for			SAS-active mast function	Prevents unintended fork	S	S	—	11-10
lift lever			controller (key-lift interlock)	lowering
Large reduction of natural			SAS-active mast function	Cuts off valve oil leaks
drop and front tilt (1/3 of			control (key-lift interlock)	when the key switch is	S	S	—	11-10
previous values)				turned OFF.
Easy monitoring of SAS			SAS-operation monitor,	Easy recovery from SAS
operation status			indicator lamp, and	faults	S	S	—	3-2
			diagnosis
Availability of maximum travel			Speedometer	Large display easy to see	S	S	—	3-4
speed control
			Speed alarm	Warning is given when
				travel speed exceeds	P	P	—	3-5
				preset level.
			Speed limiter	Sets limits to travel speed	S	S	—	3-4
Improved visibility			High-mount rear	Visibility of forklift truck from	P	P	—	9-6
			combination lamps	surrounding area
Forward view			Super-wide visible mast	Maintains advantages of	S	S	—	10-2
				internal width of wide mast.
			Operability, etc.
Easy operation			SAS-active mast function	Automatically sets the mast
			control (automatic fork	vertical.	S	S	—	11-12
			leveling control)
			Steerage, load handling	Reduced operation power	S	S	—	—
			lever, accelerator pedal
			Mini-lever		S	S	P	10-12
			Anti roll back		S	S	S	2-5
Improved traveling stability			Regenerative system	Regenerative braking	S	S	—	2-5
			(accelerator off)	equivalent to engine brake
Smooth and quick switchback			AC motor and AC controller	Quick switchback operation	S	S	—	2-5
operation				without time lag
Improved meter of screen			Multiple display	Legible display	S	S	—	3-2
Battery roll out					P	P	—	12-3

1-5

Outline of Design

Major differences from previous models

Item

New models

Previous models

Relative

Applicable

Applicable

page

model

model

General

Overhead guard

2195mm

1.6 ~ 1.8 ton

2160mm

1.6 ton

height

2195mm

2.0 ton

2180mm

2.0 ton

2215mm

2.5 ton

2180mm

2.5 ton

2215mm

3.0 ~ 3.5 ton

2275mm

3.0 ton

—

2310mm

4.0 ~ 5.0 ton

—

—

Wheelbase

1420mm

1.6 ~ 1.8 ton

1360mm

1.6 ton

1580mm

2.0 ~ 2.5 ton

1505mm

2.0 ~ 2.5 ton

1725mm

3.0 ~ 3.5 ton

1650mm

3.0 ton

2080mm

4.0 ~ 5.0 ton

—

—

Motor

Drive motor

AC:

12.0 / 13.3

kw

1.6 ~ 1.8 ton

DC:

7.6 / 8.6

kw

1.6 ton

(72V/80V)

AC:

15.4 / 17.1

kw

2.0 ~ 3.5 ton

DC:

10.1 / 10.6

kw

2.0 ~ 3.0 ton

5-2

AC: 14.9 / 16.6 kw

4.0 ~ 5.0 ton

—

—

Pump motor

AC: 12.0 / 13.5

kw

1.6 ~ 1.8 ton

DC:

11.5 / 13.0 kw

1.6 ton

(72V/80V)

AC:

16.9 / 18.6

kw

2.0 ~ 2.5 ton

DC:

14.8 / 17.0

kw

2.0 ~ 2.5 ton

10-27

AC:

16.9 / 18.6

kw

3.0 ~ 3.5 ton

DC:

16.5 / 18.5

kw

3.0 ton

AC: 22.8 / 25.4 kw

4.0 ~ 5.0 ton

—

—

PS motor

DC:

1.0 / 1.1 kw

1.5 ~ 3.5 ton

DC:

1.0 / 1.1 kw

1.5 ~ 3.0 ton

(72V/80V)

