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Toyota Forklift 8FBMT40 8FBMT45 8FBMT50 Repair Manual – PDF DOWNLOAD
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Description
Toyota Forklift 8FBMT40 8FBMT45 8FBMT50 Repair Manual – PDF DOWNLOAD
FILE DETAILS:
Toyota Forklift 8FBMT40 8FBMT45 8FBMT50 Repair Manual – PDF DOWNLOAD
Language : English
Pages : 696
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Toyota Forklift 8FBMT40 8FBMT45 8FBMT50 Repair Manual – PDF DOWNLOAD
OPERATING TIPS:
1. Operations to be carried out in safe conditions
(1) After jacking up the vehicle, always rest it on wooden blocks or sturdy supports
(2) Use a rope with suitable capacity to jack up the vehicle or any heavy part of it
2. Practical operations
(1) Make sure the tools, required measurement instruments (circuit tester, ohmmeter, oil manometer, etc.)
and specific tools are available before starting work.
(2) Before disconnecting any electrical wire, check its color and condition.
(3) When reviewing the functional components, complex parts or corresponding mechanisms, arrange the
components in the right order to avoid confusion.
(4) When dismantling and inspecting precision components such as the control valve, use clean tools and
work in a clean environment.
(5) Follow the specified dismantling, checking and reassembling procedures.
(6) When removing gaskets, joints, O-rings, self-locking nuts and split pins, always replace them with new
ones during reassembly.
(7) When replacing them, only use original Toyota spare parts.
(8) During reassembly, use the specified bolts and nuts and observe the specified tightening torque (tighten
to the middle value in the specified tightening torque). If no tightening torque is specified, adopt the value
given in the “table of standard tightening torques”.
3. Fault status check.
Do not dismantle and/or replace any components immediately; first check whether this is necessary.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Toyota Forklift 8FBMT40 8FBMT45 8FBMT50 Repair Manual – PDF DOWNLOAD
CE370-1 ...................................................................................................... 1 INDEX......................................................................................................... 3 GENERAL....................................................................................................... 5 VEHICLE EXTERIOR VIEW..................................................................................... 6 VEHICLE MODELS............................................................................................ 7 CHASSIS NUMBER............................................................................................ 7 HOW TO USE THIS MANUAL.................................................................................... 7 EXPLANATION METHOD.................................................................................... 7 TERMINOLOGY........................................................................................... 8 ABBREVIATIONS......................................................................................... 8 SI UNITS.............................................................................................. 9 OPERATING TIPS............................................................................................ 9 JACK-UP POINTS........................................................................................ 10 LIFTING THE VEHICLE................................................................................... 10 LIST OF SUSPENSION ROPE ANGLES............................................................................ 11 SAFETY LOAD FOR EACH SUSPENSION ROPE ANGLE................................................................ 11 COMPONENT WEIGHTS......................................................................................... 12 TOWING THE TRUCK.......................................................................................... 12 ELECTRICAL COMPONENTS INSPECTION.......................................................................... 13 NOTES ON SAS.............................................................................................. 13 TIGHTENING TORQUE TABLE................................................................................... 14 TABLE OF LUBRICANTS AND FLUIDS............................................................................ 15 PERIODIC MAINTENANCE...................................................................................... 15 General Indications................................................................................... 15 Periodic Replacements Table........................................................................... 16 Periodic Maintenance Table............................................................................ 16 SAS Periodic maintenance.......................................................................... 21 Lubrication Chart..................................................................................... 22 BATTERY....................................................................................................... 23 BATTERY COMPARTMENT AND REQUIRED WEIGHT................................................................... 24 STANDARD SERVICE VALUES................................................................................... 24 MULTI-DISPLAY FUNCTIONS................................................................................... 24 Battery charge indicator.............................................................................. 24 Insufficient battery charge alarm..................................................................... 25 STATE OF BATTERY CHARGE INDICATOR......................................................................... 25 PROCEDURE SET TEMPERATURE SENSOR BATTERY.................................................................. 26 BATTERY MANAGEMENT PARAMETERS............................................................................. 27 TABLE OF BDI MAX, BDI MIN, RESET VOLT VALUES.............................................................. 29 BATTERY INDICATOR TROUBLESHOOTING......................................................................... 31 TROUBLESHOOTING........................................................................................... 32 BATTERY UNIT.............................................................................................. 34 DISASSEMBLY-ASSEMBLY.................................................................................. 34 INSPECTION................................................................................................ 34 * Battery control table............................................................................... 36 STATE OF BATTERY CHARGE................................................................................... 36 BATTERY CAPACITY.......................................................................................... 37 Discharge rate........................................................................................ 37 Electrolyte specific gravity.......................................................................... 37 Electrolyte temperature............................................................................... 37 Battery age........................................................................................... 37 GEL BATTERIES............................................................................................. 37 REPLACING BATTERY PLUG TERMINALS.......................................................................... 38 CONTROL SYSTEM................................................................................................ 41 GENERAL................................................................................................... 42 CAN-BUS CONNECTION........................................................................................ 42 REAR COMPARTMENT FUSES.................................................................................... 43 FUSES UNDER DASHBOARD..................................................................................... 44 CONTACTORS................................................................................................ 45 DC/DC CONVERTERS.......................................................................................... 46 LOGIC UNITS............................................................................................... 47 DISASSEMBLY-ASSEMBLY.................................................................................. 47 CONTACTOR GROUP........................................................................................... 48 DISASSEMBLY-ASSEMBLY.................................................................................. 48 MCB CARD.................................................................................................. 49 DISASSEMBLY-ASSEMBLY.................................................................................. 49 MULTI-DISPLAY FUNCTIONS................................................................................... 50 DISASSEMBLY-ASSEMBLY.................................................................................. 50 24-12 V FUSE CARD......................................................................................... 51 DISASSEMBLY-ASSEMBLY.................................................................................. 51 ARMREST CARD.............................................................................................. 52 DISASSEMBLY-ASSEMBLY.................................................................................. 52 ARMREST CARD POTENTIOMETERS............................................................................... 53 DISASSEMBLY-ASSEMBLY.................................................................................. 