Toyota 7FBE10-20 Repair 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 corre-

sponding forklift models.

This manual deals with the above models as of February 2003. Please under-

stand that disagreement can take place between the descriptions in the man-

ual 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 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

HIGH PRESSURE HOSE FITTING

TIGHTENING TORQUE

RECOMMENDED LUBRICANT

QUANTITY AND TYPES

LUBRICATION CHART................. 0-19

PERIODIC MAINTENANCE......... 0-20

PERIODIC REPLACEMENT OF

PARTS AND LUBRICANTS

............. 0-17

........... 0-18

..... 0-25

0

1

2

3

4

5

6

7

8

9

10

11

MEMBER WEIGHTS........................ 0-11

TOWING THE VEHICLE .................. 0-11

ELECTRICAL PARTS

INSPECTION ................................ 0-12

NOTES ON SAS .............................. 0-14

STANDARD BOLT & NUT

TIGHTENING TORQUE

BOLT STRENGTH CLASS

IDENTIFICATION METHOD ......... 0-15

TIGHTENING TORQUE TABLE ...... 0-16

PRECOATED BOLTS ...................... 0-17

............. 0-15

12

13

14

15

16

17

18

0-2

VEHICLE EXTERIOR VIEW

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 ↑↑

18 1.75 7FBE18 ↑↑

0-3

0

20 2.0 7FBE20 ↑↑

FRAME NUMBER

Vehicle model Drive motor model Punching format Punching position

7FBE10

7FBE13-50011

7FBE13

7FBE15

7FBE18

7FBE20 7FBE20-50011

AR09

7FBE18-50011

Punching position

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

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
omitted in some illustrations.

8

Disassembly Procedure

1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2]
3 Remove the gear.

4

2

3

7

6

5

5

9

1

1

T = 46.1 to 48.1

(470 to 490)

[34.0 to 35.5]

Operation to be explained

Point Operations

[POINT 1]

Disassembly:
Make match marks before removing the pump cover

[POINT 2]

Inspection:
Measure the bushing inside diameter.

Limit 19.12 mm

Explanation of operation point with illustration

0-5

1. How to read component figures
(1) The component figures use the illustration in the parts

catalog for the vehicle model. Please refer to the catalog
to check the part name.

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)

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

(Example)

3201

Parts catalog

FIG number

0

1

2

3

4

5

6

Abbreviation Meaning Abbreviation Meaning

ASSY Assembly SAE

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

Society of Automotive Engineers

(USA)

7

8

9

10

11

12

13

14

15

16

17

18

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*

unit

*2

2

N (newton) kgf 1 kgf = 9.80665 N

N·m kgf·cm 1 kgf·cm = 9.80665 N·m

2

Pa (pascal) kgf/cm

2

1 kgf/cm2 = 98.0665 kPa = 0.0980665 MPa

Force*

Torque

(Moment)

Pressure*

↑↑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

1

(1 [conventional unit] = X [SI

unit])

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.

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 ones each

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.

0-7

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

Angle

0°

30°

60°

Tension Compression

1.00
time

1.04
time

1.16
time

0 time 90°

0.27 time 120°

0.58 time

Suspension

method

1tf

2t

30°

f

t

4

0

.

1

2t

60°

f

t

6

1

.

1

2t

Suspension

Angle

Tension Compression

1.41
time

2.00
time

1.00 time

1.73 time

Suspension

method

90°

f

t

1

4

.

2t

1

120°

f

t

2

2t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Rope

diameter

6 mm

(0.24 in)

8 mm

(0.32 in)

10 mm
(0.4 in)

12.5 mm
(0.5 in)

14 mm

(0.56 in)

Cutting

load

21380

(2.18)

[4807]

31480

(3.21)

[7078]

49230

(5.02)

[11690]

76880

(7.84)

[17387]

96400

(9.83)

[21675]

Single-

rope

0° 0° 30° 60° 90° 0° 30° 60° 90°

3040

(0.31)

[683.6]

4410

(0.45)

[992.3]

6960

(0.71)

[1565.6]

10980
(1.12)

[2469.5]

13730

(1.4)

[3087]

Two-rope suspension four-rope suspension

6080

(0.62)

[1367]

8830

(0.9)

[1985]

14020

(1.43)

[3153]

21570

(2.2)

[4851]

27460

(2.8)

[6174]

5880

(0.6)

[1323]

8530

(0.87)

[1918]

13440

(1.37)

[3021]

21280

(2.1)

