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

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ELECTRIC FORKLIFT TRUCKS

FBMF 16,18

FBMF 20,25

FBMF 30,35

FBMF 40,45,50

< Tillbaka till Servicemanual 7FBMF 16-50

AUGUST 2002

Pub. No. PE313

Index

SECTION INDEX

NAME SECTION

GENERAL

DEVELOPMENT OBJECTIVES CONTROLLER MULTIPLE DISPLAY BATTERY POWER TRAIN STEERING & REAR AXLE TIRES OPERATOR’S COMPARTMENT BODY & ACCESORIES

0 1 2 3 4 5 6 7 8

MATERIAL HANDLING & HYDRAULICS SYSTEM SAS MAIN OPTIONS & ATTACHMENTS WIRING DIAGRAM

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

0-1

Page

VEHICLE EXTERIOR VIEWS

MODEL LINE-UP

STANDARD EQUIPMENTS

........................................................................0-3

.....................................................0-4

..................................................0-2

0-2

VEHICLE EXTERIOR VIEWS

7FBMF16~35

7FBMF40~50

MODEL LINE-UP

Models

0-3

1 ton Series

2 ton Series

3 ton Series

4 ton Series

Frame number stamping

Model

7FBMF16

7FBMF18

7FBMF20

7FBMF25

7FBMF30

7FBMF35

7FBMF40

Capacity

(Load Center 500 mm)

1.6 ton 7FBMF16 FBMF16

1.8 ton 7FBMF18 —

2.0 ton 7FBMF20 FBMF20

2.5 ton 7FBMF25 FBMF25

3.0 ton 7FBMF30 FBMF30

3.5 ton 7FBMF35 —

4.0 ton 7FBMF40 —

4.5 ton 7FBMF45 —

5.0 ton 7FBMF50 —

Stamping Style

(Starting Number)

7FBMF18 10011

7FBMF25 10011

7FBMF35 10011

Model (80V or 72 V)

New Previous

Stamping Location

Stamp on LH & upper surface of front cross plate

7FBMF45

7FBMF50

7FBMF50 10011

0-4

STANDARD EQUIPMENTS

Standard Equipment 1.6-3.5 ton 4.0-5.0 ton Note

: STD P:OPT —: Not Available

Electrical System

Chassis SAS (System of Active Stability)

Body Overhead guard

AC Power system for travelling & load handling

AC Power controller for steering — 1.6-3.5 ton: DC system

Multiple display (All round model) P P

Wet brake system

Parking brake system of electric switch type

Full hydraulic power steering

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 Handling System

Others Electric horn

Wide visible mast (V) H3300 mm

Load bucharest H1220 mm

Fork 1.6~1.8 ton: L800 mm

Mini-lever control system

3-way valve (A400)

Headlight P P

Rear-view mirror P P

2.0~5.0 ton: L1000 mm

DEVELOPMENT OBJECTIVES

1-1

Page

DEVELOPMENT OBJECTIVES

FEATURES (SELLING POINTS)

AC POWER SYSTEM

................................................................1-6

..............................................1-2

............................................1-3

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.

FEATURES (SELLING POINTS)

Table of selling points

Selling point Function or Item Objective

Improved performance

mfr: manufacturer

: Newly adopted, : Improved

S: STD, P: OPT, –: Not available

1.5

3.5t

4.0 ~

5.0t

mfr A

Relative

page

1-3

Improvement in operation hours and work cycles without an operator noticing a decline in performance

Availability of different power modes for different needs: H mode: High power mode P mode: Power mode S mode: Standard mode

Other customized modes are available as well.

Improvement in ease of getting on and 0ff

Increased leg space Expansion of foot space S S — 1-10

Improved serviceability AC motor Need for servicing motor

Reduced need for servicing brake

Power keep function Better performance at a low

battery level

Power select function A touch on a switch selects

optimum power mode.

Load handling power control

Improvement on operator comfort

The entry area has been widened by installing the battery under floor

Improved serviceability

Overheat protector Power is reduced

AC controller Need for servicing contactor

Thermal protector Output is reduced

Wet brake system Service life of brake system

Regenerative system (accelerator off)

Ease of getting on and off equivalent to the enginepowered model

brushes is eliminated.

automatically when motor is overheated.

is eliminated.

automatically when controller is overheated.

is prolonged

Service life of brake system is prolonged.

SS—

S—

SS—1-10

SS—1-7

SS—

SS—2-2

SS—

SSS5-10

SSS2-5

1-8 2-2

1-11 2-2

2-5 5-2

Higher safety during servicing Jacking points under the

counter weight and frame

Jacking points indicated for higher safety

SS—9-2

1-4

Selling point Function or Item Objective

Safety

1.6 ~

3.5t

4.0 ~

5.0t

mfrA

Relative

Page

Improved turning stability SAS-active control rear

stabilizer

Improved material handling stability

Load collapse reduction SAS-active mast function

Operation error prevention for lift lever

Large reduction of natural drop and front tilt (1/3 of previous values)

Easy monitoring of SAS operation status

Availability of maximum travel speed control

SAS-active mast function controller (front tilt angle control)

controller (rear tilt speed control)

SAS-active mast function controller (key-lift interlock)

SAS-active mast function control (key-lift interlock)

SAS-operation monitor, indicator lamp, and diagnosis

Speedometer Large display easy to see S S — 3-4

Speed alarm Warning is given when

Speed limiter Sets limits to travel speed S S — 3-4

Rear wheel ground grip force increased when required

Controls front tilt angle for high lifting, etc. S S — 11-10

Controls rear tilt speed for high lifting, etc. S S — 11-10

Prevents unintended fork lowering

Cuts off valve oil leaks when the key switch is turned OFF.

Easy recovery from SAS faults S S — 3-2

travel speed exceeds preset level.

SS—11-6

SS—11-10

PP—3-5

Improved visibility High-mount rear

combination lamps

Forward view Super-wide visible mast Maintains advantages of

Operability, etc.

Easy operation SAS-active mast function

control (automatic fork leveling control)

Steerage, load handling lever, accelerator pedal

Mini-lever S S P 10-12

Anti roll back S S S 2-5

Improved traveling stability Regenerative system

(accelerator off)

Smooth and quick switchback operation

Improved meter of screen Multiple display Legible display S S — 3-2

Battery roll out PP—12-3

AC motor and AC controller Quick switchback operation

Visibility of forklift truck from surrounding area

internal width of wide mast.

Automatically sets the mast vertical. S S — 11-12

Reduced operation power

Regenerative braking equivalent to engine brake

without time lag

PP—9-6

SS—10-2

SS— —

SS—2-5

Outline of Design

Major differences from previous models

1-5

Item New models Previous models

General Overhead guard

Motor Drive motor

Controller Traveling Main controller & traveling motor driver 1.6 ~ 5.0 ton

Brake mechanism

SAS equipment

Frame Overhead guard

Others Floor mat Equipped 1.6 ~ 5.0 ton Nothing 1.6 ~ 3.0 ton

height

Wheelbase 1420mm 1.6 ~ 1.8 ton 1360mm 1.6 ton

(72V/80V)

Pump motor (72V/80V)

PS motor (72V/80V)

Load handling Main controller & load handling motor driver 1.6 ~ 3.5 ton

SAS Controller of SAS

Steerage 1.6 ~ 3.5 ton Steerage controller 1.6 ~ 3.0 ton

Main brake Wet brake 1.6 ~ 5.0 ton Dry brake 1.6 ~ 3.0 ton 5-10

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 specifications SAS-active control stability

Clearance

Step height

Underclearance Center of Wheelbase (Without load)

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

AC: 12.0 / 13.3 kw 1.6 ~ 1.8 ton DC: 7.6 / 8.6 kw 1.6 ton

AC: 14.9 / 16.6 kw 4.0 ~ 5.0 ton — —

AC: 12.0 / 13.5 kw 1.6 ~ 1.8 ton DC: 11.5 / 13.0 kw 1.6 ton

AC: 16.9 / 18.6 kw 2.0 ~ 2.5 ton DC: 14.8 / 17.0 kw 2.0 ~ 2.5 ton

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 — —

DC: 1.0 / 1.1 kw 1.5 ~ 3.5 ton DC: 1.0 / 1.1 kw 1.5 ~ 3.0 ton

Same motor for PS as well as hydraulic oil pump

includes the steerage control

Controller of main includes the steerage control

Mast function control

• Front tilt angle control

• Rear tilt speed control

• Automatic fork leveling control

• Key-lift interlock

2195mm 1.6 ~ 1.8 ton 2160mm 1.6 ton

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 — —

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 — —

1055mm 1.6 ~ 3.5 ton 1030mm 1.6 ~ 3.0 ton

1075mm 4.0 ~ 5.0 ton — —

525mm

545mm

535mm 4.0 ~ 5.0 ton — —

90mm

110mm

150mm 4.0 ~ 5.0 ton — —

Applicable

model

4.0 ~ 5.0 ton — —

Traveling & load handling controller 1.6 ~ 3.0 ton

1.6 ~ 5.0 ton —

4.0 ~ 5.0 ton — —

——11-6

1.6 ~ 5.0 ton

1.6 ~ 1.8 ton 515mm 1.6 ton

2.0 ton

2.5 ton

3.0 ~ 3.5 ton 675 (2nd) /160 (1st) 3.0 ton

1.6 ~ 1.8 ton 110mm 1.6 ton

2.0 ton

2.5 ton

3.0 ~ 3.5 ton 225mm 3.0 ton

——11-10

540mm 2.0 ~ 2.5 ton

130mm 2.0 ~ 2.5 ton

Applicable

model

Relative

page

—

5-2AC: 15.4 / 17.1 kw 2.0 ~ 3.5 ton DC: 10.1 / 10.6 kw 2.0 ~ 3.0 ton

10-27

Section 2, 11

Section

—

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 advantages

Simpler and smaller

construction of motor

Three-phase AC control

realizes wider control range.

