Toyota 7FBE10 Owner's Manual

FOREWORD

This manual covers the service procedures of the TOYOTA ELECTRIC POWERED FORKLIFT 7FBE10 to 20 series.

Please use these manuals for providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of February 2003. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

SECTION INDEX

NAME	SECTION
GENERAL	0
BATTERY	1
CHARGER (OPT)	2
CONTROLLER	3
MULTI-DISPLAY FUNCTIONS	4
TROUBLESHOOTING	5
MOTOR	6
DRIVE UNIT & FRONT AXLE	7
REAR AXLE	8
STEERING	9
BRAKE	10
BODY & FRAME	11
MATERIAL HANDLING SYSTEM	12
MAST	13
CYLINDER	14
OIL PUMP	15
OIL CONTROL VALVE	16
SAS FUNCTIONS (OPT)	17
APPENDIX	18

0-1

GENERAL

	Page
VEHICLE EXTERIOR VIEW...........	0-2
VEHICLE MODELS ......................	0-3
FRAME NUMBER .........................	0-3
HOW TO USE THIS MANUAL ......	0-4
EXPLANATION METHOD..................	0-4
TERMINOLOGY .................................	0-5
ABBREVIATIONS ..............................	0-5
SI UNITS .............................................	0-6
OPERATING TIPS.........................	0-7
GENERAL INSTRUCTIONS ..............	0-7
JACK-UP POINT ................................	0-8
HOISTING THE VEHICLE..................	0-9
WIRE ROPE SUSPENSION ANGLE
LIST ..............................................	0-10
SAFE LOAD FOR EACH WIRE ROPE
SUSPENSION ANGLE.................	0-10
MEMBER WEIGHTS.........................	0-11
TOWING THE VEHICLE...................	0-11
ELECTRICAL PARTS
INSPECTION.................................	0-12
NOTES ON SAS...............................	0-14
STANDARD BOLT & NUT
TIGHTENING TORQUE............	0-15
BOLT STRENGTH CLASS
IDENTIFICATION METHOD.........	0-15
TIGHTENING TORQUE TABLE .......	0-16
PRECOATED BOLTS.........................	0-17

	Page
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE	0-17	0
RECOMMENDED LUBRICANT
QUANTITY AND TYPES .........	0-18
LUBRICATION CHART ..............	0-19
PERIODIC MAINTENANCE .......	0-20
PERIODIC REPLACEMENT OF
PARTS AND LUBRICANTS ....	0-25

0-2

VEHICLE EXTERIOR VIEW

				0-3
VEHICLE MODELS
Vehicle model code	Payload (ton)	Vehicle Model	Control method	Voltage (V)
10	1.0	7FBE10	AC microcomputer controller	48
13	1.25	7FBE13
15	1.5	7FBE15
							0
18	1.75	7FBE18
20	2.0	7FBE20

FRAME NUMBER

Vehicle model	Drive motor model Punching format	Punching position
7FBE10
	7FBE13-50011
7FBE13
7FBE15	AR09
	7FBE18-50011
7FBE18
7FBE20	7FBE20-50011
		Punching position

0-4

HOW TO USE THIS MANUAL

EXPLANATION METHOD

1.Operating procedure

(1)Operating procedures are described using either pattern A or pattern B. Pattern A: Each step of the operation is explained with its own illustration.

Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations.

Example of pattern B

DISASSEMBLY · INSPECTION · REASSEMBLY

			Tightening torque unit T=N·m(kg·m)[ft·lbf]
	• Some step numbers may be	4		1
	omitted in some illustrations.
				2
				3
		7
	5	6
				T = 46.1 to 48.1
				(470 to 490)
				[34.0 to 35.5]
	8
	5
		9		1
Disassembly Procedure
1 Remove the cover. [Point 1]			Operation to be explained
2 Remove the bushing. [Point 2]
3 Remove the gear.

Point Operations

Explanation of operation point with illustration

[POINT 1]

Disassembly:

Make match marks before removing the pump cover

[POINT 2]

Inspection:

Measure the bushing inside diameter.

Limit 19.12 mm

0-5

1. How to read component figures	(Example)
(1) The component figures use the illustration in the parts
		3201
catalog for the vehicle model. Please refer to the catalog
to check the part name.	Parts catalog
	FIG number

2.Matters omitted from this manual

(1)This manual omits descriptions of the following jobs, but perform them in actual operation:

(a)Cleaning and washing of removed parts as required

(b)	Visual inspection (partially described)		0

TERMINOLOGY

CAUTION:

Important matters, negligence of which may cause accidents. Be sure to observe them.

