7FBCU
7FBCU 15-55 INDEX
.
.
NAME SECTION
GENERAL 0
BATTERY 1
CONTROLLER
MULTI-DISPLAY FUNCTIONS
TROUBLESHOOTING
MOTOR 5
DRIVE UNIT 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
SAS FUNCTIONS 17
APPENDIX 18
2
3
4
<Tillbaka till Index
0-1
GENERAL
0
0
Page
EXTERIOR VIEWS...........................0-2
VEHICLE MODEL............................. 0-3
FRAME NUMBER............................. 0-4
HOW TO USE THIS MANUAL......0-5
EXPLANATION METHOD ................0-5
TERMINOLOGY.................................0-6
ABBREVIATIONS..............................0-6
OPERATIONAL TIPS ......................0-7
JACK-UP POINT ..............................0-8
HOISTING THE VEHICLE..............0-9
CAUTION FOR TOWING................ 0-9
ATTENTIVE POINTS ON SAS....0-10
CIRCUIT TESTER .......................... 0-11
STANDARD BOLT & NUT
TIGHTENING TORQUE.............. 0-13
BOLT STRENGTH TYPE
IDENTIFICATION METHOD.......... 0-13
TIGHTENING TORQUE TABLE ......0-14
PRECOAT BOLTS..........................0-15
HIGH PRESSURE HOSE
FITTING TIGHTENING
TORQUE......................................... 0-15
WIRE ROPE SUSPENSION
ANGLE LIST ..................................0-16
SAFE LOAD FOR EACH WIRE
ROPE SUSPENSION
ANGLE............................................ 0-16
COMPONENTS WEIGHT.............0-17
0
Page
RECOMMENDED LUBRICANT
QUANTITY & TYPES..................0-18
0
LUBRICATION CHART................. 0-19
PERIODIC MAINTENANCE......... 0-21
PERIODIC REPLACEMENT OF
PARTS AND LUBRICANTS ...... 0-26
0-2
EXTERIOR VIEWS
0
0-3
0
VEHICLE MODEL
Model
Code
Load Capacity Vehicle Model Voltage Remarks
15 3000 lbs
7FBCU15
36V/48V
30-7FBCU15
↑
Dust proof
18 3500 lbs
7FBCU18
↑
30-7FBCU18
↑
Dust proof
20 4000 lbs
7FBCU20
↑
30-7FBCU20
↑
Dust proof
25 5000 lbs
7FBCU25
↑
30-7FBCU25
↑
Dust proof
7FBCHU25
↑
High capacity (battery compartment)
30-7FBCHU25
↑
• Dust proof
• High capacity (battery compartment)
30 6000 lbs
7FBCU30
↑
30-7FBCU30
↑
Dust proof
32 6500 lbs
7FBCU32
↑
30-7FBCU32
↑
Dust proof
35 8000 lbs
7FBCU35
↑
30-7FBCU35
↑
Dust proof
45 10000 lbs
7FBCU45
↑
30-7FBCU45
↑
Dust proof
55 12000 lbs
7FBCU55
↑
30-7FBCU55
↑
Dust proof
0-4
FRAME NUMBER
Frame No. Punching Position
*: EEC spec.
Vehicle Model Punching format Vehicle Model Punching format
7FBCU15
7FBCU18-60011
* 7FBCU18 60011
7FBCU35
7FBCU45-60011
7FBCU18 7FBCU45
30-7FBCU15
307FBCU18-60011
* 307FBCU18 60011
30-7FBCU35
307FBCU45-60011
30-7FBCU18 30-7FBCU45
7FBCU20
7FBCU25-60011
* 7FBCU25 60011
7FBCU55 7FBCU55-60011
7FBCU25 30-7FBCU55 307FBCU55-60011
30-7FBCU20
307FBCU25-60011
* 307FBCU25 60011
30-7FBCU25
7FBCHU25 7FBCHU25-60011
30-7FBCHU25 307FBCHU25-60011
7FBCU30
7FBCU32-60011
* 7FBCU32 60011
7FBCU32
30-7FBCU30
307FBCU32-60011
* 307FBCU32 60011
30-7FBCU32
Punching position
0-5
0
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A:Explanation of each operation step with illustration.