Motor brushes and contactors are dispensed with.

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.

Product level advantages

More powerful motor can be used without increasing size.

Wide control range offers a higher performance and operability.

Reduced maintenance cost as the needs for servicing motor brushes and contactors are eliminated.

Industry 1970 80 90

Machine tool

DC AC

Train

DC AC

Electric Automobiles (EV)

Electric Forklifts

DC AC

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

1-7

DC power system

AC power system

Mean voltage

Controller

Battery voltage

OFF

Mean voltage

• A chopper circuit converts the battery current (DC) into a rectangular waveform and controls the mean voltage at a desired level.

Sine wave

Controller

Battery voltage

Motor voltage

Commutator

Brush

• Brushes and commutator require servicing.

• Complex mechanism

Stator ferrit core

Stator coil

Motor

Battery

Contactor

Microcomputer control

• Motor power can be controlled simply via the mean DC voltage.

• Contactors for reversing the motor rotation are required.

Battery

Motor

Microcomputer control

• Controller converts battery current (DC) into AC.

• Brushes and commutator, which require servicing, arer not used.

• Compact and lightweight

• A control module converts DC into three-phase AC.

• 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

New model

Battery usage limit area

0.9

0.8

0.7

Decrease in performance

20% 40%

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

Previous model

25% up

60%

Lift interruption

80% 100%

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

2.5 ton

Traveling speed (km/h) [a]

*: Loaded *Loaded: 0-10m

HPSFBMF

mfrA H P S FBMF

Efficiency operation hours (min) [d] (Toyota 30m cycle)

*Battery 500Ah

200

185

163

161

125

Acceleration (sec) [b]

5.7

5.3

4.6

No of cycle (cycle) [e] (Toyota 30m cycle)

*Battery 500Ah

138

131

mfr: manufacturer

Slope climbing speed (km/h) [c]

*Loaded: 1/10 slope

5.3

5.2

mfrA

111 112

6.9

HPSFBMF

5.6

7.0

5.3

mfrA

4.5 ton

HPSFBMF

Traveling speed (km/h) [f]

*Loaded *Loaded: 0-10m

13 13 13

HPS

Efficiency operation hours (min) [i] (Toyota 50m cycle)

*Battery 700Ah

218

204

133

mfrA H P S FBMF

Acceleration (sec) [g]

5.9

5.4

mfrA

HPS

No of cycle (cycle) [j] (Toyota 50m cycle)

*Battery 700Ah

174

6.3

100

5.7

mfrA

Slope climbing speed (km/h) [h]

*Loaded: 1/10 slope

4.8

3.4 3.4

HPS

mfrA

HPS

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

7FBMF

290

FBMF

260

mfrA

Entry clearance (2.5 ton) [a]

(2) Improvement of comfort

By new battery layout, improved the leg space

(mm)

640

7FBMF

604

FBMF

555

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

• Power mode

: The highest efficiency mode with quick cycle time and long operation hour

• Standard mode

: The longest operation hour mode with the performance equivalent to MFRA

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>

: Fixed mode

Cycles

High power mode <H mode>

: Selectable only through

power select function

: Power select function

default setting

30m cycle pattern

Previous model

Power mode <P mode>

Standard mode <S mode>

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)

1500

519

1460 (1490)

1Eur = 0.98USD

Annual Cost Saving 69% by Eliminating ~

1000

1 1

model

451 (460)

New model

500

294

127

451

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

CONTROLLER

2-1

Page

MAIN CONTROLLERS

General

Controller Configuration Diagram

MAIN FEATURES OF CONTROLLER

.................................................................................2-2

.............................................................2-2

.............................. 2-3

.................................2-5

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

AC power system output characteristics

Torque

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.

Torque

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

AC and DC power system output characteristics with fully charged battery

AC power system output characteristics with discharged battery

DC power system output characteristics with discharged battery

Revolution

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.

Controller Configuration Diagram

1. Traveling & Load handling controller

System configuration diagram

2-3

Battery

Traveling

motor Traveling AC motor

Material

handling

AC motor

driver

Main

controller

Material handling

motor driver

Traveling and material handling controller

Controller internal configuration diagram

Traveling and material handling controller

Main controller

CPU board

Traveling motor temperature sensor

Traveling speed sensor

Direction switch

Traveling accelerator potentiometer

Brake switch

Parking brake valve

Material handling potentiometer

Oil control valve

SAS(with PS) controller

Multiple display

Material handling motor temperature sensor

Material handling speed sensor

Battery

Sensors

and

switches

Multiple

display

SAS (with PS) controller

I /

CPU

RAM

ROM

EEPROM

Comfortable operability is

realized by making fine control

using microcomputer.

I /

CAN

I/O

Solenoid

drive

circuit

Cooling fan

Power supply

contactor

Traveling motor driver

Material handling

motor driver

Oil control valve

Parking brake valve

CANBus

Controller Area

Network Bus

Traveling AC motor

Material handling

AC motor

2-4

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 motor

PS circuit

Control circuit

Swing solenoid

Knob position correcting valve

Main controller

SAS (with PS) controller

Controller internal configuration diagram

SAS (with PS) controller

CPU board

I/O

Tire angle sensor

Wheel angle sensor

CPU

I /

Yaw rate

sensor

Power & solenoid

drive board

Battery

Swing solenoid

Knob position

correcting valve

Main controller

*PS motor drive

main circuit

The portions marked with * are applicable only to 7FBMF 16 ~ 35 models. CPU: Central Processing Unit I/O: Input/Output interface

*PS motor

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.

2-5

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.

2-6

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.

MULTIPLE DISPLAY

3-1

Page

MULTIPLE DISPLAY INDICATION

MULTIPLE DISPLAY FUNCTIONS

SERVICE FUNCTIONS

.............................................................3-9

.......................................3-2

.......................................3-3

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

No. Description No. Description

Swing lock indicator Power select indicator

Upon error occurrence

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 Power select switch

Battery capacity indicator

MULTIPLE DISPLAY FUNCTIONS

Table of Multiple Display Functions

3-3

: Available

—: Not available

Functions

Status display

Level setting

Battery capacity indicator

Speedometer

Travel 2nd speed setting indicator

Swing lock indicator

Parking brake indicator

Power select indicator

Power select function

Travel power control level setting

Material handling power control level setting

Travel 2nd speed control level setting

Battery over-discharge warning

Low battery capacity warning

Overheat warning

Easy model

(standard)

All-round

model

(optional)

Warning

Integrating meters

Parking brake ON warning

Parking brake OFF warning

Return to neutral warning

Over speed alarm —

Diagnostic code display

Key switch on hour meter

Travel or material handling motors service hour meter —

Travel motor service hour meter —

Material handling motor service hour meter —

Lap time meter —

Odometer —

Trip meter —

Calendar/Clock

3-4

Explanation of list items

Easy model (standard) and all-round model

Difference between easy model (standard) and all-round model (option) As shown in the table, all-round model (option) has additional optional meters, such as No. - .

Status display

The indications with regard to the existing condition (or Status quo) of the truck before or during the operation

Battery capacity indicator Battery capacity indicator shows the remaining battery level in 10 stage mark.

Speedometer Speedometer indicates speed digitally in 1 km/h. When stopping, the part of the display of the vehicle speed shows the date and the clock, and only when traveling, displays the vehicle speed.

Travel 2nd speed setting indicator This indicator comes on or goes off whenever the operator presses the travel 2nd speed control switch. This indicator is lit when the travel 2nd speed control is effect, limiting the vehicle speed at a preset level. The speed control level can be set using the travel 2nd speed control level setup screen.

Swing lock indicator This indicator is lit when the swing lock cylinder of SAS function is locked. This indicator goes off automatically when the swing lock cylinder is unlocked.

Parking brake indicator The operation indicator blinks while the parking brake is in operation.

Power select indicator It is a mode being enclosed with of S P H which has been selected now. Whenever the power select switch is pushed, the select mode can be changed. When “POWER SELECT” is “YES” on the power control selec- tion screen, all S P H is enclosed with .

3-5

Level setting

The level with regard to the manipulation and the performance can be selected and set up in compliance with needs.

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.

Travel power control level setting Setting becomes possible only when setting “YES” on the power control selection screen. The power control level can be set besides the S P H mode.