NOTE:

Important items, negligence of which may cause accidents, or matters in operating procedure which require special attention.

Standard: Value showing the allowable range in inspection or adjustment

Limit: The maximum or minimum value allowed in inspection or adjustment.

ABBREVIATIONS

	Abbreviation	Meaning	Abbreviation	Meaning
	ASSY	Assembly	SAE	Society of Automotive Engineers
				(USA)
	ATT	Attachment	SAS	System of active stability
	LH	Left Hand	SST	Special Service Tool
	L/	Less	STD	Standard
	OPT	Option	T=	Tightening Torque
	O/S	Oversize	T	Number of teeth (T)
	PS system	Power Steering	U/S	Undersize
	RH	Right Hand	W/	With

0-6

SI UNITS

Meaning of SI

This manual uses SI units. SI represents the International System of Units, which was established to unify the various systems of units used in the past for smoother international technical communication.

New Units Adopted in SI

	Item	New unit	Conventional	Conversion rate*1 (1 [conventional unit] = X [SI
			unit	unit])
	Force*2	N (newton)	kgf	1 kgf = 9.80665 N
	Torque*2	N·m	kgf·cm	1 kgf·cm = 9.80665 N·m
	(Moment)
	Pressure*2	Pa (pascal)	kgf/cm2	1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa
			mmHg	1 mmHg = 0.133322 kPa
	Revolving speed	rpm	rpm	1 rpm = 1 r/min
	Spring con-	N/mm	kgf/mm	1 kgf/mm = 9.80665 N/mm
	Volume	l	cc	1 cc = 1 ml
	Power	W	PS system	1 PS = 0.735499 kW
	Heat quantity	W·h	cal	1 kcal = 1.16279 W·h
	Specific fuel	g/W·h	g/PS·h	1 g/PS·h = 1.3596 g/kW·h

<Reference>

*1: X represents the value in SI units as converted from 1 [in conventional units], which can be used as the rate for conversion between conventional and SI units.

*2: In the past, kilogram [kg] representing mass was often used in place of weight kilogram [kgf], which should be used as the unit of force.

Conversion between Conventional and SI Units

Equation for conversion

	Value in SI unit = Conversion rate Value in conventional unit	Conversion rate: Figure corresponding
		to X in the conversion rate column in
	Value in conventional unit = Value in SI unit Conversion rate
		the table above

When converting, change the unit of the value in conventional or SI units to the one in the conversion rate column in the table above before calculation. For example, when converting 100 W to the value in conventional unit PS, first change it to 0.1 kW and divide by the conversion rate 0.735499.

0-7

OPERATING TIPS

GENERAL INSTRUCTIONS

1.Skillful operation

(1)Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation.

(2)Check the cable color and wiring state before disconnecting any wiring.

(3)When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion.

(4)When disassembling and inspecting a precision part such as the control valve, use clean tools and operate in a clean location.

(5)Follow the specified procedures for disassembly, inspection and reassembly.

(6)Always replace gaskets, packing, O-rings, self-locking nuts and cotter pins with new oneseach time they are disassembled.

(7)Use genuine Toyota parts for replacement.

(8)Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the “standard tightening torque table”.

2.Protection of functional parts (battery operated vehicles)

(1)Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any connection failure or imperfect connection.

Failure or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers.

3.Defect status check

Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect.

4.Waste fluid disposal

Always use a proper container when draining waste fluid from the vehicle.

Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposal.

0-8

JACK-UP POINT

Always observe the following instructions when jacking up the vehicle:

•When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface.

•Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous.

•Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the vehicle with the jack only is very dangerous.

•Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle.

Jack-up point

Wooden block or stand setting points

0-9

HOISTING THE VEHICLE

When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist by any other attachment section as it is very dangerous.