Pattern B:Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY⋅INSPECTION⋅REASSEMBLY
Tightening torque unit T = N⋅m (kgf-cm) [ft-lbf]
Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bushing [Point 2] Í Operation explained later
3 Remove the gear.
Point Operations Explanation of key point for operation with an illustration
[Point 1]
Disassembly:
Put a match mark when removing the pump cover.
[Point 2]
Inspection:
Measure the bushing inside diameter.
Limit: 19.12 mm (0.7528 in)
T = 46.1 ~ 48.1
(470 ~ 490)
[34.0 ~ 35.5]
• Step Nos. are partially sometimes
omitted in illustrations.
• When a part requiring tightening
torque instruction is not indicated
in the illustration, the part name is
described in the illustration frame.
Ó
0-6
2. How to read components figures (Example)
3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters of which negligence may cause hazards on human body. Be sure to observe
them.
Note:
Important items of which negligence may cause breakage or breakdown, or matters in operation
procedure requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly SAE
Society of Automotive
Engineers (USA)
EHPS
Electronically controlled
fully hydraulic power
steering
SAS System of active stability
FHPS
Fully hydraulic power
steering
SST Special service tool
LH Left hand STD Standard
L/ Less T = Tightening torque
OPT Option {{T Number of teeth ({{)
O/S Oversize U/S Undersize
PS Power steering W/ With
RH Right hand
3201
FIG number in parts catalog
(1) The components figure uses the illustration
in the parts catalog for the vehicle model.
Please refer to the catalog for checking the
part name.
The number at the right shoulder of each
components figure indicates the Fig.
number in the parts catalog.
0-7
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure
gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and
operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packing and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.)
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Protection of functional parts
(1) Thoroughly check each connector for any failure in or imperfect connection be fore reconnecting the
battery plug after the end of vehicle inspection or maintenance.
Failure in or imperfect connection of connectors related to controllers, especially, may
damage elements inside the controllers.
4. Confirming defect status
Do not start immediate disassembly or replacement, but first confirm if such disassembly or
replacement is actually needed.
5. Handling of waste fluid, etc.
When draining waste fluid from the vehicle, always receive it with an appropriate container.
Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other
harmful substance may cause adverse affect to people or environmental destruction, sort each waste
and always ask an authorized contractor for appropriate disposal.
6. Handling of electronic parts
(1) Never apply impacts to electronic parts such as a
microcomputer or relay.
(2) Never let electronic parts be exposed to a high
temperature or humidity.
(3) Do not touch connector pins since they may be
deformed or be damaged due to static electricity.
0-8
JACK-UP POINT
Strictly observe the following instructions when jacking up the vehicle.
• When a load is on the fork, unload it and park the vehicle on a flat floor. Be sure to avoid an inclined or
rugged place.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any
other point will be dangerous.
• Never operate while the vehicle is held with a jack. Always support the frame with a wooden block after
jacking up.
• In any case, never let a part of the body (including hands and feet) be under the jacked-up vehicle.
:
Jack-up point
:
Wooden block or stand
setting point
0-9
HOISTING THE VEHICLE
When hoisting the vehicle, use the mast hook on the front of
the vehicle and a wire net on the rear wheel.
Caution:
• Use wire ropes having sufficient strength.
• Never hoist the forklift by the weight hook holes or
head guard.
CAUTION FOR TOWING
1. When towing the forklift, always lift the rear wheels away
from the ground.
2. The traveling speed in towing must not exceed the
maximum traveling speed of the forklift.
3. Always set the key switch to OFF and the direction
switch to the neutral position before starting towing.
In case of towing by connection with a wire rope with the
operator on the forklift, however, set the key switch to
ON (PS operation) and always set the direction switch to
the neutral position.
4. Before towing, either remove the fork or take an action
to prevent fork contact with the ground due to bounding.
Cautions for Deadman Brake Spec. Model
The brake exclusive to the deadman brake must be released
before towing.
The deadman brake can be released in the two following
ways. Select according to the situation.