10-27

Same motor for PS as well as hydraulic oil

4.0 ~ 5.0 ton

—

—

pump

Controller

Traveling

Main controller & traveling motor driver

1.6 ~ 5.0 ton

Traveling & load handling controller

1.6 ~ 3.0 ton

Load handling

Main controller & load handling motor driver

1.6 ~ 3.5 ton

SAS

Controller of SAS

1.6 ~ 5.0 ton

—

Section

includes the steerage control

2, 11

Steerage

1.6 ~ 3.5 ton

Steerage controller

1.6 ~ 3.0 ton

Controller of main

4.0 ~ 5.0 ton

—

—

includes the steerage control

Brake

Main brake

Wet brake

1.6 ~ 5.0 ton

Dry brake

1.6 ~ 3.0 ton

5-10

mechanism

Parking brake

Parking brake system of electric switch type

1.6 ~ 5.0 ton

Parking brake lever of ratchet type

1.6 ~ 3.0 ton

5-13

SAS

SAS specifications

SAS-active control stability

—

—

11-6

equipment

Mast function control

•

Front tilt angle control

1.6 ~ 5.0 ton

•

Rear tilt speed control

—

—

11-10

•

Automatic fork leveling control

•

Key-lift interlock

Frame

Overhead guard

1055mm

1.6 ~ 3.5 ton

1030mm

1.6 ~ 3.0 ton

Clearance

1075mm

4.0 ~ 5.0 ton

—

—

Step height

525mm

1.6 ~ 1.8 ton

515mm

1.6 ton

2.0 ton

540mm

2.0 ~ 2.5 ton

545mm

2.5 ton

3.0 ~ 3.5 ton

675 (2nd) /160 (1st)

3.0 ton

Section

535mm

4.0 ~ 5.0 ton

—

—

9

Underclearance

90mm

1.6 ~ 1.8 ton

110mm

1.6 ton

Center of Wheelbase

2.0 ton

(Without load)

130mm

2.0 ~ 2.5 ton

110mm

2.5 ton

3.0 ~ 3.5 ton

225mm

3.0 ton

150mm

4.0 ~ 5.0 ton

—

—

Others

Floor mat

Equipped

1.6 ~ 5.0 ton

Nothing

1.6 ~ 3.0 ton

—

Material handling lever

Mini-lever with armrest

1.6 ~ 5.0 ton

Manual lever on the front cowl

1.6 ~ 3.0 ton

10-12

Seat

ORS seat with seat belt

1.6 ~ 5.0 ton

Seat with seat belt

1.6 ~ 3.0 ton

8-4

1

0

11

12

13

1-6

AC POWER SYSTEM

AC system in industrial trend

Industries have already employed AC power system by making use of its features. Three major features are:

	System design	Product level
	advantages	advantages
	Simpler and smaller	More powerful motor can
1	construction of motor	be used without
		increasing size.
	Three-phase AC control	Wide control range offers
2	realizes wider control	a higher performance
	range.	and operability.
	Motor brushes and	Reduced maintenance
	contactors are	cost as the needs for
3	dispensed with.	servicing motor brushes
		and contactors are
		eliminated.

Industry	1970	80	90
Machine tool
	DC		AC
Train
	DC		AC
Electric
Automobiles (EV)	DC		AC
Electric Forklifts
		DC

Thereby industrial truck engineers worldwide have already been aware of the splendid features of AC power system to be implemented in electric forklift trucks.

New AC drive motor systems have been adopted not only in the smaller capacity models, but also in the larger capacity models. This new system resolves the opposing factors between larger output necessity and compactness.

1-7

AC power system as compared with DC power system

In the DC power system the controller will chop the battery current in repetition and control the frequency cycles of ON and OFF. The motor performance will change in proportion with the frequency cycles between ON and OFF, thereby the inching at start to the max. performance is controlled.

The AC power system in the new models includes a controller that transforms the battery current into a threephase alternating current. The motor power is controlled by changing the sinusoidal waveform (frequency, amplitude, etc.) of the three-phase alternating current.

Motor drive voltage, motor construction, and controller details differ between DC and AC power systems, as follows:

Comparison between DC and AC power systems

Motor voltage

Motor construction

Controller

Mean voltage

Motor

Commutator

Brush

ON

Battery

Controller

Contactor

DCpower

system

Battery

OFF Mean voltage

Microcomputer

control

voltage

• A chopper circuit converts the bat-

•

Brushes and commutator require

•

Motor power can be controlled sim-

tery current (DC) into a rectangular

servicing.

ply via the mean DC voltage.

waveform and controls the mean

•

Complex mechanism

•

Contactors for reversing the motor

voltage at a desired level.

rotation are required.

Sine wave

Stator ferrit core

Stator coil

Controller

Battery

Motor

AC power

Battery

voltage

system

Motor

Microcomputer

voltage

control

• Controller converts battery current

•

Brushes and commutator, which re-

•

A control module converts DC into

(DC) into AC.

quire servicing, arer not used.

three-phase AC.

•

Compact and lightweight

•

Contactor for reversing the motor

rotation are not required.