0-10

WIRE ROPE SUSPENSION ANGLE LIST

Suspension	Tension Compression	Suspension
Angle		method

	0	1.00	0 time	1tf
		time

2t

30

	30	1.04	0.27 time
		time

2t

60	1.16	0.58 time	60
	time
			2t

Suspension	Tension Compression	Suspension
Angle		method

	90	1.41	1.00 time	90
		time
				2t

	120	2.00	1.73 time
		time		120
				2t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (tf) [lbf]

	Rope	Cutting	Single-	Two-rope suspension				four-rope suspension
			rope
	diameter	load
			0	0	30	60	90	0	30	60	90
	6 mm	21380	3040	6080	5880	5200	4310	12160	11770	10400	8630
		(2.18)	(0.31)	(0.62)	(0.6)	(0.53)	(0.44)	(1.24)	(1.2)	(1.06)	(0.88)
	(0.24 in)
		[4807]	[683.6]	[1367]	[1323]	[1169]	[970]	[2734]	[2646]	2337	[1940]
	8 mm	31480	4410	8830	8530	7650	6280	17650	17060	15300	12550
		(3.21)	(0.45)	(0.9)	(0.87)	(0.78)	(0.64)	(1.8)	(1.74)	(1.56)	(1.28)
	(0.32 in)
		[7078]	[992.3]	[1985]	[1918]	[1720]	[1411]	[3969]	[3937]	[3440]	[2322]
	10 mm	49230	6960	14020	13440	11770	9810	27460	26480	23540	19610
		(5.02)	(0.71)	(1.43)	(1.37)	(1.2)	(1.0)	(2.8)	(2.7)	(2.4)	(2.0)
	(0.4 in)
		[11690]	[1565.6]	[3153]	[3021]	[2646]	[2205]	[6174]	[5954]	[5292]	[4410]
	12.5 mm	76880	10980	21570	21280	18630	14710	43150	41190	37270	29420
		(7.84)	(1.12)	(2.2)	(2.1)	(1.9)	(1.5)	(4.4)	(4.2)	(3.8)	(3.0)
	(0.5 in)
		[17387]	[2469.5]	[4851]	[4631]	[4190]	[3308]	[9702]	[9261]	[8379]	[6615]
	14 mm	96400	13730	27460	26480	23540	18630	54920	52960	47070	37270
		(9.83)	(1.4)	(2.8)	(2.7)	(2.4)	(1.9)	(5.6)	(5.4)	(4.8)	(3.8)
	(0.56 in)
		[21675]	[3087]	[6174]	[5954]	[5292]	[4190]	[12348]	[11907]	[10584]	[8379]

					0-11
MEMBER WEIGHTS
			Unit: kg (lbs)
Member	Vehicle model		Weight
BATTERY ASSY		See P1-2
Drive motor ASSY	All Models		Approx. 37		(82)
Pump motor ASSY	All Models		Approx. 31		(68)
Front axle ASSY W/ drive motor ASSY	All Models		Approx. 122		(269)
Rear axle ASSY W/ rear axle cylinder ASSY	All Models		Approx. 45		(99)
	7FBE10		Approx. 405		(893)
	7FBE13		Approx. 598 (1319)
Counterweight
	7FBE15		Approx. 697 (1537)
	7FBE18		Approx. 853 (1881)
	7FBE20		Approx. 1040		(2293)
Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork,	7FBE10 to 7FBE18		330	(730)
Lifting height 3000mm, V mast)
	7FBE20		400	(880)
	7FBE10		2225	(4906)
	7FBE13		2425	(5347)
Vehicle weight
	7FBE15		2685	(5920)
	7FBE18		2840	(6262)
	7FBE20		3155	(6957)

TOWING THE VEHICLE

Note the cautions below when towing the vehicle.

1. Lift the rear wheels for towing

2. The traveling speed when towing must not exceed the maximum traveling speed of the forklift.

3. Before starting towing, always set the key switch to OFF and the direction switch to the neutral position.

4. Before towing, either remove the fork or take action to prevent the fork from coming into contact with the ground due to bouncing.

0-12

ELECTRICAL PARTS INSPECTION

1.Always disconnect the battery plug before inspecting or servicing electrical parts.

2.Pay sufficient attention when handling electronic parts.

(1)Never subject electronic parts, such as computers and relays, to impact.

(2)Never expose electronic parts to high temperature or moisture.

(3)Do not touch connector terminals, as they may be deformed or damaged due to static electricity.

3.Use a circuit tester that matches the object and purpose of measurement.

Analog type: This type is convenient for observing movement during operation and the operating condition. Measured value is only a reference

Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or movement.

(1)Difference between results of measurement with analog and digital types

The results of measurements using the analog type and the digital type may be different. Differences between the polarities of the analog type and the digital type are described below.