Material handling power control level setting Setting becomes possible only when setting “YES” on the power control selection screen. The power control level can be set besides the S P H mode.

Travel 2nd speed control level setting The travel 2nd speed set up and its cancellation can be done on the screen, and the maximum speed is restrained from exceeding by the set up speed.

Warning

Faults or risks can be detected and warning are given .

Battery over-discharge warning If the battery is further discharged to another preset level after the low battery level warning has been given, all segments in the battery level indicator blink and a buzzer sounds to warn the operator.

Low battery capacity warning If the battery level goes below a preset level, the battery level indicator blinks. If the operator turns the key switch from OFF to ON when the battery level is below this level, a buzzer will sound five seconds to warn the operator.

Overheat warning

Overheat warning indicator blinks and a buzzer sounds to warn the operator when traveling motor, or material handling motor, and the controller overheats.

Parking brake ON warning The buzzer sounds when the operator attempt to start the truck with the parking brake set.

Parking brake OFF warning The buzzer sounds to warn the operator when moving from the drive seat without setting the parking brake.

Return-to-neutral warning The buzzer sounds when the operator turns the key switch on while depressing the accelerator pedal or turning the direction switch on to start the vehicle.

Over speed alarm (option) When the set speed is exceeded, it is detected and the speed indicator blinks and the buzzer sounds to give a warning to the operator. Unlike travel 2nd speed control, even if the set speed is exceeded, any speed restriction is not applied.

Diagnostic mode indicator This indicator blinks when the diagnostic mode operates, the error code is displayed, and the buzzer sounds.

3-6

Integrating meters (or multiple hour meter)

The indication differs between the easy model (standard) and the all-round model (option), as listed in the table

on page 3-3. The meter ~ are available to the all-round model.

In addition to the key-on-hours, the travelling and the material handling hours, and the travel distance can be shown by total figures.

Key switch on hour meter Total hours of the Key switch on time are shown

Travel or material handling motors service hour meter (option)

Drive motor running hours + (plus) material handling motor running hours are shown in total hours. Length of time during which both motors are running, one motor only is counted.

Travel motor service hour meter (option) Travel motor running hours in total are shown.

Material handling motor service hour meter (option) Material handling motor running hours in total are shown.

Lap time meter (option)

Key on time in total during predetermined period is shown.

Odometer (option) Travel distance in total is shown.

Trip meter (option)

Travel distance per trip is shown.

Calender / clock See page 3-2 (Top drawing.)

Display screen list

<Initial screen> Initial screen is displayed for a few seconds after key-switch ON.

Press switch ........ Travel 2nd speed control ON and OFF

Press switch ........Hour meter screen

Press switch ........ Power select (S

Press switch ........for more than 2 seconds ... Next screen

→P→

<Normal function> The power select switch is reset in the S mode.

3-7

Press switch ........Decrease the set level

Press switch ........ Increase the set level

Press switch ........ Next screen

<Over speed alarm setting> All-round model (option) only

Press switch ........Decrease the set speed

Press switch ........Increase the set speed

Press switch ........ Next screen

Press switch ........Changes the setting from “NO” to “YES”

Press switch ........Changes the setting from “YES” to “NO”

Press switch ........Select “YES”

Travel power control

→

screen Select “NO”

Next screen

→

- Continued -

3-8

Press switch ........ Changes the setting from “NO” to “YES”

Press switch ........ Changes the setting from “YES” to “NO”

Press switch ........ Select “YES”

Select “NO”

Clock set screen

→

Normal function screen

→

3-9

SERVICE FUNCTIONS

Multiple display has the service function to use when the serviceman maintain and set the specification of the vehicle. Never to destroy important internal data by using the service function wrong, the service functions are protected by the password.

Functions Description

Used for displaying the operation status of electrical systems

Analyzer

onboard or for accessing information on errors detected by the controller.

Tuning

Option setting

Specifications

Availability of controls

Multiple hour meter startup

Used for fine-tuning the traveling and material handing control features.

Used for changing the setups according to the availability of options.*

Used for changing the setups according to the availability of various control features.

Used for starting up the multiple hour meter.

Used for setting and canceling the demonstration mode. (Function

Demonstration mode

prohibiting material handing operation during traveling which is set at the time delivery.)

Matching

Wheel dia. (tire constant)

Used for readjusting the sensor signal voltage values associated with the standard vehicle condition.

Used for improving the speedometer accuracy by updating the wheel diameter information.

These functions are used to adjust the controller and display setups to the availability of optional or control features. They do not enable or disable the actual functioning of the optional or control features.

BATTERY

4-1

Page

SPECIFICATION

NECESSARY BATTERY WEIGHT

RECOMMENDED BATTERIES

BATTERY CONNECTOR RELEASE

BATTERY STOPPER

BATTERY INTERCHANGEABILITY

RECOMMENDED BATTERY LIST

TABLE OF WORKING HOURS

.........................................................................4-2

........................................4-2

..............................................4-2

................................................................4-3

........................................4-4

..............................................4-5

....................................4-2

.....................................4-3

4-2

SPECIFICATION

The batteries are not set up as TOYOTA genuine parts. Use a battery compatible to DIN43 536 (See the battery case dimensions listed in the table on page 4-4).

Length

In case where high height battery type and battery roll out option are selected, the battery case dimensions are different from the STD type. Use a battery attached with the intermediate tapping led.

Height

Width

NECESSARY BATTERY WEIGHT

When installing a battery, refer to the table on page 4-4. adjust the weight so that the necessary minimum weight is satisfied.

RECOMMENDED BATTERIES

Refer to the table on page 4-4.

BATTERY CONNECTOR RELEASE

The battery connector release is the standard equipment in all the models. Since the battery connecter is located under the battery hood, it is necessary to disconnect at the operator’s seat by the lever operation.

4-3

Note: Use a battery connector (320A, 50sq) compatible to DIN

43 589 with Auxiliary electrode (the recommended connector is FEM 320A made by REELS. The dimensions of the hook is as illustrated. Don't use any other connector. When a battery is installed locally, always check that the connector can be released by the release lever.

BATTERY STOPPER

Newly designed battery stopper prevents the battery from coming out, even if the truck should tip over. Always check that the stopper is securely locked by the spring, as illustrated.

Where the high height type battery option or the battery roll out type option is installed, always check that the battery hood is securely locked, because the hoods prevent the battery from coming out even if the truck should tip over.

48mm

Controller cover

127mm

Stopper pin

BATTERY INTERCHANGEABILITY

The dimensions of the battery case for the previous models are equivalent to those of high height battery type option on the new models. But in order to install the previous battery on the new model, it is necessary to change the battery connector and the cable (160A, 35 sq

320A, 50 sq).

→

Spring

Battery guard

Battery caseStopper pin

4-4

RECOMMENDED BATTERY LIST

Vehicle type Voltage

7FBMF16,18 80 STD 4PzS440L

7FBMF20,25 80 STD 5PzS550L

7FBMF30,35 80 STD 6PzS660L

7FBMF

40,45,50

Battery

type

OPT

(High

height

battery

and Battery roll out)

OPT

(High

height

battery

and Battery roll out)

OPT

(High

height

battery

and Battery roll out)

80 STD 7PzS770L

OPT

(High

height

battery

and Battery roll out)

DIN No. Supplier Model

3PzS420L

4PzS560L

5PzS700L

6PzS840L

VARTA

OLDHAM

FULMEN

VARTA

OLDHAM

CHLORIDE

FULMEN

VARTA

OLDHAM

FULMEN

VARTA

OLDHAM

CHLORIDE

FULMEN

VARTA

OLDHAM

FULMEN

VARTA

OLDHAM

CHLORIDE

FULMEN

VARTA

OLDHAM

FULMEN

VARTA

OLDHAM

FULMEN 80 v 6EPSZ 930 930 ↑↑↑ ↑

DNA4(4PzS480Hx) 480 ↑↑↑ ↑

DNA55(PzS600Hx) 600 ↑↑↑ ↑

DNA6(6PzS720Hx) 720 ↑↑↑ ↑

DOA5(5PzS750Hx) 750 ↑↑↑ ↑

DNA7(7PzS840Hx) 840 ↑↑↑ ↑

DOA6(6PzS900Hx) 900 ↑↑↑ ↑

Installed battery Battery case Necessaey minimum battery weight

Capacity

[AH/5hr]