1-8

Power keep function

(Functions in power mode: P, standard mode: S)

Power keep function using the benefit of AC power system further lengthen the operation hours epochally. With conventional electric powered forklift trucks, the vehicle performance decreases gradually as the battery level goes low.

The power keep function adopted to new models takes advantage of the increased controllability provided by the AC system to keep the vehicle performance even when the battery level has become low. With this power keep function, the maximum operating hours have increased by 25%, and the number of work cycles that can be completed without the operator noticing a decline in performance has also increased by 25%.

New power keep function offers a significant and essential improvement in the material handling efficiency. (See page 2-2 for further detail.)

Battery discharge level and vehicle performance

				Battery capacity
				warning
1.1					Battery usage
			New model
					limit area
1
0.9
0.8		Previous model			Lift
					interruption
Decrease in
performance				25% up
0.7			60%
0%	20%	40%		80%	100%

Battery discharge level (%)

Previous model (2.5 ton:S mode) Efficiency operation hour: 161min

New model (2.5 ton:S mode)

Efficiency operation hour: 200min

Even the battery indicator is flashing to indicate the charge warning, the performance level of 7FBMF series is batter than that of the former FBMF models.

In view of the battery protection, it is advisable to charge the battery before discharging to the limit.

1-9

Performance features in comparison

mfr: manufacturer

Traveling speed (km/h)

Acceleration (sec)

Slope climbing speed (km/h)

2.5 ton

[a]

[b]

[c]

*: Loaded

*Loaded: 0-10m

*Loaded: 1/10 slope

16

16

5.3

5.7

7.0

5.3

5.2

6.9

5.6

5.6

14

14

14

4.6

5.3

H

P

S

FBMF

mfrA

H

P

S

FBMF mfrA

H

P

S FBMF mfrA

Efficiency operation hours (min)

No of cycle (cycle)

[d] (Toyota 30m cycle)

[e] (Toyota 30m cycle)

*Battery 500Ah

*Battery 500Ah

200

185

131

138

161

163

111

112

125

88

H

P

S

FBMF

mfrA

H

P

S

FBMF

mfrA

Traveling speed (km/h)

Acceleration (sec)

Slope climbing speed (km/h)

4.5 ton

[f]

[g]

[h]

*Loaded

*Loaded: 0-10m

*Loaded: 1/10 slope

14

6.3

4.8

13

13

13

5.9

5.7

3.4

3.4

5.4

H

P

S

mfrA

H

P

S

mfrA

H

P

S

Efficiency operation hours (min)

No of cycle (cycle)

[i] (Toyota 50m cycle)

[j] (Toyota 50m cycle)

*Battery 700Ah

*Battery 700Ah

204

218

100

96

174

80

133

67

H

P

S

mfrA

H

P

S

mfrA

1-10

Operator comfort

(1)Improvement of the ease of getting on and off

By new battery layout, improved the ease of getting on and off

(mm)560

290

260

7FBMF FBMF mfrA

Entry clearance (2.5 ton) [a]

(2)Improvement of comfort

By new battery layout, improved the leg space

(mm)640 604

555

7FBMF FBMF mfrA

Leg space (2.5 ton) [b]

1-11

Power select function

Using the power select function, the operator can select a desirable power mode.

Even though the conventional models also had a power selection switch, it only produced a small difference in the acceleration.

New models use an AC motor instead of a DC motor.

Since and AC motor is simpler and smaller, it becomes possible to install a motor that produces an output higher than that of a conventional DC motor.

In addition, the operator can select appropriate mode from the following power modes simply by operating a switch.

• High power mode	: The most active mode with the quickest cycle-time
<H mode>
• Power mode	: The highest efficiency mode with quick cycle time and long operation hour
<P mode>
• Standard mode	: The longest operation hour mode with the performance equivalent to MFRA
<S mode>

In order to further satisfy the individual customer, a power select function has been provided.

The power select function enables the operator to select one from six power modes, including H, P and S modes, for traveling. The operator can select H mode for operations requiring power and high performance. Select S mode for long time operations, providing the operator with optimum performance to suit the operator’s needs and greatly enhance efficiency.

<7FBMF25>

Cycles

44

43

42

41

High power mode <H mode>

Previous

model

: Fixed mode

:Selectable only through power select function

: Power select function default setting

Power mode <P mode>

Standard mode <S mode>

30m cycle pattern		180min	240min

Efficient operation hours

1-12

Reduced maintenance cost

The following particular items are inherent to the conventional electric powered models.