1)Analog circuit tester

Forward

Reverse

2)Digital circuit tester

Forward

Reverse

Example of measurement result

Tester range: k range

Analog type

Continuity

Forward

11 k

No continuity

Reverse

Example of measurement result

Tester range: 2 M range

Digital type

No continuity

Forward

1

Continuity

Reverse

2 M

0-13

(2)Difference in result of measurement with a 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.

(mA)

Forward current

6
5
4	Germanium
3	diode
2	Silicon
	diode
1
0	0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
	Forward voltage	(V)

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.

	Resistor	Meter
	0
flow	Variable resistor
Current	Resistor
	Range: 10	(SW1)
	Resistor
	Range: 1
	Power source: 1.5V
	Red	Black

Always use the range described in the repair manual for measurement.

0-14

NOTES ON SAS

1.For the explanations of SAS functions and operation, also see “New Model Feature 7FBE10 to 20 Pub.

No.PE314”.

2.See page 17-6 FOR REPAIR WORK of this repair manual before servicing.

3.If repair or replacement is performed in any section of the vehicle that relates to SAS function, perform necessary matching to ensure proper SAS function (see page 4-47).

4.always be sure to operate the vehicle carefully. Be aware of the difference in control features between with and without SAS.

5.Many precision valves are used in the SAS oil control valves. When disassembling or replacing hydraulic parts (valves, piping, etc.), be sure to clean the parts before installation. Periodic change of the hydraulic oil is also very important.

6.As the vehicle is equipped with high-precision electronic devices, modification of electrical parts may cause vehicle failure. Be sure to use genuine Toyota parts for replacement and installation of the electrical parts (auxiliary equipment, optional parts, etc.).

0-15

STANDARD BOLT & NUT TIGHTENING TORQUE

Tightening torque of standard bolts and nuts are not indicated throughout the manual. Use the charts and table below to judge the standard tightening torque.

1.Find the class of the bolt strength on the table below and then find the bolt tightening torque on the tightening torque table.

2.The nut tightening torque can be judged from its corresponding bolt type.

BOLT STRENGTH CLASS IDENTIFICATION METHOD

Identification by bolt shape

Identification by part No.

		Shape and class	Class	Hexagon head bolt
	Hexagon		4 = 4T
		Bolt with raised	5 = 5T	Part No.
	head bolt
		or etched
			6 = 6T	91611-40625
	Hexagon	numeral on head	7 = 7T	Length (mm)
			8 = 8T	Nominal diameter (mm)
	bolt
				Class
	(standard)	No mark	4T
	Hexagon	No mark	4T
	flange bolt
	Hexagon	Bolt with two
	head bolt	raised lines on	5T
	(standard)	head		Nominal diameter
	Hexagon	Bolt with two
		raised lines on	6T
	flange bolt			Length
		head
	Hexagon	Bolt with three
	head bolt	raised lines on	7T
	(standard)			Stud bolt
		head
	Hexagon	Bolt with four		Part No.
	head bolt	raised lines on	8T
				92132-40614
	(standard)	head
				Length (mm)
				Nominal diameter (mm)
	Welded bolt		4T	Class
		No mark	4T	Nominal diameter
	Stud bolt			Length
		2 mm groove(s)
		on one/both	6T
		edge(s)

0-16

TIGHTENING TORQUE TABLE

					Standard tightening torque
	Nominal		Hexagon				Hexagon
		Pitch	head bolt
Class	diameter						flange bolt
		mm
	mm
			N·m	kgf·cm		ft·lbf	N·m		kgf·cm	ft·lbf
	6	1.0	5.4	55		48in·lbf	5.9		60	52in·lbf
	8	1.25	13	130		9	14		145	10
4T	10	1.25	25	260		19	28		290	21
	12	1.25	47	480		35	53		540	39
	14	1.5	75	760		55	83		850	61
	16	1.5	113	1150		83
	6	1.0	6.4	65		56in·lbf	7.5		75	65in·lbf
	8	1.25	16	160		12	18		175	13
5T	10	1.25	32	330		24	36		360	26
	12	1.25	59	600		43	65		670	48
	14	1.5	91	930		67	100		1050	76
	16	1.5	137	1400		101	157		1600	116
	6	1.0	7.8	80		69in·lbf	8.8		90	78in·lbf
	8	1.25	19	195		14	21		215	16
6T	10	1.25	38	400		29	43		440	32
	12	1.25	72	730		53	79		810	59
	14	1.5	110	1100		80	123		1250	90
	16	1.5	170	1750		127	191		1950	141
	6	1.0	11	110		8	12		120	9
	8	1.25	25	260		19	28		290	21
7T	10	1.25	52	530		38	58		590	43
	12	1.25	95	970		70	103		1050	76
	14	1.5	147	1500		108	167		1700	123
	16	1.5	226	2300		166
	6	1.0	12	125		9	14		145	9
	8	1.25	29	300		22	32		330	24
8T	10	1.25	61	620		45	68		690	50
	12	1.25	108	1100		80	123		1250	90
	14	1.5	172	1750		127	196		2000	145
	16	1.5	265	2700		195	299		3050	221