A. Releasing after battery removal
B. Releasing with the battery installed
Case A:
1. Remove the battery.
Case A
(15 ~ 32 model)
Case A
(35 ~ 55 model)
Assist bolt Assist bolt
Adjusting bolt
Case B
(15 ~ 32 model)
2. Loosen the lock nut for the assist bolt for forced
releasing of the brake, and tighten the assist bolt fully to
release the brake.
3. Be sure to adjust after towing. (See Page 10-57, 58.)
Case B:
1. Remove the toe board.
2. Loosen the deadman brake cable adjusting bolt and free
the cable from the cable clamp.
15 ~ 32 model:
Remove the PS controller first for easier operation.
0-10
35 ~ 55 model:
Move the position of the pump motor No. 1 W/motor
bracket first for easier operation.
3. Be sure to adjust after towing. (See Page 10-57, 58.)
ATTENTIVE POINTS ON SAS
1. Reference should be made to seperate manual “New Model Feature 7FBCU15 to 55 Pub. No.PU312”
for the explanations of SAS functions and operations.
2. Read Section 17 “SAS Precautions for Repair” on Page 17-12 in this repair manual in advance.
3. Whenever the repair or replacement is performed to the place where relative to SAS function, maching
procedure by which the SAS regain proper function must be performed. (See VOL.2 Page 3-54)
4. The warning on the SAS caution label must be confirmed when the modification or change is such as
to change the original specification.
If improper, change the label. (See Page 17-27)
5. Care should always be exercised for safety operation whenever you operate the truck.
Make distinction between the SAS featured trucks and those of none, because the control features are
different.
6. The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oil
will adversely affect the functions of these valves, always wash the parts clean at the time of
installation after disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic
replacement of the hydraulic oil is very important.
7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause
faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary
equipment, optional parts, etc.).
Adjusting bolt
Case B (35 ~ 55 model)
0-11
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according
to the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured value
should only be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.
1. Difference in measurement results with the digital type and analog type
* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual.
Cautions when the polarities are different between the analog type and digital type are described
below.
(1) Analog circuit tester
Measurement result example
Tester range: kΩ range
(2) Digital circuit tester
Measurement result example
Tester range: MΩ range
Forward direction Reverse direction
Analog type
Forward
Continuity exists
11 kΩ
Reverse
No continuity
∞
Forward direction Reverse direction
Digital type
Forward
No continuity
1
Reverse
Continuity exists
2 MΩ
0-12
2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.
The diode characteristics are shown in the figure below.
The resistance values of the same semiconductor measured
with two types of circuit testers having different power supply
voltages are different.
This manual describes the results of measurement with a
circuit tester whose power supply voltage is 3.0 V.
3. Difference in measurement result by measurement range (analog type)
In the analog type circuit tester, changing the measurement range switches over the internal circuit to
vary the circuit resistance. Even when the same diode is measured, the measurement result varies
with the measurement range.
Always use the range described in the repair manual for
measurement.
0
1
2
3
4
5
6
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
(V)Forward voltage
Germanium
diode
(mA)
Forward current
Silicon
diode
Resistor Meter
0Ω
Variable resistor
Resistor
Resistor
Range:×10
Range:×1
Power source: 1.5V
Red
Black
(SW1)
Current flow
0-13
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2. The nut tightening torque can be judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1. Identification by bolt shape 2. Identification by part No.
Shape and class Class Hexagon head bolt
Hexagon
head bolt
4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
4T
Hexagon
flange bolt
4T
Hexagon
head bolt
5T
Hexagon
flange bolt
6T
Hexagon
head bolt
7T
Hexagon
head bolt
8T
Welded bolt 4T
Stud bolt
4T
6T
Bolt head No.
No mark
No mark
Diameter
Length
Two protruding
lines
Two protruding
lines
Three protruding
lines
Four protruding
lines
Diameter
Length
No mark
Grooved
Parts No.
9 1 6 1 1 - 4 0 6 2 5
Length (mm)
Diameter (mm)
Class
Stud bolt
Parts No.