Supplying distilled water to the battery

Material handling motor brush replacement

Material handling motor contactor replacement

Traveling motor brush replacement

Traveling motor contactor replacement

The new 7FBMF model eliminates the need for brush and contactor replacement because the new AC motor does not have brushes and the new AC controller does not have contactors.

The average customer can benefit from this by an annual cost savings of 69% for maintenance expenditures.

Eur (USD)		1460 (1490)	1Eur = 0.98USD
1500
	519	5	Annual Cost Saving 69%
1000			by Eliminating	~
	294	4
500	127	3	451 (460)
	69
			2
	451	1	1
0		Previous	New model
		model

Taking advantage of the wider control range of the AC power system, a regenerative system is adopted.

The AC induction motor generates a braking force when the vehicle is traveling with the accelerator pedal at rest. Also the electromotive force generated in the AC motor, while the accelerator pedal is released, converts the braking effect energy into electrical energy that is sent to the battery.

This regenerative system increases the operation hours. At the same time, the regenerative system improves the traveling feel because it allows the operator to use less brake pedal force to slow the truck down. Furthermore, the regenerative system reduces load on the brake system, slowing down brake lining wear and decreasing the brake maintenance costs.

1-13

Stabilizing features

The world-first System of Active Stability (SAS), adopted by the 7FB series models, is available for the new models, too.

Using the SAS the new models achieve the stability level equivalent to that achieved by the 7FB series models. The following outlines the SAS. For more details of the SAS option, refer to Section 11 “SAS”.

	Stability feature	Outline
	Rear stabilizer (swing lock)	The rear wheel swing mechanism is locked at high lift-heights and
		heavy loads, and during a quick turn to obtain a better ground grip
		force from all four wheels.
Mast function control
	Front tilt angle control	The front tilt angle is smaller at high heights and heavy loads;
		greater at low heights and light loads.
	Rear tilt speed control	The rear tilt speed is slower at high heights and faster at low
		heights.
	Key-lift interlock	The lift lever cannot function by inadvertent contact.
	Automatic fork leveling control	A push on a control button followed by a front tilt operation tilts the
		mast until the forks are horizontal.

Improvement on operability

1.Mini lever

The hydraulic control levers are displaced to the arm rest fore-front and optimal length, and spacing are given on basis of human engineering. An operator can manipulate the control lever with a hand on the arm rest. Fine operation adjustment can be achieved with the display. The control lever position is adjustable vertically as well as to lengthwise.

Pleasant material handling operation with less fatigue can be ensured.

1-14

Anti-rollback

The anti-rollback function is provided to prevent the truck from rolling down on a slope. This is realized by making use of the combined features of the drive motor electric brake and the parking brake.

Restarting can be done smoothly without rolling down.

Model line-up

The model line-up has been widened by the development to 3.5 ~ 5 ton class new model ranges; besides, the 1.8 ton model is added onto the 1 ~ 3 ton classes to meet with varied needs from the markets.

: New : Continuation

Capacity (kg)

1600	1800	2000	2500	3000	3500	4000	4500	5000
7FBMF
TOYOTA
FBMF

2-1

CONTROLLER

	Page
MAIN CONTROLLERS .............................................................	2-2
General .................................................................................	2-2
Controller Configuration Diagram ..............................	2-3
MAIN FEATURES OF CONTROLLER .................................	2-5

2

0

11

12

13

2-2

MAIN CONTROLLERS

General

AC system

The AC motor drive system controller has been provided with:

•Microcomputer-assisted travel inverter control (converts DC to three-phase AC)

•CAN (Controller Area Network) communication function between main controller and traveling/material handling controller.

•Communication function between multiple display and SAS controller.

This is a multi-functional controller with advanced electronics technology.

The controller offers the power select function and power keep function that take full advantage of the AC power system.

Power select function: Allows the operator to select from three traveling modes, H (High power) mode, P (Power) mode, and S (Standard) mode.

Power keep function: Maintains a high performance level even when the battery level becomes low and increases stress-free operation hours. (Available when P or S mode is selected.)

		AC motor maximum output
	Torque	AC power system output
		characteristics
		DC power system output
		characteristics (DC motor
		maximum output)

Revolution

Compared to the DC motor, the AC motor has higher output and a range of output characteristics is obtainable from the increased output.

AC and DC power system output characteristics with fully charged battery

Torque	AC power system output
	characteristics with discharged battery

DC power system output characteristics with discharged battery

Revolution

When the battery is discharged, the AC motor provides output characteristics closer to those of a fully charged battery than a DC motor does.