4PzG400 400 708 1026 627 1220

4PzS440L 440 ↑↑↑ ↑

4PzS480Hx 480 ↑↑↑ ↑

DPA4 400 ↑↑↑ ↑

80 v 4EPSZ 460 460 ↑↑↑ ↑ 80 v 4EPSZ 500 500 ↑↑↑ ↑

3PzG360 360 567 1028 784 1240

3PzS420L 420 ↑↑↑ ↑

3PzS450Hx 450 ↑↑↑ ↑

DZA3 390 ↑↑↑ ↑

DOA3 450 ↑↑↑ ↑ WESD7 360 ↑↑↑ ↑ WFSD7 450 ↑↑↑ ↑

SDH3 360 ↑↑↑ ↑

EGX3 450 ↑↑↑ ↑

5PzG500 500 852 1026 627 1530

5PzS550L 550 ↑↑↑ ↑

5PzS600Hx 600 ↑↑↑ ↑

DPA5 500 ↑↑↑ ↑

80 v 5EPSZ 575 575 ↑↑↑ ↑ 80 v 5EPSZ 625 625 ↑↑↑ ↑

4PzG480 480 711 1028 784 1560

4PzS560L 560 ↑↑↑ ↑

4PzS600Hx 600 ↑↑↑ ↑

DZA4 520 ↑↑↑ ↑

DOA4 600 ↑↑↑ ↑ WESD9 480 ↑↑↑ ↑ WFSD9 600 ↑↑↑ ↑

SDH4 480 ↑↑↑ ↑

EGX4 600 ↑↑↑ ↑

6PzG600 600 996 1026 627 1780

6PzS660L 660 ↑↑↑ ↑

6PzS720Hx 720 ↑↑↑ ↑

DYA6(6PzS660L) 660 ↑↑↑ ↑

80 v 6EPSZ 690 690 ↑↑↑ ↑ 80 v 6EPSZ 750 750 ↑↑↑ ↑

5PzG600 600 855 1028 784 1860

5PzS700L 700 ↑↑↑ ↑

5PzS750Hx 750 ↑↑↑ ↑

DZA5 650 ↑↑↑ ↑

WFSD9 600 ↑↑↑ ↑

WFSD11 750 ↑↑↑ ↑

EGX4 600 ↑↑↑ ↑

EGX5 750 ↑↑↑ ↑

7PzG700 700 1140 1034 627 2030

7PzS770L 770 ↑↑↑ ↑

7PzS840Hx 840 ↑↑↑ ↑

DYA7(7PzS770L) 770 ↑↑↑ ↑

80 v 7EPSZ 805 805 ↑↑↑ ↑ 80 v 7EPSZ 875 875 ↑↑↑ ↑

6PzG720 720 999 1028 784 2180

6PzS840L 840 ↑↑↑ ↑

6PzS900Hx 900 ↑↑↑ ↑

6PzS840L 840 ↑↑↑ ↑

Dimensions[mm] Dimensions[kg]:With case

Length Width Height

TABLE OF WORKING HOURS

Table of Working Hours (S-Mode)

4-5

Model

7FBMF16 80, (72)

7FBMF18 80, (72)

7FBMF20 80, (72)

7FBMF25 80, (72)

7FBMF30 80, (72)

7FBMF35 80, (72)

7FBMF40 80, (72)

Battery Voltage

(V)

Battery Capacity

(AH/5hr)

400 4 h 30 min.

480 5 h 40 min.

400 4 h 20 min.

480 5 h 25 min.

500 4 h 55 min.

600 6 h 00 min.

500 4 h 30 min.

600 5 h 35 min.

720 6 h 50 min.

600 5 h 15 min.

720 6 h 30 min.

700 5 h 05 min.

840 6 h 15 min.

Working Hours

( h min. )

7FBMF45 80, (72)

700 4 h 50 min.

840 6 h 00 min.

700 4 h 30 min.

7FBMF50 80, (72)

840 5 h 35 min.

Note:

1. Working Hours 7FBMF16 ~ 35 : TOYOTA 30m operation cycle 7FBMF40 ~ 50 : TOYOTA 50m operation cycle

2. Working Hours of H-Mode 1 ton Series : about 65% down of S-Mode Above 2 ton model : about 73% down of S-Mode

3. Working Hours of P-Mode All model : about 92% down of S-Mode

POWER TRAIN

5-1

Page

DRIVE MOTOR

DRIVE UNIT

FRONT AXLE

BRAKE

PARKING BRAKE

PARKING BRAKE SYSTEM

BRAKE PEDAL

........................................................................................5-10

............................................................................5-2

.................................................................................5-7

..............................................................................5-9

....................................................................5-13

.........................................................................5-17

.................................................5-15

5-2

DRIVE MOTOR

General

1. The new models use a newly developed AC induction motor as the drive motor. Being compact, powerful, and maintenance-free, the new motor has ideal characteristics for a motor used in a battery-powered forklift truck.

2. Since the new motor is so compact, it provided enough space under the floor to install the battery. With the battery installed under the floor, the new models incorporate improvements in the ease of getting on and off of the vehicle and operator comfort.

3. The new motor is maintenance-free; it does not have brushes that have to be serviced.

Drive unit

Field core

Rotor

Field winding

Speed sensor bearing

Drive motor characteristic

The newly developed AC induction motor characteristics are as follows:

• The motor is directly installed to the drive unit case (semi-built-in structure). Consequently, the drive motor as-

sembly is very compact.

• Optimized motor core form and coils have improved the motor efficiency.

• High-precision rpm sensors have been adopted to directly detect revolving speed, realizing power selection

function, power keep function and other fine-textured functions.

• The motor temperature detection sensor has been adopted to alert the controller and prevent the motor from

overheating during overloaded operation.

Note: The truck performance may go down temporarily under the severe use condition such as contin-

uous operation with a heavy load. The performance decline at the time is not at all abnormal since it has been so arranged that the controller and the motor can be prevented from overheating. The temperature sensors incorporated in the controllers as well as the motors detect the temperature rise, and the control by which current supply toward the motors has undergone restriction will take place. On the occasion the monitoring display shows where subjected to overheat. In the event of the overheat indication, wait the truck operation for a while until the display indication has gone away.

Main specifications

5-3

7FBMF16,18 72/80 12.0/13.3 Three phase AC

7FBMF20,25,30,

STD

7FBMF40,45,50 72/80 14.9/16.6 Three phase AC

Models

Nominal

voltage (V)

72/80 15.4/17.1 Three phase AC

Drive unit

Rated output

(kW)

Length

Rotor

Type

Body size

Diameter × Length (mm)

270 × 260 62

270 × 285 73

270 × 340 96

Field winding

Weight

(kg)

Field core

Diameter

Speed sensor bearing

5-4

Structure and principle of AC induction motor

AC induction motor has no brushes, commutator and the sliding portion as opposed to the conventional DC motor.

Consequently it has the following characteristics:

1. For the same output, the motor dimensions can be reduced by the portion L for the brushes and commutator.

2. For the same motor dimensions, core dimensions can be increased by the portion L, subsequently increasing the output.

3. Smaller number of parts and no sliding portion make the motor highly reliable.

An optimum AC induction motor has been developed for new models by incorporating these characteristics.

Induction motor Previous motor (DC motor)

Commutator (Sliding portion)

Field core

Field winding

Rotor

Field winding

Rotor

Field core

Brushes

A rotor assembly consists of a number of identical aluminum conductor bars sunk into slots in a laminated steel core, and the end rings that combine both ends of the conductor bars on the sides of the core as shown. Since the bars and the end rings form like a cage for a squirrel or mouse, it is called a cage rotor.

Core

Rotor assembly

End ring

Cage rotor

Slots in a laminated steel field core

End ring

Aluminum conductor bar

5-5

Operational sequence

1. The current flows in a fixed direction in the field winding in the figure. Magnetic field is produced around the field winding in the illustrated direction according to the right-hand rule*, and magnetic poles (N-pole and Spole) are generated.

2. Now suppose that the magnetic poles are rotated clockwise. Then the bar of the rotor is considered to be rotated to the counterclockwise direction.

3. Now, according to the Fleming’s right-hand rule*, electro motive force is generated to the bar of the rotor in the illustrated direction.

4. Because of the electro motive force generated to the bar of the rotor, a clockwise force is generated to the bar according to Fleming’s left-hand rule.*

5. Thus rotational torque is generated by electromagnetic force. The rotating speed of rotor is slightly slower than the revolution of the field pole.

6. Actually, the field winding on the periphery is not moving. Sine wave from each phase of the three-phase alternating current produces rotating magnetic field, generating torque to the rotor.

Field winding

Direction of current

Direction of current induced in the bar

Current direction

Rotor (field winding)

Field winding

Direction of force

Rotational direction of pole

N pole

Magnetic field

S-pole

: Current flow from the rear to the front

: Current flow from the front to the rear

Rotational direction of pole

Direction of force

Rotational direction of cage rotor

Magnetic field

Rotational direction of Magnetic pole

* See the next page.

5-6

Operating principle of motor

Before explaining the operating principle of motor, Ampere’s right thread rule and Fleming’s rule will be explained.

1. Right handed screw rule Extend the thumb of the right hand and close the fingers. If you point the thumb in the direction of current flow as illustrated, the magnetic field is produced at right angle to the current direction and in the direction of the closed fingers.

Magnetic field

Direction of current

2. Fleming’s right-hand rule Arrange for a fixed object on which a linear object can freely move as shown. In this state, when the magnetic field is produced in the illustrated direction, moving the linear object in the illustrated direction produces current. The direction of current is as illustrated:

3. Fleming’s left-hand rule Arrange for a fixed object on which a linear object can freely move as shown. In this state, when the magnetic field is produced in the illustrated direction, current flowing in the fixed object causes a force acts on the linear object in the illustrated direction.