9 2 1 3 2 - 4 0 6 1 4
Length (mm)
Diameter (mm)
Class
0-14
TIGHTENING TORQUE TABLE
Class
Diameter
mm
Pitch
mm
Specified torque
Hexagon
head bolt
Hexagon
flange bolt
N
⋅mkgf-cmft-lbf
N
⋅m
kgf-cm ft-lbf
4T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
5.4
13
25
47
75
113
55
130
260
480
760
1150
48 in-lbf
9
19
35
55
83
5.9
14
28
53
83
⎯
60
145
290
540
850
⎯
52 in-lbf
10
21
39
61
⎯
5T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
6.4
16
32
59
91
137
65
160
330
600
930
1400
56 in-lbf
12
24
43
67
101
7.5
18
36
65
100
157
75
175
360
670
1050
1600
65 in-lbf
13
26
48
76
116
6T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
7.8
19
38
72
110
170
80
195
400
730
1100
1750
69 in-lbf
14
29
53
80
127
8.8
21
43
79
123
191
90
215
440
810
1250
1950
78 in-lbf
16
32
59
90
141
7T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
11
25
52
95
147
226
110
260
530
970
1500
2300
8
19
38
70
108
166
12
28
58
103
167
⎯
120
290
590
1050
1700
⎯
9
21
43
76
123
⎯
8T
6
8
10
12
14
16
1.0
1.25
1.25
1.25
1.5
1.5
12
29
61
108
172
265
125
300
620
1100
1750
2700
9
22
45
80
127
195
14
32
68
123
196
299
145
330
690
1250
2000
3050
9
24
50
90
145
221
0-15
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the
following cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or
tightened) by tightness check, etc.
Note:
For torque check, use the lower limit of the
allowable tightening torque range. If the bolt moves,
retighten it according to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with
clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact
surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the
fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Seal lock agent
Nominal diameter
of screw
Standard tightening torque N
⋅m (kgf-cm) [ft-lbf]
Hose inside
diameter mm (in)
Standard Tightening range
7/16 ⎯ 20UNF 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
9/16 ⎯ 18UNF 49 (500) [36.2] 47 ~ 52 (480 ~ 530) [34.7 ~ 38.3] 9 (0.35)
3/4 ⎯ 16UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 ⎯ 14UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47), 15 (0.59)
1
⋅1/16 ⎯ 12UNF 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
1
⋅5/16 ⎯ 12UNF 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
PF3/8 49 (500) [36.2] 47 ~ 52 (480 ~ 530) [34.7 ~ 38.3] 9 (0.35)
PF1/2 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
0-16
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
Unit: N (tf) [lbf]
Lifting angle Tension Compression
Suspension
method
Lifting angle Tension Compression
Suspension
method
0° 1.00 time 0 time 90° 1.41 time 1.00 time
30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
60° 1.16 time 0.58 time
Rope
diameter
Cutting
load
Single-rope
suspension
Two-rope suspension Four-rope suspension
0° 0° 30° 60° 90° 0° 30° 60° 90°
6 mm
(0.24 in)
21380
(2.18)
[4807]
3040
(0.31)
[683.6]
6080
(0.62)
[1367]
5880
(0.6)
[1323]
5200
(0.53)
[1169]
4310
(0.44)
[970]
12160
(1.24)
[2734]
11770
(1.2)
[2646]
10400
(1.06)
[2337]
8630
(0.88)
[1940]
8 mm
(0.32 in)
31480
(3.21)
[7078]
4410
(0.45)
[992.3]
8830
(0.9)
[1985]
8530
(0.87)
[1918]
7650
(0.78)
[1720]
6280
(0.64)
[1411]
17650
(1.8)
[3969]
17060
(1.74)
[3937]
15300
(1.56)
[3440]
12550
(1.28)
[2322]
10 mm
(0.4 in)
49230
(5.02)
[11.69]
6960
(0.71)
[1565.6]
14020
(1.43)
[3153]
13440
(1.37)
[3021]
11770
(1.2)
[2646]
9810
(1.0)
[2205]
27460
(2.8)
[6174]
26480
(2.7)
[5954]
23540
(2.4)
[5292]
19610
(2.0)
[4410]
12.5 mm
(0.5 in)
76880
(7.84)
[17387]
10980
(1.12)
[2469.5]
21570
(2.2)
[4851]
21280
(2.1)
[4631]
18630
(1.9)
[4190]
14710
(1.5)
[3308]
43150
(4.4)
[9702]
41190
(4.2)
[9261]
37270
(3.8)
[8379]
29420
(3.0)
[6615]
14 mm
(0.56 in)
96400
(9.83)
[21675]
13730
(1.4)
[3087]
27460
(2.8)
[6174]
26480
(2.7)
[5954]
23540
(2.4)
[5292]
18630
(1.9)
[4190]
54920
(5.6)
[12348]
52960
(5.4)
[11907]
47070
(4.8)
[10584]
37270
(3.8)
[8379]
2t
1 tf
2t
90°
1
.