Compared with a DC motor of an equivalent size, an AC motor has a higher output.

The output characteristics of an AC motor are determined by the amplitude and frequency of the alternating current output by the controller.

The controller has a map stored in its memory of the optimum combinations of the current and frequency. Using these, the optimum output characteristics can be obtained for all conditions. When the power selection switch is operated, the controller switches the map and changes the output characteristics. The power select function thus enables the output characteristics to be changed in accordance with the vehicle usage conditions.

Power keep function

With a DC power system, the output characteristics are determined by the controller output voltage. The maximum output, therefore, is the output from the motor when the battery voltage is fully applied (chopper duty 100%). The output will decrease with the battery voltage as the battery is discharged.

With an AC power system, however, it is possible to maintain a high performance even when the battery level becomes low because the combination of the amplitude and frequency of the alternating current is changed as the battery level goes low.

2-3

Controller Configuration Diagram

1. Traveling & Load handling controller

System configuration diagram

	Battery				Traveling motor temperature sensor
		Traveling			Traveling speed sensor
		motor			Direction switch
	Traveling	driver			Traveling accelerator potentiometer
	AC motor
			Main		Brake switch
					Parking brake valve
			controller
					Material handling potentiometer
	Material	Material			Oil control	valve
		handling
	handling	motor			SAS(with PS) controller
	AC motor	driver
					Multiple display
					Material handling motor temperature sensor
					Material handling speed sensor
	Traveling and material handling controller
	Controller internal configuration diagram
	Traveling and material handling controller
	Main controller				Battery
	CPU board
					Power supply
					contactor
	Sensors
	and
	switches
		CPU	I	Cooling fan
			/
		RAM	O
	I	ROM
/					Traveling motor driver	Traveling
	O					AC motor
	Multiple		CAN
	display
			I/O
	EEPROM				Material handling	Material
					motor driver	handling
						AC motor
		Solenoid
			drive
	SAS		circuit		Oil control valve
	(with PS)
	controller
					Parking brake valve
		Comfortable operability is			CANBus
		realized by making fine control			Controller Area
		using microcomputer.			Network Bus

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CPU:	Central Processing Unit
ROM:	Read Only Memory (with built-in control program)
RAM:	Random Access Memory (memory content lost when power turned off)

EEPROM:Electrically Erasable Programmable Read Only Memory (memorizes data required for control and er-

	ror code.)
I/O:	Input/Output interface
CANI/O:	Controller Area Network Input/Output interface

2. SAS (With Power Steering) Controller

System configuration diagram

Battery

		Tire angle sensor
		Wheel angle sensor
	PS circuit	Control circuit
PS motor		Swing solenoid

			Knob position correcting valve
			Main controller
	SAS (with PS) controller
	Controller internal configuration diagram
	SAS (with PS) controller
	CPU board
	I/O	Yaw rate	Battery
		sensor

				Swing solenoid
Tire angle sensor		I
		/
	CPU
		O	Power & solenoid
Wheel angle sensor	I		drive board	Knob position
	/			correcting valve
	O

Main controller	*PS motor drive	*PS motor
	main circuit

The portions marked with * are applicable only to 7FBMF 16 ~ 35 models. CPU: Central Processing Unit

I/O: Input/Output interface

2-5

MAIN FEATURES OF CONTROLLER

1.Regenerative system (accelerator off)

When the vehicle travels with the accelerator off, a braking force produced by the motor generates electricity, which is retrieved by the battery. The working of the regenerative system extends the available operation hours and the service life of brake linings. At the same time, the regenerative system improves the travel speed controllability and stability because it allows the operator to use the soft braking force exerted by the motor. Even if the direction lever is at the neutral position, the regenerative system will function when the accelerator is off.

2.Regenerative system (brake pedal depressed)

Regenerative system is operated when the brake pedal is depressed as well, which allows to extend the available operation hours and the service life of brake lining.

Even if the direction is at the neutral position, the regenerative system will function when the brake pedal is depressed.

3.Regenerative system (switch back)

The switch back operation (It means the directional change during traveling) also regenerate electricity like the previous model. Furthermore the AC controller in the new model has no contactor for traveling so that the switch back operates smoother than before.

4.Power select function

Three traveling and material handling modes are available from a selection switch on the multiple display: H (high power) mode, P (power) mode, and S (standard) mode.

5.Advanced power select function (option)

The advanced power select function allows the operator to select a traveling power mode and a material handling power mode independently from each other. It also allows the operator to define a mode other than H, P, and S.