Direction of current

Direction of magnetic field

Magnetic field

Direction of motion

Direction of current

Magnetic field

Direction of motion

Direction of force

Direction of magnetic field

Magnetic field

Direction of force

Direction of current

Magnetic field

DRIVE UNIT

Features

1. The drive unit has been changed, as follows:

5-7

Previous models

4-axes, 3-stages speed reduction

2. The parking brake has been set up on the drive motor shaft due to the adoption of the wet brake.

3. New models like the previous models, the drive motor has been installed to the drive unit in “Semi-built-in structure”, on a parallel to the front axle.

4. New models, like the previous models, use the liquid gasket (FIPG) to obtain high sealing effect on the drive unit housing.

5. As the lubricant, use the gear oil suitable for the wet brake.

Note: Use gear oil only TOYOTA specified:

SHELL DONAX TD

6. New models like the previous models, helical gear having high transmitting efficiency has been adopted to all the gears.

7. Gear ratio table

New model Previous model

1-ton Series 89/16 × 54/11 = 27.307 52/23 × 62/33 × 45/12 = 15.929

3-axes, 2-stages speed reduction

New models

2-ton Series 96/15 × 60/11 = 34.909 52/23 × 62/33 × 45/12 = 15.929

3-ton Series 96/15 × 60/11 = 34.909 56/19 × 62/33 × 45/12 = 20.766

4-ton Series* 88/15 × 51/19 = 15.747 —

* Without wheel reduction

5-8

Drive unit sectional view

Third axle (front axle center)

Second axle (pinion shaft)

First axle (motor input shaft)

Parking brake

5-9

FRONT AXLE

Difference between previous models and new models

The axle housing and the axle brackets are integrated, and bolted to the drive unit housing. The reactive force vs. the drive-force and the brake effects will be received by the axle bracket mount bolts.

Type of front axle

Semi floating type front axle design has been used for all the models. 7FBMF40, 45 and 50 models use planet gears between the tires and the differential gears.

Front axle (1.6 ~ 3.5 ton)

Axle shaft

Front axle (4.0 ~ 5.0 ton)

Axle bracket

Planet gear

5-10

BRAKE

Difference between previous model and new model

The wet brake has been adopted in place of the dry brake with the result that reliability and durability have been considerably improved, especially against water and mud. Besides the brake has become free from worn particles out of the brake lining.

Dry brake

Brake disc

Wet brake (1.6 ~ 2.5 ton)

Brake piston

Wet brake (3.0·3.5 ton)

Brake specification

Item 1.6 ~ 1.8 ton 2.0 ~ 2.5 ton 3.0·3.5 ton 4.0 ~ 5.0 ton

Brake lining dimensions

(thickness × outside dia. × inside dia.)mm0.5 × 221 × 150

Brake disc

Wet brake (4.0 ~ 5.0 ton)

←←

0.8 × 276 × 200

Brake pistion

Quantity of brake disk 2 × 2 2 × 2 3 × 2 1 × 2

Brake & drive unit oil SHELL DONAX TD

Brake valve

The full power type brake valve has been adopted for all the models (1.6 to 5.0 ton capacity).

Specification of valve

Item 1.6 ~ 5.0 ton

Type Full power CHPS

Fluid used ISO VG#32

1.6 ~ 3.5 ton

From oil pump

To oil tank

5-11

4.0 ~ 5.0 ton

To front brake

To PS

From oil pump

To PS

To oil tank

5-12

Note:

1. Lubricant for brake For the lubrication of the brake discs as well as for the drive gearing, the same oil are used, since the wet brake discs are dipped in gear oil. Only TOYOTA specified oil must be used.

TOYOTA Specified oil: SHELL DONAX TD

It must be strictly forbidden to use the oil other than those specified by TOYOTA or oil mixed with another since it will give the adverse effect, such as the brake mal-function and the noise occurrence.

2. Service for brake life In case that the brake has become ineffective or noise should arise, the deterioration of the gear oil and the brake discs can be suspected as the possible causes. At the time, the gear oil should be renewed at first. If it is still ineffective, wearing down of the brake discs can be considered. Then the brake discs should be renewed together with the gear oil.

3. Washing It must be strictly avoided to splash water round the breather (or bleed) plug while washing the truck since water will penetrate into gear oil through the breather plug.

PARKING BRAKE

The wet disc parking brake has been adopted for all the models (1.6 ~ 5.0 ton). Specification (for all the models)

Item 1.6 ton ~ 5.0 ton

5-13

Parking brake lining dimension

0.45 × 136 ×105

Thickness × Outside Dia. × Inside Dia.

Quantity of discs 2

Parking brake oil SHELL DONAX TD

Function

• Newly designed parking brake system differs from the previous system in that the parking brake force arises when the brake discs are compressed on the motor shaft through the piston pressed by the conical disc springs.

• On turning the parking switch ON, the solenoid valve releases oil in the chamber ‘A’ so that the force of the conical disc springs will apply the brake.

• On turning the parking switch OFF, pressurized oil is fed to the brake housing from the PS pump through the solenoid valve. Then the conical disc springs are compressed throgh hydraulic pressure so that the brake will be released.

Piston

Disc

Conical disc spring

Drive motor

5-14

Parking brake switch

• The parking brake system is actuated by the electrical selector switch as illustrated:

Turn it to the right: Parking brake on

Turn it to the left: Parking brake release

Note:

• Always stop the truck and turn on the parking brake switch (turn to the right) to engage the parking brake before getting off the vehicle. Check to confirm that the parking brake is engaged.

• Never turn off the key switch unnecessarily while traveling, because it will cause the truck a sudden stop with a shock.

• Never pull off the battery plug while traveling (except in case of emergency), because it will cause the truck a sudden stop with a shock.

• It is impossible to release the parking brake if the power steering pump should stop supplying the parking brake with pressurized oil; therefore, in case that the traction of the truck is in urgent need, the parking brake cover plug should be removed to release the parking brake manually with a specified tool (bolt).

PARKING BRAKE SYSTEM

Main controller

Brake change valve solenoid

ON/OFF

SOL

Pump motor for steering (7FBMF15~35)

Pump motor (7FBMF40, 45&50)

To steering valve and oil control valve

Brake

change

valve

Oil pump

5-15

Parking

brake

OFF

Electrical signal

Key SW

Seat SW

Parking SW

Direction SW

Accelerator SW

Hydraulic line

Function

1. The parking brake will be released when it receives oil pressure from the brake change valve. When it does not take oil pressure, it becomes the condition that a parking brake piston is pressed by the cone spring, and the parking brake is effective.

2. The brake change valve changes an oil way to the parking brake by the solenoid valve. Solenoid ON: The parking brake is released as it makes the oil way to the parking brake opened. Solenoid OFF: The parking brake is applied as it makes the oil way to the parking brake closed.

3. The motor (The PS motor for 1.6 to 3.5 tons models and the pump motor for 4.0 to 5.0 tons models) starts driving when both the key switch and the direction switch are turned on. Then, oil pressure will arise from the oil pump directly connected to the motor.

4. The main control controller controls the solenoid valve by the signals from each switch.

Note: The traveling speed sensor which detects the traveling condition of the vehicle also has relation

to the parking brake system through the traveling controller.

5-16

5. To try to travel the vehicle makes the parking brake released. When all the following conditions are satisfied, the parking brake is released by turning on the solenoid valve.

• Turning on the key switch

• Turning on the seat switch (The seated condition)

• Shifting the parking switch left (Release side)

• Turning on the direction switch (Forward or Reverse)

• Switching on the accelerator (Depressing the accelerator pedal) In reverse, either of the following manipulation makes the parking brake operated by changing the solenoid from ON to OFF.

• Turning off the key switch

• Shifting the parking switch right (Parking side) When the switch other than mentioned above is turned off, the parking brake is not actuated at once but controlled as the following items 6, 7 and 8.

6. When a foot is left from the accelerator pedal during traveling, the parking brake is applied from 10 seconds later after an electric brake acts and the vehicle stops completely. And, it is the same when the direction lever is made a neutral position during traveling.

7. Brake control on a slope If the accelerator pedal is released with the neutral direction lever position after the vehicle stops on the slope once, the electric brake (the regenerative brake) works for 10 seconds to prevent the truck from going down, and then it makes the parking brake acted in place of the electric brake.

8. If the seat switch is turned off during traveling, the controller considers the condition as an emergent situation, and it makes the parking brake acted by changing the solenoid valve from ON to OFF as soon as the vehicle stops by the electric brake.

5-17

BRAKE PEDAL

• 1.6 ~ 3.5 ton New models use the pendent type brake pedal in place of the step down type brake pedal on the previous models.

• 4.0 ~ 5.0 ton: The pendent type brake pedal and the double link mechanism have been adopted.

Regenerative sensor

The limit switch has been adopted for reliability as that of the previous model, and sensing ability has been improved. When the readjustment is required for the regenerative brake, service accessibility is good.