4
1
t
f
2t
30°
1
.
0
4
t
f
2t
120°
2
f
t
2t
60°
1
.
1
6
t
f
0-17
COMPONENTS WEIGHT
Member Model Weight kg (lbs)
Battery ASSY See page 1-2.
Drive motor ASSY
15
⋅18 Approx. 90 (198)
20 ~ 32 Approx. 120 (265)
35 ~ 55 Approx. 190 (419)
Pump motor ASSY
15
⋅18 Approx. 40 (88)
20 ~ 32 Approx. 65 (143)
35 ~ 55 Approx. 65 (143)
Counterweight
15 Approx. 565 (1246)
18 Approx. 695 (1532)
20 Approx. 670 (1477)
25 Approx. 1065 (2348)
30 Approx. 1195 (2635)
32 Approx. 1370 (3021)
35 Approx. 1420 (3131)
45 Approx. 2240 (4939)
55 Approx. 2370 (5226)
V mast ASSY L/fork and backrest
(with lift cylinder, max. lifting
height: 3300 (130 in))
15
⋅18
Approx. 440 (970)
20
⋅25
Approx. 510 (1120)
30
⋅32
Approx. 630 (1390)
V mast ASSY L/fork and backrest
(with lift cylinder, max. lifting
height: 3000 (118 in))
35 Approx. 890 (1960)
45 Approx. 950 (2090)
55 Approx. 1270 (2800)
0-18
RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Application Quantity l (US gal) Classification Type
Drive unit
15
⋅18 model 3.8 (1.00)
API
GL-4
Hypoid gear oil
SAE75W-80W
15
⋅18 (dead-man spec.) model
20 ~ 32 model
5.5 (1.45)
35 ~ 55 model 2.0 (0.53)
Differential 35 ~ 55 model 4.5 (1.18)
Planetary gear 35 ~ 55 model Proper quantity
Hydraulic oil
(V
⋅FV⋅FSV mast:
lifting height
3300 mm (130 in))
15
⋅18 model
17.0 (4.49)
ISO
VG32
Hydraulic oil
20 ~ 32 model 22.0 (5.81)
Hydraulic oil
(V
⋅FV⋅FSV mast:
lifting height
3000 mm (118 in))
35 ~ 55 model 34.5 (9.11)
Brake line 15 ~ 32 model Proper quantity ⎯
SAE J-1703
DOT-3
Chassis parts All model Proper quantity ⎯
• MP grease
• Molybdenum
disulfide grease
Battery All model Proper quantity ⎯ Distilled water
0-19
LUBRICATION CHART
15 ~ 32 Model
1Chain
2 Drive unit
3 Tilt cylinder front pin
4 Mast support bush
5 Front wheel bearing
6 Tilt steering lock mechanism
7 Steering knuckle king pin
8 Rear wheel bearing
9 Tie rod end pin
10 Rear axle cylinder end pin
11 Brake master cylinder
12 Oil tank
13 Rear axle beam front pin
14 Rear axle beam rear pin
15 Swing lock cylinder crank and rod pin
1
3
4
5
1
5
4
11
12
13
(20 ~ 30 model) 15
15 (15
⋅18 model)
7
8
9
10
14
1
2
6
5
4
6
6
1
1
1
6
2
3
1
6
1
6
1
1
1
1
1
1
3
4
5
7
8
9
10
2
6
3
I
II
III
IV
V
{ Inspection
z Replacement
c MP Grease
d Engine Oil
e Hypoid gear Oil
f Hydraulic Oil
g Brake Fluid
h Molybdenum disulfide greass
I. Inspect every 8 hours (daily)
II. Inspect every 40 hours (weekly)
III. Inspect every 170 hours (monthly)
IV. Inspect every 1000 hours (6 monthly)
V. Inspect every 2000 hours (annual)
1
0-20
35 ~ 55 Model
1
4
5
6
3
4
12
13
15
8
9
10
11
14
1
2
5
4
5
5
1
1
1
5
2
3
1
5
1
1
1
1
1
3
1
4
5
6
8
9
10
11
2
7
3
I
II
III
IV
V
1
3
3
3
1Chain
2 Differential
3 Drive unit
4 Tilt cylinder front pin
5 Mast support bush
6 Planetary gear
7 Tilt steering lock mechanism
8 Steering knuckle king pin
9 Rear wheel bearing
10 Tie rod end pin
11 Rear axle cylinder end pin
12 Oil tank
13 Rear axle beam front pin
14 Rear axle beam rear pin
15 Swing lock cylinder crank and rod pin
{ Inspection
z Replacement
c MP Grease