53 ACCELERATOR POTENTIOMETER................................................................................. 54 DISASSEMBLY-ASSEMBLY.................................................................................. 54 STEERING POTENTIOMETER.................................................................................... 55 DISASSEMBLY-ASSEMBLY.................................................................................. 55 Point Operations...................................................................................... 56 [Point 1]......................................................................................... 56 [Point 2]......................................................................................... 56 TILT ANGLE POTENTIOMETER.................................................................................. 57 DISASSEMBLY-ASSEMBLY.................................................................................. 57 Point Operations...................................................................................... 57 [Point 1]......................................................................................... 57 MAST PRESSURE SENSOR...................................................................................... 58 DISASSEMBLY-ASSEMBLY.................................................................................. 58 MAST HEIGHT SWITCH........................................................................................ 59 DISASSEMBLY-ASSEMBLY.................................................................................. 59 YAW RATE SENSOR........................................................................................... 59 DISASSEMBLY-ASSEMBLY.................................................................................. 59 CALIBRATIONS.............................................................................................. 60 MULTI-FUNCTION DISPLAY........................................................................................ 63 GENERAL................................................................................................... 64 Display and buttons................................................................................... 64 Initializing screen................................................................................... 65 MENU MAP.................................................................................................. 66 OPERATOR MENU............................................................................................. 66 ADMINISTRATOR MENU........................................................................................ 67 Password menu......................................................................................... 67 Password entry procedure.............................................................................. 68 ADMINISTRATOR menu screen............................................................................. 69 Symbols............................................................................................... 69 ADMINISTRATOR menu screen (with vehicle startup using key)................................................ 69 POWER CONTROL......................................................................................... 71 TRACTION SETTING...................................................................................... 72 MATERIAL HANDLING..................................................................................... 73 TRUCK MANAGEMENT...................................................................................... 76 SHOCK SENSOR.......................................................................................... 78 ADMINISTRATOR menu screen (with vehicle startup using pin code via keypad)................................ 80 PIN ENTRY............................................................................................. 82 PROFILE SETTING - POWER CONTROL....................................................................... 83 PROFILE SETTING - TRACTION SETTING.................................................................... 84 PROFILE SETTING - MATERIAL HANDLING SETTING........................................................... 85 MATERIAL HANDLING..................................................................................... 88 TRUCK MANAGEMENT...................................................................................... 88 SHOCK SENSOR.......................................................................................... 89 MASK MENU................................................................................................. 90 Mask menu password.................................................................................... 91 MASK MENU screen...................................................................................... 91 ANALYZER.................................................................................................. 92 ANALYZER MENU screen.................................................................................. 96 1. DIAG MEMORY........................................................................................ 97 2. I/O TEMP/VOLT...................................................................................... 99 3. I/O TRAVELING......................................................................................100 4. I/O M. HANDLING....................................................................................102 5. I/O STEERING.......................................................................................104 6. I/O OTHERS.........................................................................................105 7. ACTIVE TEST........................................................................................105 8. SW VERSION.........................................................................................106 TUNING....................................................................................................106 TUNING MENU screen....................................................................................109 1. TRACTION...........................................................................................110 2. M. HANDLING........................................................................................117 3. VALVE SAS..........................................................................................121 4. LIFT VALVE.........................................................................................122 5. TILT VALVE.........................................................................................123 6. ATT1 VALVE.........................................................................................125 7. ATT2 valve.........................................................................................126 8. ATT3 VALVE.........................................................................................127 OPTION SET................................................................................................128 OPTION SET screen.....................................................................................132 1. OPTIONSET..........................................................................................134 2. MAINTENANCE........................................................................................136 3. RENT TIME..........................................................................................138 4. BATTERY............................................................................................139 5. TWIS FLAG..........................................................................................140 6. ROT LAMP 1.........................................................................................141 7. ROT LAMP 2.........................................................................................142 8. FLASH LAMP.........................................................................................143 9. DIPPED LIGHT.......................................................................................145 10. WORK LAMP.........................................................................................145 11. WIPERS/WASHER.....................................................................................146 12. DIR LIGHTS........................................................................................147 13. HEATER............................................................................................147 MATCHING..................................................................................................148 MATCHING screen.......................................................................................150 1. SERIAL NUMBER......................................................................................151 2. DRIVE..............................................................................................152 3. MINI LEVER.........................................................................................154 4. SAS................................................................................................158 5. LOAD METER.........................................................................................161 6. H-SELECTOR.........................................................................................162 7. ADJUST BATTERY.....................................................................................164 8. TIRE DATA..........................................................................................166 9. ELT BRAKE..........................................................................................166 OTHERS MENU...............................................................................................167 OTHERS MENU