Sensor for Regenerative brake

Brake pedal

Brake valve

Brake pedal (1.6 ton ~ 3.5 ton)

Brake pedal

Brake valve

Brake pedal (4.0 ton ~ 5.0 ton)

STEERING & REAR AXLE

Page

STEERING .......................................................................6-2

REAR AXLE (1.6 ~ 3.5 ton model) .................................6-5

6-1

REAR AXLE (4.0 ~ 5.0 ton model) .................................6-7

6-2

STEERING

1.6 ~ 3.5 ton

Power steering system

New models like the previous models have adopted Electronically controlled fully-Hydraulic Power Steering (EHPS) as the standard equipment.

Brake valve for parking release

Solenoid valve for knob

PS pump

Steering sensor

Rear axle beam

PS cylinder

PS valve

Oil tank

6-3

Principle of EHPS (Electronically controlled full-Hydraulic Power Steering)

1. The steering sensor will defect the steering wheel revolution speed without mechanical contact while the operator rotating the steering wheel.

2. In the meantime, the detected speed is turned into electronic pulse signals and being sent to the controller.

3. The controller will adjust the current being supplied to the power steering motor corresponding to the pulse signals.

4. Thus the adequate power steering motor speed in response to the steering manipulation can be obtained.

PS cylinder

Steering sensor

PS valve

PS pump

Steering wheel

PS motor

Controller

6-4

4.0 ~ 5.0 ton

Power steering system

Fully hydraulic power steering has been adopted as the standard equipment.

Solenoid valve

Brake valve

PS valve

Brake valve for parking release

Oil tank

PS cylinder

Power Steering valve (PS valve)

Pump

Rear axle beam

1. When the truck is running straight forward (or when the steering wheel is not in operation), the power steering valve absorbs the reaction from the tires before it is transmitted to the steering wheel.

2. When the battery voltage is stopped, the power steering valve works instead of the pump by making the manual steering circuitry.

6-5

REAR AXLE (1.6 ~ 3.5 ton model)

The structure of the rear axle for the new models is similar to that of the previous FBMF series. As the illustration shows, the lock cylinder rod mount clevis has been added on the portion (B) for the active rear stabilizing control. The rear axle cylinder mount pins (A) are eccentric in shape so that the wheel angle can be adjusted by rotating the eccentric pin as illustrated on the next page.

6-6

Rotation of cylinder pin 0° (min.) ~ 360° (max.)

Tire angle adjustment range

Toe-out side approx

1°

Toe-in side approx

1.5°

Toe-in side: Approx. 1.5

Toe-out side: Approx. 1

Toe-in side approx

1.5°

Toe-out side approx

1°

Adjustment of cylinder pin angle

Lock plate

Bolt

Rotatable every 60° at 2 places

Cylinder pin

6-7

REAR AXLE (4.0 ~ 5.0 ton model)

The rear axle assembly parts are similar to those of 7FB35 series.

1. The rear axle can be lubricated with grease at 12 points (A1 ~ A12) shown in the illustration, while steerig the rear axle to the left and right.

2. For active control rear stabilizing, a lock cylinder rod mounting clevis has been added at point B.

3. The rear axle cylinder mount pins (A) are eccentric in shape so that the wheel angle can be adjusted by the rotating the pin angle as illustrated on the next page.

A8 (LH)

A9 (RH)

A10

A11

A12

6-8

Rotation of cylinder pin 0° (min.) ~ 360° (max.)

Tire angle adjustment range

Toe-out side approx

1°

Toe-in side approx

1.5°

Toe-in side: Approx. 1.5

Toe-out side: Approx. 1

Toe-in side approx

1.5°

Toe-out side approx

1°

Adjustment of cylinder pin angle

Lock plate

Cylinder pin

Bolt

Rotatable every 30°

TIRES

7-1

Page

SPECIFICATIONS

7FBMF16 ~ 35 Tire Specifications

7FBMF40, 7FBMF45, and 7FBMF50

Tire Specification

SPECIFICATION TABLE

7FBMF16·18·20·25·30·35

7FBMF40·45·50

......................................................................7-2

..............................................................7-3

..........................................................7-5

.................................................7-5

..................................................................7-6

.............................. 7-2

7-2

SPECIFICATIONS

7FBMF16 ~ 35 Tire Specifications

General

• New models like previous models have adopted the pneumatic shaped cushion tire.

• A pneumatic tire is available as the option for 7FBMF16, 7FBMF18, 7FBMF20, and 7FBMF25 models.

• The wide tread specifications are available as the option for 7FBMF16 ~ 35 with the standard size.

• The oversize front tire is available as the option for 7FBMF16, 7FBMF18 and 7FBMF20.

Note: See the table on page 7-5 for the further detail.

Front tire

Table 1 7FBMF16 and 7FBMF18 front tire

Standard Tire Over size Tire

Standard Tread Wide Tread Standard Tread Wide Tread

Tire Size 21

Tread (Front) mm 920 975 945

Overall Width mm 1115 1170 1110

Table 2 7FBMF20 front tire

Standard Tread Wide Tread Standard Tread Wide Tread

Tire Size 21

Tread (Front) mm 975 1100 975 1100

Overall Width mm 1170 1300 1175 1300

Table 3 7FBM25 front tire

Standard Tread Wide Tread Standard Tread Wide Tread

Tire Size 23

8-9 21

Standard Tire Over size Tire

8-9 21

Standard Tire Over size Tire

9-10 23

8-9 6.50-10

8-9 23

9-10

9-10 23

9-10

Tread (Front) mm 975 1100

Overall Width mm 1170 1300

Table 4 7FBMF30 and 7FBMF35

Standard Tread Wide Tread Standard Tread Wide Tread

7-3

Standard Tire Over size Tire

Tire Size 23

Tread (Front) mm 970 1070

Overall Width mm 1220 1320

Rear tire

Table 5 7FBMF16~35 rear tire

Tire Size 5.00-8 18

Tread (Rear) mm 895 940 940

10-12 23

7FBMF16·18·20 7FBMF25 7FBMF30·35

10-12

7-8 18

7FBMF40, 7FBMF45, and 7FBMF50 Tire Specification

General

• New models have adopted the pneumatic shaped cushion tire.

• A pneumatic tire is available as option (except for the tire size 28

• The dual tire is available as the option.

Note: See the table on page 7-6 for the further details.

12.5-15).

7-8

Front tire

Table 6 7FBMF40, 7FBMF45, and 7FBMF50 single tire

7FBMF40 7FBMF45 7FBMF50

All Mast V Mast & FV Mast FSV Mast All Mast

Tire Size 250-15 250-15 28

Tread (Front) mm 1120 1120 1150 1150

Overall Width mm 1345 1345 1440 1440

Rear tire

Table 7 7FBMF40, 7FBMF45, 7FBMF50 rear tire

Model

Tire

Tire Size 7.00-12

Tread (Rear) mm 1100

12.5-15 28

7FBMF40·45·50

12.5-15

7-4

Note:

• Front tire wheels are not interchangeable between the new models and the previous models.

• The interchangeability of the rear wheels between the new models and the previous models is as shown in Table 8.

• The truck with the non-marking white tires should be equipped with the earth band for grounding where the working floor has high friction factor such as resin coat, because the condition has high potential to generate static electricity.

Table 8 Interchangeability of the rear wheel

: Interchangeable

: Not interchangeable

Previous model

FBMF16 FBMF20 FBMF25 FBMF30

New model Tire size 5.00-8 18

7-8 18

7FBMF16 5.00-8 — — —

7FBMF18 5.00-8 — — —

7FBMF20 5.00-8

7FBMF25 18

7FBMF30 18

7FBMF35 18

××

7-8 —

××

7-8 — — —

—

7-8

SPECIFICATION TABLE

7FBMF16·18·20·25·30·35

7-5

7FBMF40·45·50

7-6

OPERATOR’S COMPARTMENT

8-1

Page

OPERATOR’S COMPARTMENT

DRIVING POSITION

SEAT

ACCELERATOR PEDAL

DIRECTION SWITCH

INSTRUMENT PANEL

..............................................................................................8-4

...................................................................8-3

..........................................................8-6

................................................................8-7

..............................................................8-8

...........................................8-2

8-2

OPERATOR’S COMPARTMENT

Pattern of shift

Center of steering

Layout of pedal

Center of vehicle

No. NAME No. NAME

1 Parking switch 9 Control lever (Lift)

2 Horn switch 10 Control lever (Tilt)

3 Direction lever 11 Control lever (Attachment)

4 Turn signal switch (OPT) 12 Control lever (Attachment)

5 Ignition key switch 13 Brake pedal

6 Light switch 14 Accelerator pedal

7 Steering wheel 15 Tilt steering lock lever

8 Seat 16 Seat stand release lever

8-3

DRIVING POSITION

The new model mounted with the battery assembly underfloor room creates the ample foot space, contributing to the operation comfort. (The same as that of 7FB25 having established evaluation in the market.)

The enlarged distance between the operator’s seat and the accelerator pedal (with FBMF series in comparison) will relieve the operator of ankle fatiguing by daily work.