d Engine Oil
e Hypoid gear Oil
f Hydraulic Oil
g Molybdenum disulfide greass
I. Inspect every 8 hours (daily)
II. Inspect every 40 hours (weekly)
III. Inspect every 170 hours (monthly)
IV. Inspect every 1000 hours (6 monthly)
V. Inspect every 2000 hours (annual)
0-21
PERIODIC MAINTENANCE
Inspection Method
I : Inspection
⋅Repair or replacement if required.
M: Measurement
⋅Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector
Inspection Period
Item
Every
month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
ELECTRICAL SYSTEM
Motor
Rotation sound I ←← ←
Looseness in the connecting parts T ←← ←
Insulation resistance M ←←
Brush wear and sliding condition
(For pump motor and PS motor only)
I ←
Commutator contamination, damage
(For pump motor and PS motor only)
I ←
Brush, spring wear
(For pump motor and PS motor only)
M
Battery
Charging level I ←← ←
Electrolyte level I ←← ←
Electrolyte specific gravity M ←← ←
Terminal looseness I ←← ←
Abnormality in the upper portion of the
battery case
I ←← ←
Insulation resistance M ←←
Voltage measurement of each battery cell after
charging
M
Magnet
contactor
Contact looseness, damage, abrasion I ←← ←
Operating condition of the auxiliary contact,
contamination, abrasion
I ←← ←
Mounting condition of the arc shooter I
Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead wire,
looseness
I
Microswitch
Operating condition and timing I ←← ←
Damage and looseness of installing parts I ←← ←
Direction switch Operation condition, dama ge I ←← ←
Controller
Operation condition I ←← ←
Interior contamination, damage C ←← ←
Motor input voltage M
Fuse Looseness I ←← ←
0-22
Inspection Period
Item
Every
month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Wiring
(including
charging cord)
Harness deterioration, champ damage and
looseness
I ←← ←
Looseness in connecting parts, taping condition I ←← ←
Connecting condition and damage of the
battery connector
I ←← ←
POWER TRANSFER SYSTEM
Drive unit
Oil leakage I ←← ←
Oil level I ←← ←
Bolt or nut looseness T
Differential
(35 ~ 55 model)
Leak I ←← ←
Oil level I ←← ←
Bolt loosening T
Planetary gear
(35 ~ 55 model)
Leak I ←← ←
Oil level I ←← ←
Bolt loosening T
DRIVE SYSTEM
Wheels
Tire cuts, damage and uneven wearing I ←← ←
Loose rim and hub nuts T ←← ←
Tire groove depth M ←← ←
Metal chips, pebbles and other foreign matter
trapped in tire grooves
I ←← ←
Rim, side bearing and disc wheel damage I ←← ←
Abnormal sound and looseness of front wheel
bearing
I ←← ←
Abnormal sound and looseness of rear wheel
bearing
I ←← ←
Front axle Cracks, damage and deformation of housing I
Rear axle
Cracks, damage and deformation of beam I
Looseness of axle beam in vehicle longitudinal
direction
M* M
STEERING SYSTEM
Steering wheel
Play and looseness I ←← ←
Function I ←← ←
Steering valve
Oil leak I ←← ←
Looseness of mounting T ←← ←
Power steering
Oil leake I ←← ←
Mounting and linkage looseness I ←← ←
Damage of power steering hose I
Knuckle
King pin looseness I ←← ←
Cracks and deformation I
0-23