6.Power keep function

The power keep function maintains the vehicle performance at a high level even when the battery level is low. With the new models, stress-free operation hours for a battery charged have increased.

(The power keep function is available only when the operator selects P or S mode.)

7.Auto-off system

If the operator leaves the vehicle with the key switch ON, the auto-off system forcibly shuts down the controller (equivalent to key switch OFF) after a preset period to prevent wasteful expenditure of energy. To restart the vehicle, turn the key switch OFF and then ON.

8.Seat switch

The seat switch does not allow the vehicle to travel as well as any material handling to operate by the minilevers unless someone is on the operator's seat.

9.Anti-rollback function

The anti-rollback function makes it easy to start the vehicle on an inclined surface. This function is achieved by controlling both the drive motor and the brake system.

10.2-speed travel speed control

The 2-speed travel speed control switch sets a speed limit. The set value is adjustable by a switch on the multiple display.

11.Thermal Protector Overheat warning:

Temperature in the controllers and motors are monitored by temperature sensors. If an abnormally high temperature is detected, the controller output is reduced to prevent overheating. The display will warn the operator.

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12.Battery level computation

The controller monitors decrease in the battery voltage, computes the remaining capacity, and displays it as the current battery level.

13.Diagnostic function

The diagnostic function can detect abnormalities in the traveling controller and the material handling controller, operation mechanisms such as the accelerator, and sensors. When an abnormality is detected, the diagnostic function outputs a diagnostic code and takes the appropriate measure.

14.Analyzer function

The multiple display has an analyzer mode that can be used for troubleshooting or for testing operation mechanisms and motor drivers.

15.Over-discharge warning function

When the remaining capacity level reaches a specified level, the multiple display shows a warning and the load handling operation is restricted.

This will protect the battery and will urge the operator to charge the battery.

It is possible to release this restriction temporarily by turning the key switch off at once before resetting as emergency measures.

16.Return-to-neutral function

If the operator turns the key switch ON with the direction lever at the forward or reverse position or with the accelerator pedal depressed, the vehicle will not start. The operator has to return the direction lever and accelerator pedal to their neutral positions once in order to allow it to restart.

17.Parking brake ON warning

The buzzer sounds when the operator attempt to start the truck with the parking brake switch turned ON.

18.Parking brake OFF warning

The buzzer sounds to warn the operator when moving from the drive seat without the parking brake switch turned on.

19.Mini-lever control

Based on operation signals of the mini-lever, the main controller controls material handling operation by controlling solenoid valves and the material handling controller.

3-1

MULTIPLE DISPLAY

	Page
MULTIPLE DISPLAY INDICATION	....................................... 3-2
MULTIPLE DISPLAY FUNCTIONS .......................................	3-3
SERVICE FUNCTIONS .............................................................	3-9

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3-2

MULTIPLE DISPLAY INDICATION

General

Various essential data with regard to the truck status, warning signs, setting, meters, etc. are visible by switching display.

(Indication of - will be changed according to the functional operation.)

During parking

Initial screen after the key switching on

During traveling

Upon error occurrence

No.	Description	No.	Description
	Swing lock indicator		Power select indicator
	Parking brake indicator		Multiple display area
	Travel 2nd speed setting indicator		Travel 2nd speed control set switch
	Diagnostic mode indicator		Hour meter select switch
	Overheat warning indicator	11	Power select switch
	Battery capacity indicator

3-3

MULTIPLE DISPLAY FUNCTIONS

Table of Multiple Display Functions

: Available

—: Not available

			Easy model	All-round
Functions				model
			(standard)
				(optional)
		Battery capacity indicator
		Speedometer
Status		Travel 2nd speed setting indicator
display		Swing lock indicator
		Parking brake indicator
		Power select indicator
		Power select function
Level		Travel power control level setting
setting		Material handling power control level setting
		Travel 2nd speed control level setting
	11	Battery over-discharge warning
	12	Low battery capacity warning
	13	Overheat warning
Warning	14	Parking brake ON warning
	15	Parking brake OFF warning
	16	Return to neutral warning
	17	Over speed alarm	—
	18	Diagnostic code display
	19	Key switch on hour meter
	20	Travel or material handling motors service hour meter	—
	21	Travel motor service hour meter	—
Integrating	22	Material handling motor service hour meter	—
meters	23	Lap time meter	—
	24	Odometer	—
	25	Trip meter	—
	26	Calendar/Clock

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