screen....................................................................................167 1. METER START........................................................................................169 2. DEMO MODE..........................................................................................169 3. TO DEFAULT SET.....................................................................................170 4. MASK PASSWORD......................................................................................174 5. MANAGER PASS.......................................................................................175 6. CONTRAST...........................................................................................175 7. DELUXE MODE........................................................................................176 TROUBLESHOOTING...............................................................................................177 CONNECTOR CHECK...........................................................................................178 BEFORE TROUBLESHOOTING................................................................................178 WIRE HARNESS AND CONNECTORS INSPECTION PROCEDURE..........................................................178 Continuity check......................................................................................178 Short circuit check...................................................................................179 Visual and contact pressure checks....................................................................179 INSULATION CHECK PROCEDURE................................................................................179 Truck insulation check................................................................................180 Battery insulation check..............................................................................180 Motor insulation check................................................................................180 MOTOR WINDING CHECK PROCEDURE.............................................................................180 Motor phase continuity check..........................................................................180 TEMPERATURE SENSOR CHECK PROCEDURE........................................................................181 Sensor integrity check................................................................................181 Sensor insulation check...............................................................................181 CAN-BUS CHECK PROCEDURE...................................................................................181 Software version check................................................................................181 Wiring harness and connections check..................................................................182 DIAGNOSTIC CODES LIST.....................................................................................183 WHEN AN ERROR CODE IS DISPLAYED...........................................................................195 TRACTION LOGIC UNIT...................................................................................195 201...............................................................................................195 202...............................................................................................195 203...............................................................................................196 204...............................................................................................197 205...............................................................................................198 206...............................................................................................199 207...............................................................................................200 208...............................................................................................201 209...............................................................................................202 20A...............................................................................................202 20B...............................................................................................202 20C...............................................................................................202 20D...............................................................................................203 20E...............................................................................................204 210...............................................................................................205 211...............................................................................................206 212...............................................................................................206 213...............................................................................................207 214...............................................................................................208 215...............................................................................................209 216...............................................................................................209 217...............................................................................................210 218...............................................................................................210 219...............................................................................................210 21A...............................................................................................211 21B...............................................................................................211 21C...............................................................................................212 21D...............................................................................................213 21E...............................................................................................214 21F...............................................................................................215 220...............................................................................................216 221...............................................................................................217 222...............................................................................................218 223...............................................................................................218 224...............................................................................................219 225...............................................................................................220 226...............................................................................................221 227...............................................................................................221 228...............................................................................................222 229...............................................................................................223 22A...............................................................................................224 22B...............................................................................................225 22C...............................................................................................226 22D...............................................................................................226 22E...............................................................................................227 22F...............................................................................................227 230...............................................................................................228 231...............................................................................................229 232...............................................................................................230 233...............................................................................................230 234...............................................................................................231 235...............................................................................................231 236...............................................................................................231 237...............................................................................................232 238...............................................................................................233 239...............................................................................................234 23A...............................................................................................235 23B...............................................................................................236 23C...............................................................................................236 23D...............................................................................................236 23E...............................................................................................237 23F...............................................................................................237 240...............................................................................................238 241...............................................................................................238 242...............................................................................................239 243...............................................................................................239 