Inspection Period
Item
Every
month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
BRAKING SYSTEM
Brake pedal
Play and reserve M ←← ←
Braking effect I ←← ←
Parking brake
Operating force I ←← ←
Braking effect I ←← ←
Rod and cable looseness and damage I ←← ←
Brake pipe Leak, damage and mounting condition I ←← ←
Reservoir tank Leak and fluid level I ←← ←
Master
cylinder and
wheel cylinder
Function, wear, damage, leak and mounting
looseness
I
Brake drum and
brake shoe
Clearance between drum and lining M ←← ←
Wear of shoe sliding portion and lining I
Drum wear and damage I
Shoe operating condition I
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Backing plate
Deformation, cracks and damage I
Loose mounting T
MATERIAL HANDLING SYSTEM
Forks
Abnormality of fork and stopper pin I ←← ←
Misalignment between left and right fork fingers I ←← ←
Cracks at fork root and welded part I
*1
Mast and lift
bracket
Deformation and damage of each part and
crack at welded part
I ←← ←
Mast and lift bracket looseness I ←← ←
Wear and damage of mast support bushing I
Wear, damage and rotating condition of rollers I ←← ←
Wear and damage of roller pins I
Wear and damage of mast trip I ←← ←
Chain and chain
wheel
Tension, deformation and damage of chain I ←← ←
Chain lubrication I ←← ←
Abnormality of chain anchor bolt I ←← ←
Wear, damage and rotating condition of chain
wheel
I ←← ←
Var i o u s
attachments
Abnormality and mounting condition of each
part
I ←← ←
0-24
Inspection Period
Item
Every
month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
HYDRAULIC SYSTEM
Cylinder
Loosening and damage of cylinder mounting T ←← ←
Deformation and damage of rod, rod screw and
rod end
I ←← ←
Cylinder operation I ←← ←
Natural drop and natural forward tilt
(hydraulic drift)
M ←← ←
Cylinder
Oil leak and damage I ←← ←
Wear and damage of pin and cylinder bearing I ←← ←
Lifting speed M ←← ←
Uneven movement I ←← ←
Oil pump Oil leak and abnormal sound I ←← ←
Hydraulic oil
tank
Oil level and contamination I ←← ←
Tank and oil strainer C ←
Oil leak I ←← ←
Control lever
Loose linkage I ←← ←
Operation I ←← ←
Oil control valve
Oil leak I ←← ←
Relief pressure measurement M
Relief valve and tilt lock valve functions I ←← ←
Hydraulic piping
Oil leak I ←← ←
Deformation and damage I ←← ←
Loose joint T ←← ←
SAFETY DEVICES, ETC.
Head guard
Cracks at welded portion I ←← ←
Deformation and damage I ←← ←
Back-rest
Loosening of mounting T ←← ←
Deformation, crack and damage I ←← ←
Lighting system Function and mounting condition I ←← ←
Horn Function and mounting condition I ←← ←
Direction
indicator
Function and mounting condition I ←← ←
Instruments Functions I ←← ←
Backup buzzer Function and mounting condition I ←← ←
Rear-view
mirror
Dirt, damage I ←← ←
Rear reflection status I ←← ←
Seat
Loosening and damage of mounting I ←← ←
Seatbelt damage and function I
←← ←
0-25
Inspection Period
Item
Every
month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Body
Damage and cracks of frame, cross members,
etc.