0-17

PRECOATED BOLTS

Seal lock agent

1.Do not replace or restore a precoated bolt as it is in the following cases:

(1)After it has been removed.

(2)When it has been moved by tightness check, etc.

(loosened or tightened)

NOTE:

For torque check, tighten the bolt at the lower limit of the allowable tightening torque range; if the bolt moves, retighten it according to the steps below.

2.How to reuse precoated bolts

(1)Wash the bolt and threaded hole.

(The threaded hole must be washed even when replacing the bolt with a new one)

(2)Completely dry the washed parts by blowing with air.

(3)Apply a 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 corresponding nipple contact surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or other damage on the contact surfaces before installation.

2.When connecting the 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.

Nominal diameter		Tightening torque standard N·m (kgf·cm) [ft·lbf]				Inside diameter
						of hose
of screw
		Standard		Tightening range
						mm (in)
7/16-20UNF	25 (50) [18.1]		24 to 26 (240 to 270) [17.4 to 19.5]			6 (0.24)
9/16-18UNF	49	(500) [36.2]	47 to 52 (480 to 530) [34.7 to 38.3]			9 (0.35)
3/4-16UNF	59	(600) [43.4]	56 to 62	(570 to 630) [41.2 to 45.6]		12 (0.47)
7/8-14UNF	59	(600) [43.4]	56 to 62	(570 to 630) [41.2 to 45.6]		12 (0.47)
7/8-14UNF	78	(800) [57.9]	74 to 82	(740 to 840)	[53.5 to 60.8]	15 (0.59)
1•1/16-12UNF	118	(1200) [86.8]	112 to 123	(1140 to 1250) [82.5 to 90.4]		19 (0.75)
1•5/16-12UNF	137 (1400) [101.3]		130 to 144 (1330 to 1470) [96.2 to 106.4]			25 (0.98)
PF1/4	25	(250) [18.1]	24 to 26 (240 to 270)		[17.4 to 19.5]	6 (0.24)
PF3/8	49	(500) [36.2]	47 to 52 (480 to 530)		[34.7 to 38.3]	9 (0.35)
PF1/2	59	(600) [43.4]	56 to 62 (570 to 630)		[41.2 to 45.6]	12 (0.47)
PF3/4	118	(1200) [86.8]	112 to 123	(1140 to 1250) [82.5 to 90.4]		19 (0.75)
PF1	137 (1400) [101.3]		130 to 144 (1330 to 1470) [96.2 to 106.4]			25 (0.98)

0-18

RECOMMENDED LUBRICANT QUANTITY AND TYPES

Application					Type			Capacity
Drive unit			Castle hypoid gear oil W					Approx. 0.4 l (0.11 US gal)
			(API GL-4, SAE 75W-80)				(Until purring out from the filler port)
Hydraulic oil			STD: Castle hydraulic oil (ISO VG32)				See “Hydraulic oil level by lifting
			Cold storage vehicle: Mobil Aero HFE				height” below
			MP grease
Chassis parts			Chassis grease special					Appropriate amount
			Esso beacon 325
Battery			Distilled water					Appropriate amount
Hydraulic oil level by lifting height
									Unit:l (US gal)
Lifting height					V mast	SV mast		FV Mast	FSV Mast
			Capacity		14 (3.70)	14 (3.70)		17 (4.49)
To 3000mm
		Hydraulic oil level
(118 in)						12.4 (3.27)
		in the tank
			Capacity		15 (3.96)	15 (3.96)		19 (5.01)	16 (4.22)
To 4000mm
		Hydraulic oil level
(157.5 in)						14.2 (3.75)
		in the tank
			Capacity		18 (4.75)				19 (5.01)
To 6000mm
		Hydraulic oil level
(236 in)						17.2 (4.54)
		in the tank

