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

...

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.

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

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

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

15. Over-discharge warning function When the remaining capacity level reaches a specified level, the multiple display shows a warning and the load handling operation is restricted. This will protect the battery and will urge the operator to charge the battery. It is possible to release this restriction temporarily by turning the key switch off at once before resetting as emergency measures.

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

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

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

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

MULTIPLE DISPLAY

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Page

MULTIPLE DISPLAY INDICATION

MULTIPLE DISPLAY FUNCTIONS

SERVICE FUNCTIONS

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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

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: 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

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