[4631]

26480

(2.7)

[5954]

5200

(0.53)

[1169]

7650

(0.78)

[1720]

11770

(1.2)

[2646]

18630

(1.9)

[4190]

23540

(2.4)

[5292]

4310

(0.44)

[970]

6280
(0.64)
[1411]

9810

(1.0)

[2205]

14710

(1.5)

[3308]

18630

(1.9)

[4190]

12160

(1.24)

[2734]

17650

(1.8)

[3969]

27460

(2.8)

[6174]

43150

(4.4)

[9702]

54920

(5.6)

[12348]

11770

(1.2)

[2646]

17060
(1.74)
[3937]

26480

(2.7)

[5954]

41190

(4.2)

[9261]

52960

(5.4)

[11907]

Unit: N (tf) [lbf]

10400

(1.06)

2337

15300

(1.56)

[3440]

23540

(2.4)

[5292]

37270

(3.8)

[8379]

47070

(4.8)

[10584]

8630

(0.88)

[1940]

12550

(1.28)

[2322]

19610

(2.0)

[4410]

29420

(3.0)

[6615]

37270

(3.8)

[8379]

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)

0-11

Mast ASSY W/ lift bracket (W/ lift cylinder, L/ fork,
Lifting height 3000mm, V mast)

Vehicle weight

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

3. Before starting towing, always set the key switch to OFF

4. Before towing, either remove the fork or take action to

7FBE10 to 7FBE18 330 (730)
7FBE20 400 (880)
7FBE10 2225 (4906)
7FBE13 2425 (5347)
7FBE15 2685 (5920)
7FBE18 2840 (6262)
7FBE20 3155 (6957)

maximum traveling speed of the forklift.

and the direction switch to the neutral position.

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

Example of measurement result
Tester range: kΩ range

Analog type

Continuity

Forward

11 kΩ

No continuity

Reverse

∞

2) Digital circuit tester
Example of measurement result

Forward

Reverse

Tester range: 2 MΩ range

Digital type

No continuity

Forward

1

Reverse

Continuity

2 MΩ

(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.

0-13

(mA)

Forward current

6

5

4

Germanium

diode

3

2

1

0

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Silicon

diode

(V)Forward voltage

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.

Resistor Meter

0 Ω

Variable resistor

Current flow

Resistor

Range:×10

Resistor

Range:×1

Power source: 1.5V

Red

(SW1)

Black

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
bolt

(standard)

Hexagon
flange bolt

Hexagon
head bolt
(standard)

Hexagon
flange bolt

Bolt with raised
or etched
numeral on head

No mark 4T

No mark 4T

Bolt with two
raised lines on
head

Bolt with two
raised lines on

4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T

5T

6T

head

Hexagon
head bolt
(standard)

Hexagon
head bolt
(standard)

Bolt with three
raised lines on
head

Bolt with four
raised lines on
head

7T

8T

Welded bolt 4T

Hexagon head bolt

Part No.
91611-40625
Length (mm)
Nominal diameter (mm)
Class

Nominal diameter

Length

Stud bolt

Part No.
92132-40614
Length (mm)
Nominal diameter (mm)
Class

Stud bolt

No mark 4T

2 mm groove(s)
on one/both

6T

edge(s)

Nominal diameter

Length

0-16

TIGHTENING TORQUE TABLE

Standard tightening torque

Class

4T

5T

6T

Nominal

diameter

mm

6

8
10
12
14
16

6

8
10
12
14
16

6

8
10
12
14
16

Pitch

1.0

1.25

1.25

1.25

1.5

1.5

1.0

1.25

1.25

1.25

1.5

1.5

1.0

1.25

1.25

1.25

1.5

1.5

mm

Hexagon
head bolt

N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf

5.4
13
25
47
75

113

6.4
16
32
59
91

137

7.8
19
38
72

110
170

55
130
260
480
760

1150

65
160
330
600
930

1400

80
195
400
730

1100

1750

48in·lbf

9
19
35
55
83

56in·lbf

12
24
43
67

101

69in·lbf

14
29
53
80

127

Hexagon
flange bolt

5.9
14
28
53
83



7.5
18
36
65

100
157

8.8
21
43
79

123
191

60
145
290
540
850



75
175
360
670

1050
1600

90
215
440
810

1250
1950

52in·lbf

65in·lbf

78in·lbf

10
21
39
61



13
26
48
76

116

16
32
59
90

141

7T

8T

6

8
10
12
14
16

6

8
10
12
14
16

1.0

1.25

1.25

1.25

1.5

1.5

1.0

1.25

1.25

1.25

1.5

1.5

11
25
52

95
147
226

12

29

61
108
172
265

110
260
530

970
1500
2300

125

300

620

1100
1750
2700

8
19
38
70

108
166

9
22
45
80

127
195

12
28

58
103
167



14

32

68
123
196
299

120
290

590
1050
1700



145

330

690
1250
2000
3050

9
21
43
76

123



9
24
50
90

145
221

PRECOATED BOLTS

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

Seal lock agent

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

0-17

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

of screw

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)