556

Previous model (FBMF25) New model (7FBMF25)

640

8-4

SEAT

The same seat as 7FGF25 series has been adopted to 7FMF16 to 50. (The same seats have had an established reputation by the name of Grammer seat). The new seat is provided with the seat switch function.

Features:

1. ORS (Operator Restrain System)

If the truck should tip over, ORS will protect the operator by restraining means.

2. Side support with gripping hole

• Operator support in case of emergency

• Used as a grip when getting on

3. The seat belt:

• ELR type (Emergency Locking Retractor)

4. Adjustment function of seat back tilt angle

Forward 5

5. Dial-type suspension adjustment mechanism

• The knob position is in front of the seat.

• The adjustable body weight range for the suspension is from 50 kg to 130 kg.

/Backward 5

6. Seat switch

The seat switch is built-in.

7. Bull mark

8. Fabric seat is available as an option.

Seat stand opening & closing

Procedure: Open and close the seat stand by the following procedure.

<7FBMF16~35>

1. Move the mini lever box to the rearmost position.

2. Slide the seat to the foremost position.

8-5

3. Pull the lock release lever, and tilt the steering post forward.

4. Open the seat stand.

<7FBMF40~50>

1. Tilt up the mini lever box fully to the backward.

2. Slide the seat to the rearmost position.

3. Pull the lock release lever, and tilt the steering post forward.

4. Open the seat stand.

8-6

ACCELERATOR PEDAL

The accelerator pedal is installed on the front toe board. The feeling of initial operation became smoother thanks to the resin mold pedal. With the enlarged (A) pedal stroke angle combined with the change of the seated position (See Page 8-3), the ankle will be relieved of fatigue.

New model Previous model

Pedal operating angle(A) 19° 15°

Pedal stroke end angle(B) 27° 25°

8-7

DIRECTION SWITCH

• A finger touch type direction switch has been adopted to reduce the force needed for operation and to make it easier to operate with the fingertips (same as in previous model).

• An exclusive resin knob, similar to that of turn signal switch, is used at the lever tip to improve the design around the steering wheel (same as in current model).

• The direction switch lever is always on LH side (same as current model).

Direction switch

Turn signal switch

8-8

INSTRUMENT PANEL

Instrument panel

• Resin fabrication realized new design.

• The instrument panel consists of two pieces on 7FBM16 to 35 and three pieces, on 7FBMF40 to 50. The quality of the material is excellent in intensity and is made from eco-friendly polypropylene.

• The instrument panel is furnished with the holder as the standard provision.

7FBMF 16 ~ 35

Document holder (A4 size)

LH panel

RH panel

Holder

Lower panel

Lower panel (or lower part of panel)

The lower panel covers the area between the instrument panel and the toe board. Thereby, following improvements are made:

• Components, such as the link mechanism, are protected from dirt or mud.

• The foot area became spacious with operational ease.

BODY & ACCESORIES

9-1

Page

NOTICES-HOIST AND JACK POSITION

BODY & FRAME

ACCESSORIES

Lights

....................................................................................9-6

.........................................................................9-3

...........................................................................9-6

............................ 9-2

9-2

NOTICES-HOIST AND JACK POSITION

1. Hoisting by holding the mast and the rear wheels

When hoisting the vehicle, hold the front by the outer mast top tie beam, and the rear by the rear tire wheels. Never use overhead guard or counter weight to hoist the vehicle.

2. Lifting truck with a jack

(1) Jacking points on the front side are provided on the bottom sur-

face of the frame structure behind the front tires.

(2) Note the following about the jacking point:

• Position a jack under the frame structure at a point that is 150 mm (5.9 in) or closer to the fender.

• Do not work under a truck supported by a jack only.

• Always support the truck with blocks or stands when you are working on it.

• For information on the jacking point on the rear side, refer to the next page explaining the counter weight.

150

9-3

BODY & FRAME

Fender

As for the wide tread/specs., (2.0 to 3.5 ton) and the dual tire specs (4.0 to 5.0 ton), the fenders are bolted on the body frame to cover the front wheels.

Fender

Counterbalance weight

In the previous models, the controller is enclosed in the counterbalance weight. In the new models, the controller is installed into the partition covered by the seat stand to protect it from getting wet.

Controller room

Jack up point

The jack point is made for the new models on the undersurface of the counterbalance weight in a concave form.

9-4

Step

7FBMF 16 ~ 35

• Aiming at unique, and unchangeable cleanliness desirous for the electric forklift trucks, the step on the LH side has been made from resin compound, so that the step has become corrosion free and water clean feature.

• Further, the step surface forms a number of the skid proof holes for a safety ride.

7FBMF30

• The height of the step for 7FBMF30 become lower than that of the previous model so that the auxiliary step has been dispensed with.

7FBMF40, 45, 50

• Easy to get on due to wide open step area and the skid proof feature have been added on.

9-5

Toe Board

The toe board is separated into two parts, front and rear. Battery maintenance can be easily performed. The rear toe board consists of two plates hinged at the middle between them so that the battery change or the battery maintenance will be facilitated. The front toe board can be lifted without using the tool since it is not bolted to the place. The toe board is equipped with the stopper bar to support the rear toe board when opened.

Rear toe board hinge

Rear toe board stopper

When opening the rear toe board, lock the rear toe board in the following procedure:

Open the rear toe board fully. (Approx. 95°) Slide the stopper bar upward fully. Turn the stopper bar left fully.

Floor mat

Frame

Front toe board

Rear toe board

Rear toe board hinge

Rear toe board stopper bar

Opened rear toe board

Rear toe board stopper bar

9-6

ACCESSORIES

Lights

(1) List of lights and OPT settings OPT: Option

Head light

Front combination light

Rotary beacon

Rear working light

Rear combination light

9-7

Headlights As with previous model, headlight is large

OPT

diameter square type with guard.

Front combination lights As 7FB25 model, the front combination light is

OPT

integrated.

Front combination lights with Mast

If outside mast piping OPT and front combination lights in 7FBMF40 ~ 50 FSV or FV A450, the lights are installed with mast.

Rear combination lights As 7FB25 model, the rear combination light is

OPT (7FBMF40 ~ 50, FSV or FV, A450)

OPT high-mount type which is installed crosswise to improve visibility, prevent damage and enhance appearance as 7FB25 model.

Rear working light Rear working light is square type same as the

OPT headlight (same as in the previous models).

Rotary Beacon Rotary beacon is same as the previous models. OPT

Front combination lights with mast

9-8

(2) Light switch

The position of the light switch has been changed to the left of steering wheel, and it improves operation. The switch is 3-step switching, and it is possible to switch the lights with one switch. 1st step : Clearance lights, Tail lights 2nd step : Head lights, Clearance lights, Tail lights 3rd step : Clearance lights, Tail lights, Rear working light

LIGHT SWITCH

MATERIAL HANDLING & HYDRAULICS SYSTEM

Page

10-1

V MAST

FV MAST

FSV MAST

FORK, FORKBAR, AND LOAD BACKREST

MAST WEIGHT

MAST INTERCHANGEABILITY

HYDRAULIC CIRCUIT

LOAD HANDLING LEVER (MINI-LEVER)

OIL CONTROL VALVE

PUMP MOTOR

STEERING MOTOR

OIL PUMP

LIFTING SPEED

TILT CYLINDER

.......................................................................................10-2

.....................................................................................10-4

..................................................................................10-5

.........................................................................10-8

...........................................10-9

..........................................................10-10

.......................10-12

.........................................................10-16

........................................................................10-27

...............................................................10-28

.................................................................................10-29

......................................................................10-30

......................................................................10-31

...................10-6

OIL TANK

OTHER HYDRAULIC PARTS

A4 PIPING

.................................................................................10-32

................................................................................10-35

.............................................10-34

10-2

V MAST

The V mast is standard equipment. The basic structure of the V mast of 7FBMF16 to 30 is the same as that of the previous model. The basic mast structure of 7FBMF35 is the same as 7FGJF35. The basic mast structures of 7FBMF40, 45 and 7FBMF50 are the same as 7FD35 and 7FD45 respectively. See below about the improvement from the previous model.

1) Mast durability improvement The structure around the tilt bracket of 7FBMF30, 35 is the same as that of 7FGF30 and 7FGJF35 so that the mast has an improved durability.

Previous model (3.0 ton) New model (3.0 ton, 3.5 ton)

2) Front view As the previous model, an optimum front visibility is obtained by adopting proper mast rails and finger bars. For the models of 4.0 ton, 4.5 ton and 5.0 ton, we adopt the same mast rail and finger bar as those of 7FD35 series and obtain an optimum front visibility.

3) Chain The chain size of 7FBMF16 to 30 is the same as that of the previous model. For 7FBMF35, we adopt the same size as 7FGJF35 (BL834). For 7FBMF40 to 50, we adopt the same size as 7FD35 series (7FBMF40, 45: BL834, 7FBMF50: BL1034).

4) Lift cylinder The basic structure of the lift cylinder of 7FBMF16 to 30 is the same as that of the previous model. The lift cylinder of 7FBMF35 is the same as 7FGJF35. The lift cylinder of 7FBMF40 to 50 is the same as 7FD35 series. Only the cylinder of 7FBMF35 has the shock less landing mechanism.

