FOREWORD
This Manual (Volume 1) contains maintenance, specifications and repair pro-cedure for the chassis, body and material handling system of the TOYOTA ELECTRICAL POWERED FORKLIFT 7FBR10 to 18 series.For electrical wiring diagrams, diagnosis and service procedures of electrical controller and display, please refer to Volume 2 (Pub. No. CE352) issued simultaneously.Please use these manuals for providing quick, correct servicing of the corre-sponding forklift models.This manual deals with the above models as of July, 2012. 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.(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18
REPAIR MANUAL VOL.2 (Pub. No. CE352)TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18, 20, 25, 30
REPAIR MANUAL VOL.1 (Pub. No. CE343)TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18, 20, 25, 30
REPAIR MANUAL VOL.2 (Pub. No. CE344)
SECTION INDEX
NAMESECTION
INSTRUCTION MANUALNMFGENERAL0BATTERY1CHARGER2CONTROLLER3DISPLAY4TROUBLESHOOTING5MOTOR6DRIVE UNIT7SUSPENSION & CASTER WHEEL8STEERING9FRONT BRAKE & AXLE10REAR BRAKE11BODY12MATERIAL HANDLING SYSTEM13MAST14CYLINDER15OIL PUMP16OIL CONTROL VALVE17HYDRAULIC PIPING18TBC•EPS19APPENDIX20ELECTRIC WIRING DIAGRAM21
Section indicated by solid characters are included in this manual.Section indicated by half-tone characters: Refer to vol. 2 (Pub. No. CE352).
NMF-1
NMF
0123456789101112131415161718192021
NEW MODEL FEATURES
Page
AIM OF DEVELOPMENT..................................NMF-2MAIN SELLING POINTS...................................NMF-3MAIN DIFFERENCES FROM PREVIOUS MODELS.........................NMF-6BATTERY..........................................................NMF-7ON-VEHICLE CHARGER.................................NMF-20DRIVE MOTOR..................................................NMF-27PUMP MOTOR..................................................NMF-28BASIC FUNCTION............................................NMF-33DRIVE UNIT......................................................NMF-42MULTI FUNCTION DISPLAY DX......................NMF-43PIN CODE ENTRY SYSTEM.............................NMF-92
NMF-2
AIM OF DEVELOPMENT
Product Development
Even in the midst of the economic downturn following the collapse of Lehman Brothers in September 2008, the key market for indoor products, represented by the reach-type forklifts used in the shipping, warehousing and foodstuffs industries, is becoming stronger. However, following the entry of competing brands of indoor products into the market in 2005 and the heightened competition as a result, Toyota's lead over other brands in terms of domestic market share is tending to diminish.Reflecting opinions expressed by users in 2008, Toyota has worked to provide a complete equipment range, and currently holds that as a priority. However, to maintain its No.1 ranking in the domestic market share and increase its lead over its competitors into the future, Toyota has also worked on the key performance attributes of its electric forklifts, including reducing their power consumption and noise levels as well as improving their durability.1.Reduced consumption of electric power We have introduced newly developed technology, including new AC motors and new motor drivers that will reduce power consumption by reducing electrical loss.We have also aimed to increase operator awareness of energy savings by installing the Multifunction display DX, which includes functions that display power consumption.The following energy-saving technologies have been adopted this time.•Adopting the AC pump motor •Adopting the new coil winding method on the drive pump motor •Using low-loss elements in the motor driver for the drive pump•Providing a power meter in the multifunction display DX that shows the consumed and regenerated power levels•Providing an optional integrating wattmeter in the multifunction display DX that shows daily and monthly power consumption•Using low rolling resistance bearings in the drive unit2.Improved Noise reduction and durabilityWe have also improved durability and reduced noise levels by introducing new features such as lower rotation rates in the drive unit, improved gear meshing and a battery protection function.•Lower gear rotation rates in the drive unit and improved gear meshing•Installing a battery electrolyte temperature sensor and adding battery electrolyte level/temperature warnings and performance limitation functions to the multifunction display DX (Installed as options on some models)•Improved battery management through the provision of a rest-day equalized charging function•Providing ribs on the rear door to reduce instrument panel deformation during collisionsIn addition to the above, we have also improved operability by incorporating advanced functions offered in other Toyota models.•Inclusion of a wheel indicator as standard•Enhanced management functions through the use of PIN code entry system and the addition of a tuning memory function for each operator (optional)•An improved anti-rollback function for easier operation on slopes Along with the SAS-R, which has attracted the praise of many users since it was first released, and following the expansion of the equipment range in 2008 and the latest improvements in basic performance, we are confident that the enormous superiority of the GENEO-R over its competitors will make it a formidable weapon in our efforts to further dominate the key market of the shipping, warehousing and foodstuffs industries.