Tightening torque standard N·m (kgf·cm) [ft·lbf] Inside diameter

Standard Tightening range

of hose

mm (in)

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

Hydraulic oil STD: Castle hydraulic oil (ISO VG32)

Chassis parts

Battery Distilled water Appropriate amount

Hydraulic oil level by lifting height

Castle hypoid gear oil W
(API GL-4, SAE 75W-80)

Cold storage vehicle: Mobil Aero HFE

MP grease
Chassis grease special
Esso beacon 325

Approx. 0.4 l (0.11 US gal)

(Until purring out from the filler port)

See “Hydraulic oil level by lifting
height” below

Appropriate amount

Unit:l

Lifting height V mast SV mast FV Mast FSV Mast

Capacity 14 (3.70) 14 (3.70) 17 (4.49) 

To 3000mm

(118 in)

To 4000mm

(157.5 in)

Hydraulic oil level

in the tank

Capacity 15 (3.96) 15 (3.96) 19 (5.01) 16 (4.22)

Hydraulic oil level

in the tank

12.4 (3.27)

14.2 (3.75)

l (US gal)

l l

To 6000mm

(236 in)

Capacity 18 (4.75) 19 (5.01)

Hydraulic oil level

in the tank

17.2 (4.54)

LUBRICATION CHART

0-19

I

II

III

IV

V

{: Inspection and addition I. Inspection every 8 hours (daily)

z: 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

Item

ELECTRICAL SYSTEM

Rotation sound abnormality I ←←←

Motor

Battery

Looseness in the connecting parts T ←←←
Insulation resistance M ←←
Charging level (Display) I ←←←
Electrolyte level I ←←←
Electrolyte specific gravity M ←←←
Looseness in the connecting parts I ←←←
Abnormality in the upper portion of the

battery and/or the case
Insulation resistance M ←←

Voltage measurement of each battery cell
after charging

Timer function (Timer test) I ←←←

Inspection timing

Every

month

Every

170 hours

I ←←←

Every 3
months

Every

500 hours

Every 6

months

Every

1000 hours

Every 12

months

Every

2000 hours

M

Looseness in the connecting parts T ←←←

Charger

Magnet switch

Micro switch

Direction lever Operating condition, damage I ←←←

HVR function voltage measurement M

Operating condition of the magnetic switch,
contact contamination, roughness

Contact looseness, damage, abrasion I ←←←

Operating condition, contamination and
abrasion of the auxiliary contact

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

main circuit lead wire
Operating condition and timing I ←←←

Damage and looseness of installation
locations

I ←←←

I ←←←

I

I

0-21

Inspection timing

Item

Operating condition I ←←←

Controller

Fuses Looseness of the installation locations I ←←←

Wiring
(incl. charging
cable)

POWER TRANSMISSION SYSTEM

Drive unit

Interior contamination, damage C ←←←

Motor input voltage M

Harness deterioration, damage and
looseness of the clamp

Looseness of the connections, taping
condition

Connecting condition and damage of the
battery connector

Oil leak I ←←←
Oil level I ←←←
Bolt or nut looseness T

Every

month

Every

170 hours

I ←←←

I ←←←

I ←←←

Every 3
months

Every

500 hours

Every 6

months

Every

1000 hours

Every 12

months

Every

2000 hours

DRIVE SYSTEM

Front axle Damage and deformation I

Damage and deformation I

Rear axle

Wheels

STEERING SYSTEM

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

on tire
Loosening of wheel nut and bolt T ←←←

Rim, side ring and disc wheel damage I ←←←
Looseness and abnormal noise of front

wheel bearing
Looseness and abnormal noise of rear

wheel bearing

I ←←←

I ←←←

I ←←←

Steering wheel

Steering valve

Wheels for
steering

Play, loosening, looseness I ←←←
Function I ←←←
Oil leak I ←←←
Looseness of the installation locations T ←←←