I
Bolts and nuts looseness T
SAS
Functions I ←← ←
Loosening and damage at sensor mounting
portion
I ←← ←
Damage, deformation, oil leakage and loosen-
ing of the mounting of functional parts
I ←← ←
Loosening and damage of wire harnesses I ←← ←
Lock cylinder accumulator performance I
Rusting and corrosion of load sensor I
Others Grease up L ←← ←
0-26
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
z : Replacement
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
Replacement timing
Item
Every
month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Drive unit oil z
Differential oil (35 ~ 55 model) z
Planetary gear oil (35 ~ 55 model) z
Hydraulic oil z ←
Hydraulic oil filter
z New vehicle
initial replacement
z ←
Wheel bearing grease z
Brake fluid (15 ~ 32 model) z ←
Brake master cylinder rubber parts z
Wheel cylinder cup seals z
Brake fluid reservoir hose
(15 ~ 32 model)
z Every 2 years
Power steering hose z Every 2 years
Power steering rubber parts z Every 2 years
Hydraulic hose z Every 2 years
Chain z Every 3 years
Swing lock cylinder
z Every 10,000
hours
1-1
1
BATTERY
1
Page
BATTERY COMPARTMENT AND REQUIRED
WEIGHT
.......................................................................... 1-2
SERVICE STANDARD .................................................. 1-3
DISPLAY........................................................................... 1-3
TROUBLESHOOTING .................................................. 1-4
BATTERY ASSY............................................................. 1-5
REMOVAL
⋅INSTALLATION............................................. 1-5
INSPECTION ................................................................... 1-6
1-2
BATTERY COMPARTMENT AND REQUIRED WEIGHT
1
When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
See New Model Features (Pub. No. PU312) for the battery recommendation.
Compartment dimensions
mm (in.)
Minimum required battery
weight (with case)
kg (lb)
Remarks
Depth X Width Y Height Z
7FBCU15
⋅18 680 (26.8) 878 (34.6) 585 (23.0) 830 (1840)
7FBCU20
⋅25
775 (30.5) 992 (39.1) 585 (23.0)
1090 (2400)
7FBCHU25
7FBCU30
⋅32
870 (34.3) 992 (39.1) 585 (23.0)
1360 (3000)
7FBCU35
996 (39.2) 1148 (45.2) 585 (23.0)
1542 (3400)
7FBCU45
996 (39.2) 1148 (45.2) 585 (23.0)
1635 (3600)
7FBCU55
1 161 (45.7 ) 1148 (45.2) 585 (23.0)
1918 (4230)
D
e
p
t
h
Height
Width
X
Y
Z
1-3
1
SERVICE STANDARD
DISPLAY
Battery Charge Indicator
The battery charge indicator indicates 10 levels of battery
charge on the LCD.
Low Remaining Battery Charge Warning
When the remaining battery charge drops below the set
level, the charge display blinks.
When the key switch is turned to OFF and ON again in this
state, the buzzer sounds for 5 seconds to warn the operator.
Battery Overdischarge Warning Function
When the battery charge decreases further below the set
level after the remaining battery charge warning, any attempt
at traveling or material handling operation will cause all
charge indicator segments to blink and the alarm to sound to
warn the operator.
Specific gravity upon full charge 1.280 [20°C (68°F)]
Specific gravity upon end of discharge 1.150 [20°C (68°F)]
Discharge end voltage
36 V 32.0 V
48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled (deionized) water
Insulation resistance 1MΩ or more
Battery charge indicator
Battery
discharged
state %
LCD
10
F
987654321
E
0 to 10
(exclusive)
{{{{{{{{{{
10 to 20
(exclusive)
⎯ {{{{{{{{{
20 to 30
(exclusive)
⎯⎯{{{{{{{{
30 to 40
(exclusive)
⎯⎯⎯{{{{{{{
40 to 50
(exclusive)
⎯⎯⎯⎯{{{{{{
50 to 60
(exclusive)
⎯⎯⎯⎯⎯{{{{{
60 to 70
(exclusive)
⎯⎯⎯⎯⎯⎯{{{{
70 to 80
(exclusive)
⎯⎯⎯⎯⎯⎯⎯{{{
80 to 90
(exclusive)
⎯⎯⎯⎯⎯⎯⎯⎯ {{
90 to 100
(exclusive)
⎯⎯⎯⎯⎯⎯⎯⎯⎯ {
100 or more ⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯
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