0-19

LUBRICATION CHART

	I
	II
	III
	IV
	V
: Inspection and addition	I. Inspection every 8 hours (daily)
: Replacement	II. Inspection every 40 hours (weekly)
A: MP grease	III. Inspection every 170 hours (monthly)
B: Motor oil	IV. Inspection every 1000 hours (6 monthly)
C: Gear oil (SAE 75W-80)	V. Inspection 2000 hours (annual)

D:Hydraulic oil (ISO VG32)

E:Chassis grease special

1.	Mast strip	8.	Steering rack and pinion gear
2.	Tilt cylinder front pin	9.	Accelerator link
3.	Mast support bushing	10. Oil tank
4.	Lift chain	11. Tilt steering lock device
5.	Drive unit	12.		Rear wheel bearing
6.	Brake link	13.		Rear axle bearing
7.	Oil control valve lever pin

0-20

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 timing	Every	Every 3	Every 6	Every 12
		month	months	months	months
Item		Every	Every	Every	Every
		170 hours	500 hours	1000 hours	2000 hours

ELECTRICAL SYSTEM

	Rotation sound abnormality	I
Motor	Looseness in the connecting parts	T
	Insulation resistance		M
	Charging level (Display)	I
	Electrolyte level	I
	Electrolyte specific gravity	M
Battery	Looseness in the connecting parts	I
	Abnormality in the upper portion of the
		I
	battery and/or the case
	Insulation resistance		M
	Voltage measurement of each battery cell				M
	after charging
	Timer function (Timer test)	I
	Looseness in the connecting parts	T
Charger	HVR function voltage measurement				M
	Operating condition of the magnetic switch,				I
	contact contamination, roughness
	Contact looseness, damage, abrasion	I
	Operating condition, contamination and	I
	abrasion of the auxiliary contact
Magnet switch	Mounting condition of the arc shooter				I
	Operating condition and timing				I
	Looseness of the coil installation locations				I
	Mounting condition and looseness of the				I
	main circuit lead wire
	Operating condition and timing	I
Micro switch	Damage and looseness of installation	I
	locations
Direction lever	Operating condition, damage	I

							0-21
		Inspection timing	Every		Every 3	Every 6	Every 12
			month		months	months	months
Item			Every		Every	Every	Every
			170 hours		500 hours	1000 hours	2000 hours
		Operating condition	I
Controller		Interior contamination, damage	C
		Motor input voltage					M
Fuses		Looseness of the installation locations	I
		Harness deterioration, damage and	I
		looseness of the clamp
Wiring
		Looseness of the connections, taping
(incl. charging			I
		condition
cable)
		Connecting condition and damage of the	I
		battery connector
POWER TRANSMISSION SYSTEM
		Oil leak	I
Drive unit		Oil level	I
		Bolt or nut looseness					T
DRIVE SYSTEM
Front axle		Damage and deformation					I
		Damage and deformation					I
Rear axle		Looseness of rear axle bearing					I
		Abnormal noise of rear axle bearing					I
		Tire pressure	M
		Tire crack, damage and abnormal wear	I
		Tire tread depth	M
		Metal piece, stone and other foreign matter	I
		on tire
Wheels		Loosening of wheel nut and bolt	T
		Rim, side ring and disc wheel damage	I
		Looseness and abnormal noise of front	I
		wheel bearing
		Looseness and abnormal noise of rear	I
		wheel bearing
STEERING SYSTEM
Steering wheel		Play, loosening, looseness	I
		Function	I
Steering valve		Oil leak	I
		Looseness of the installation locations	T
Wheels for		Turning angle to left and right					I
steering