Turning angle to left and right I

0-22

Item

Oil leak I ←←←

Power steering

Looseness of the installation locations I ←←←

Damage of power steering hose I

BRAKING SYSTEM

Reserve M ←←←

Brake pedal

Braking performance I ←←←
Operating force and pull margin I ←←←

Parking brake

Braking performance I ←←←
Looseness and damage I ←←←

Rod and cable

Operating condition I ←←←
Clearance between disc and pad M ←←←

Wear of sliding portion and pad I
Disc wear and damage I

Disc brake

Looseness of the disc installation locations I

Inspection timing

Every

month

Every

170 hours

Every 3
months

Every

500 hours

Every 6

months

Every

1000 hours

Every 12

months

Every

2000 hours

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
Deformation and damage of each part and

crack at welded part
Wear and damage of roller I ←←←

Mast and
lift bracket

Mast and lift bracket looseness I ←←←

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
Chain and
chain wheel

chain

Abnormality of chain anchor bolt I ←←←

*1

I ←←←

I ←←←

Various
attachments

Wear, damage and revolution of chain

wheel

Abnormality and installation condition of

each part

I ←←←

I ←←←

0-23

Inspection timing

Item

HYDRAULIC SYSTEM

Looseness, deformation and damage of rod

and rod end

Cylinder operation I ←←←

Natural drop and natural forward tilt M ←←←

Oil leak and damage I ←←←
Cylinder

Oil pump Oil leak and abnormal sound I ←←←

Hydraulic oil
tank

Wear and damage of pin and cylinder

bearing

Loosening and damage of cylinder

mounting

Lifting speed M ←←←

Uneven movement I ←←←

Oil level and contamination I ←←←

Oil leak I ←←←

Tank and oil strainer cleaning C ←

Every

month

Every

170 hours

I ←←←

I ←←←

T ←←←

Every 3
months

Every

500 hours

Every 6

months

Every

1000 hours

Every 12

months

Every

2000 hours

Hydraulic oil
filter

Control lever

Oil control
valve

Hydraulic hose
and piping

SAFETY DEVICES, ETC.

Head guard
and backrest

Lighting system Function and installation condition I ←←←
Direction

indicator
Horn Function and installation condition I ←←←

Filter clogging C

Loose linkage I ←←←

Operation I ←←←

Oil leak I ←←←

Safety valve function I ←←←

Relief pressure measurement M

Oil leakage, deformation and damage I ←←←

Looseness T ←←←

Looseness of the installation locations T ←←←

Deformation, crack and damage I ←←←

Crack at welded portion I ←←←

Function and installation condition I ←←←

Backup buzzer Function and installation condition I ←←←

Rear view
mirror

Rear reflection status I ←←←

Dirt, damage I ←←←

0-24

Inspection timing

Item

Instruments Operation I ←←←

Loosening and damage of mounting I ←←←

Seat

Body

SAS

Seatbelt damage and function I ←←←

Deadman seat operation I ←←←

Damage and cracks in frame, cross mem-

bers, etc.

Bolts and nuts looseness T

Functions I ←←←

Loosening and damage at sensor mounting

portion

Damage, deformation, oil leakage and loos-

ened installation of functional parts

Loosening and damage of wire harnesses I ←←←

Rusting and corrosion of load sensor I

Every

month

Every

170 hours

I ←←←

I ←←←

Every 3
months

Every

500 hours

Every 6

months

Every

1000 hours

Every 12

months

Every

2000 hours

I

Others Grease up L ←←←

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

0-25

●: Replacement

Replacement cycle

Item

Drive unit gear oil ● ←

Hydraulic oil ● ←

Hydraulic oil filter

Rear wheel bearing grease ● ←

Power steering hose

Power steering rubber parts

Hydraulic hose

Lift chain

Every

month

Every

170 hours

● New

vehicle initial

replacement

Every

3 months

Every

500 hours

Every

6 months

Every

1000 hours

● ←

Every

12 months

Every

2000 hours

●Every
2 years

●Every
2 years

●Every
2 years

●Every
3 years

0-26

BATTERY

BATTERY COMPARTMENT AND

REQUIRED WEIGHT

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

1-1

Page

0

SERVICE STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

BATTERY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

REMOVAL · INSTALLATION . . . . . . . . . . . . . . . . . . . . . 1-5

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

REPLACING BATTERY PLUG TERMINAL . . . . . . . . . . 1-9

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3

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