10-3

5) Lift cylinder piping The basic structure of the lift cylinder piping of 7FBMF16 to 30 is the same as that of the previous model. The safety down valve is an inline type similar to that of the previous model, but the additional fitting for the pressure sensor is connected. The lift cylinder piping of 7FBMF35 is the same as that of 7FGJF35. The lift cylinder piping of 7FBMF40 to 50 is the same as that of 7FD35 series.

6) Lift roller The lift roller of 7FBMF16 to 30 is the same as that of the previous model. The roller of 7FBMF35 is the same as 7FGJF35. The roller of 7FBMF40 to 50 is the same as 7FD35 series.

7) Lost load center (Distance between the center of front axle and the front face of fork) See below table.

(mm)

1.6, 1.8 ton 2.0, 2.5 ton 3.0 ton 3.5 ton 4.0, 4.5 ton 5.0 ton

New model 410 430 460 495 520 580

Previous model 405 420 485 — — —

10-4

FV MAST

Full-free mast (FV mast)

The FV mast is available as an option except for 7FBMF35 and 7FBMF50. The basic structure of the FV mast of 7FBMF16 to 30 is the same as that of the previous model. The mast of 7FBMF40 and 45 is the same as 7FD35. See below about the improvement from the previous model.

1) Mast durability improved It is the same as that of V mast.

2) Front view It is the same as that of V mast.

3) Chain It is the same as that of V mast.

4) Lift cylinder The basic structure of the lift cylinder of 7FBMF16 to 30 is the same as that of the previous model. The lift cylinder of 7FBMF40 and 45 is the same as 7FD35.

6) Lift roller It is the same as that of V mast.

7) Lost load center (Distance between the center of front axle and the front face of fork) It is the same as that of V mast.

10-5

FSV MAST

Full-free three-stage mast (FSV mast)

The FSV mast is available as an option. The basic structure of the FSV mast of 7FBMF16 to 30 is the same as that of the previous model. The basic mast structure of 7FBMF35 is the same as 7FGJF35. The basic mast structures of 7FBMF40, 45 and 7FBMF50 are the same as 7FD35 and 7FD45 respectively. See below about the improvement from the previous model.

1) Mast durability improvement It is the same as that of V mast.

2) Front view As the previous model, an optimum front visibility is obtained by adopting proper mast rails and finger bars. For over 4.0 ton truck, we adopt the same mast rail and finger bar as those of 7FD35 series and obtain an optimum front visibility.

3) Chain It is the same as that of V mast.

5) Lift cylinder piping The basic structure of the lift cylinder piping of 7FBMF16 to 30 is the same as that of the previous model. An additional fitting for the pressure sensor is connected to the flow regulator housing. The lift cylinder piping of 7FBMF35 is the same as that of 7FGJF35. The lift cylinder piping of 7FBMF40 to 50 is the same as that of 7FD35 series.

6) Lift roller It is the same as that of V mast.

7) Lost load center (Distance between the center of front axle and the front face of fork) See below table.

1.6, 1.8 ton 2.0, 2.5 ton 3.0 ton 3.5 ton 4.0, 4.5 ton 5.0 ton

New model 430 460 480 505 550 610

Previous model 430 450 495 — — —

(mm)

10-6

FORK, FORKBAR, AND LOAD BACKREST

Fork

The fork of 7FBMF16 to 30 is the same as that of the previous model. The fork of 7FBMF35 is the same as that of 7FGJF35. The fork of 7FBMF40 to 50 is a newly adopted one. Refer to the table of “6.2. Fork” about its size. The standard fork color is black. The orange-colored fork is also prepared as an option. As the previous model, the option “without fork set” is available for all the mast too.

( : STD, : Available)

Model

7FBMF16, 18 80 40 —

7FBMF20, 25 100 40 — —

7FBMF30 100 45 —

7FBMF35 125 45 —

7FBMF40, 45 150 50 —

7FBMF50 150 60 —

Width of fork

(mm)

Thickness of

fork (mm)

800 1000 1100 1200 1400 1500

Length of fork (mm)

Forkbar & load backrest

Load backrest

The load backrest is the standard equipment of the mast. The backrest of 7FBMF16 to 30 is the same as that of the previous model. The backrest of 7FBMF35 is the same as that of 7FGJF35. The backrest of 7FBMF40 to 50 is a newly adopted one, but its structure is the same as that of 7FBMF16 to 35: Flat steal type. The option “W/O load backrest” is available for all the mast of 7FBMF series.

7FBMF16 ~ 35 (V, FV, FSV)

Model 920 1020 1070 1170 1470

Height of

load

backrest

(mm)

1220

7FBMF16, 18 — — — —

7FBMF20, 25 — —

7FBMF30, 35 — —

( : STD, : Available)

Length of forkbar (mm)

Outside width of load backrest [+60 mm]

7FBMF40 ~ 50 (V,FV,FSV)

Model 1170 1320 1470 1630

10-7

Length of forkbar (mm)

Outside width of load backrest [+60 mm]

Height of

load

backrest

(mm)

7FBMF40, 45

1220

7FBMF50

10-8

MAST WEIGHT

Mast Type

V 3000 410 465 570 680 890 1060

FV 3000 450 505 610 NA 930 NA

FSV 3700 560 650 795 890 1070 1350

Maximum

fork height

mm kg kg kg kg kg kg

7FBMF16, 18 7FBMF20, 25 7FBMF30 7FBMF35 7FBMF40, 45 7FBMF50

3300 440 500 610 715 930 1100

3500 460 520 630 730 950 1110

3700 470 530 650 750 970 1170

4000 490 565 680 830 1050 1270

4500 540 615 760 900 1100 1350

5000 570 655 800 940 1150 1430

3300 480 540 660 NA 960 NA

3500 500 560 680 NA 980 NA

3700 510 570 700 NA 1000 NA

4000 530 605 740 NA 1100 NA

4000 580 670 815 920 1100 1380

4300 610 690 855 955 1130 1420

4700 650 720 895 985 1190 1480

5000 680 740 935 1070 1220 1520

5500 700 790 1015 1125 1270 1610

6000 770 840 1075 1200 1370 1690

Note:

1) The value is without the weight of load backrest and forks.

2) The value in this list is rounded off to the nearest one.

MAST INTERCHANGEABILITY

1: Interchangeability in the new model

10-9

Model group

VFSVFV

7FBMF16, 18

7FBMF20, 25

7FBMF30

7FBMF35 —

7FBMF40, 45

7FBMF50 —

: Interchangeable with the other masts in each model groups. : Interchangeable, but the tilt cylinder has to be exchanged at the same time.

2: Interchangeability with the previous model There is no interchangeability of the mast between the previous model and the new model.

3: Interchangeability with 7FGF25 series Only the mast of 7FBMF16, 18 can be interchangeable with those of 7FGF15 and 18. Note that the pressure sensor and the sensor harness is different between the 7FBMF16, 18 and 7FGF15, 18 and these parts have to be exchanged when swapping the mast.

Mast

10-10

HYDRAULIC CIRCUIT

A general hydraulic circuit is shown below.

1.6 ton ~ 3.5 ton

Lift cylinder

Tilt cylinder

Oil control valve

Return filter

Oil tank

Brake valve

Steering valve

Solenoid valve

Power steering cylinder

Service brake

Steering & change valve return

Parking brake

Brake return

Change valve

Oil pump for steering

Pump motor for steering

Suction filter

Oil pump

Pump motor

Just as on the old models, both suction and return filters are provided as standard equipment to protect the hydraulic equipment. The return filter is installed under the front toe-board.

4.0 ton ~ 5.0 ton

10-11

Lift cylinder

Oil control valve

Return filter

Tilt cylinder

Steering valve

Power steering cylinder

Steering return

Solenoid valve

Service brake

Brake valve

Brake return

Change valve return

Parking brake

Change valve

Suction filter

Pump motor

Oil tank

Oil pump

Both suction and return filters are provided as standard equipment to protect the hydraulic equipment.

10-12

LOAD HANDLING LEVER (MINI-LEVER)

1) The structure of mini-lever Mini lever is available as standard to meet the demand of European market.

The operation stroke has been made smaller and operating force has been decreased by changing the position of the lever from over cowl to right front of the seat. Operability is improved and operator’s fatigue with the lever operation is reduced.

It is easy to replace the vehicle from previous model with new model because the lever is independent forwardback single axis lever that is the same as manual lever cowl position of previous model.

Fork automatic leveling control switch is located on back of tilt lever. Once the button is pushed, the movement condition of the button is held by the locking mechanism of inside switch, and the fork automatic leveling function is effective. When the button is pushed again, the lock is released and the fork automatic leveling control function is canceled. (Refer to page 11-10 Active mast function controller for detail function.)

Lever position is adjustable in forward-back direction. Loosen the knob that fix lever box, and set the lever box at the position that operator prefer, and tighten the knob to fix the lever box.

Guard is installed around the lever.

Load handling operation is prohibited when operator leaves the seat.

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

Specifications and Main Features

Frequently Asked Questions

User Manual