0-22

		Inspection timing	Every	Every 3	Every 6	Every 12
			month	months	months	months
	Item		Every	Every	Every	Every
			170 hours	500 hours	1000 hours	2000 hours
		Oil leak	I
	Power steering	Looseness of the installation locations	I
		Damage of power steering hose				I
	BRAKING SYSTEM
	Brake pedal	Reserve	M
		Braking performance	I
	Parking brake	Operating force and pull margin	I
		Braking performance	I
	Rod and cable	Looseness and damage	I
		Operating condition	I
		Clearance between disc and pad	M
		Wear of sliding portion and pad				I
	Disc brake	Disc wear and damage				I
		Looseness of the disc installation locations				I
		Operating condition				I
		Return spring fatigue				I
	MATERIAL HANDLING SYSTEM
		Damage or wear of fork or stopper pin	I
	Fork	Fork deformation and wear	I
		Cracks at fork root and welded part of tooth				I*1
		Deformation and damage of each part and	I
		crack at welded part
		Wear and damage of roller	I
	Mast and	Mast and lift bracket looseness	I
	lift bracket	Wear and damage of mast support bushing				I
		Wear and damage of roller pin				I
		Wear and damage of mast strip	I
		Chain lubrication	I
		Deformation, damage and slackness of	I
	Chain and	chain
	chain wheel	Abnormality of chain anchor bolt	I
		Wear, damage and revolution of chain	I
		wheel
	Various	Abnormality and installation condition of	I
	attachments	each part

0-23

	Inspection timing	Every	Every 3	Every 6	Every 12
		month	months	months	months
Item		Every	Every	Every	Every
		170 hours	500 hours	1000 hours	2000 hours

HYDRAULIC SYSTEM

		Looseness, deformation and damage of rod	I
		and rod end
		Cylinder operation	I
		Natural drop and natural forward tilt	M
		Oil leak and damage	I
	Cylinder	Wear and damage of pin and cylinder	I
		bearing
		Loosening and damage of cylinder	T
		mounting
		Lifting speed	M
		Uneven movement	I
	Oil pump	Oil leak and abnormal sound	I
		Oil level and contamination	I
	Hydraulic oil	Oil leak	I
	tank
		Tank and oil strainer cleaning			C
	Hydraulic oil	Filter clogging				C
	filter
	Control lever	Loose linkage	I
		Operation	I
		Oil leak	I
	Oil control	Safety valve function	I
	valve
		Relief pressure measurement				M
	Hydraulic hose	Oil leakage, deformation and damage	I
	and piping	Looseness	T
	SAFETY DEVICES, ETC.
		Looseness of the installation locations	T
	Head guard	Deformation, crack and damage	I
	and backrest
		Crack at welded portion	I
	Lighting system	Function and installation condition	I
	Direction	Function and installation condition	I
	indicator
	Horn	Function and installation condition	I
	Backup buzzer	Function and installation condition	I
	Rear view	Rear reflection status	I
	mirror	Dirt, damage	I

0-24

	Inspection timing	Every	Every 3	Every 6	Every 12
		month	months	months	months
Item		Every	Every	Every	Every
		170 hours	500 hours	1000 hours	2000 hours
Instruments	Operation	I
	Loosening and damage of mounting	I
Seat	Seatbelt damage and function	I
	Deadman seat operation	I
	Damage and cracks in frame, cross mem-				I
Body	bers, etc.
	Bolts and nuts looseness				T
	Functions	I
	Loosening and damage at sensor mounting	I
	portion
SAS	Damage, deformation, oil leakage and loos-	I
	ened installation of functional parts
	Loosening and damage of wire harnesses	I
	Rusting and corrosion of load sensor				I
Others	Grease up	L

0-25

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

				●: Replacement
	Replacement cycle	Every	Every	Every	Every
		month	3 months	6 months	12 months
	Item	Every	Every	Every	Every
		170 hours	500 hours	1000 hours	2000 hours
	Drive unit gear oil			●
	Hydraulic oil			●
		● New
	Hydraulic oil filter	vehicle initial		●
		replacement
	Rear wheel bearing grease			●
	Power steering hose				● Every
					2 years
	Power steering rubber parts				● Every
					2 years
	Hydraulic hose				● Every
					2 years
	Lift chain				● Every
					3 years

0-26

1-1

BATTERY

	Page
BATTERY COMPARTMENT AND
REQUIRED WEIGHT ...........................................	1-2
SERVICE STANDARDS. . . . . . . . . . . . . . . . . . . . . . . .	1-3	1
.....................................................................DISPLAY	1-3
TROUBLESHOOTING............................................	1-4
BATTERY ASSY .....................................................	1-5
REMOVAL · INSTALLATION...............................................	1-5
INSPECTION ....................................................................	1-6
REPLACING BATTERY PLUG TERMINAL.....................	1-9