244...............................................................................................240 245...............................................................................................240 246...............................................................................................241 247...............................................................................................241 251...............................................................................................242 253...............................................................................................242 254...............................................................................................243 255...............................................................................................243 256...............................................................................................244 257...............................................................................................244 258...............................................................................................245 25A...............................................................................................245 25B...............................................................................................246 25C...............................................................................................246 25D...............................................................................................246 260...............................................................................................247 261...............................................................................................247 262...............................................................................................248 MCB CARD (TRCB section)...............................................................................248 453...............................................................................................248 45A...............................................................................................249 45C...............................................................................................250 494...............................................................................................250 496...............................................................................................251 4B6...............................................................................................251 4C1...............................................................................................251 4C3...............................................................................................252 4C4...............................................................................................253 4C5...............................................................................................254 4C6...............................................................................................255 4C7...............................................................................................255 4C8...............................................................................................256 4C9...............................................................................................256 4CA...............................................................................................256 4CB...............................................................................................257 4CC...............................................................................................257 4CD...............................................................................................257 4CF...............................................................................................257 4F1...............................................................................................258 4F2...............................................................................................259 4F5...............................................................................................260 4FA...............................................................................................261 4FB...............................................................................................262 4FC...............................................................................................263 4FD...............................................................................................263 4FE...............................................................................................264 LIFT LOGIC UNIT.......................................................................................264 501...............................................................................................264 502...............................................................................................265 503...............................................................................................265 504...............................................................................................266 505...............................................................................................267 506...............................................................................................268 507...............................................................................................269 508...............................................................................................270 509...............................................................................................271 50A...............................................................................................271 50B...............................................................................................271 50C...............................................................................................271 50D...............................................................................................272 50E...............................................................................................273 510...............................................................................................274 511...............................................................................................275 512...............................................................................................275 513...............................................................................................276 514...............................................................................................277 515...............................................................................................277 516...............................................................................................278 517...............................................................................................278 518...............................................................................................278 519...............................................................................................278 51A...............................................................................................279 51B...............................................................................................279 51C...............................................................................................280 51D...............................................................................................281 51E...............................................................................................282 51F...............................................................................................282 520...............................................................................................282 521...............................................................................................282 522...............................................................................................282 523...............................................................................................283 524...............................................................................................283 525...............................................................................................284 526...............................................................................................284 527...............................................................................................285 528...............................................................................................285 529...............................................................................................286 52A...............................................................................................287 52B...............................................................................................287 52C...............................................................................................288 52D...............................................................................................288 52E...............................................................................................289 52F...............................................................................................289 530...............................................................................................290 531...............................................................................................291 532...............................................................................................291 533...............................................................................................292 534...............................................................................................292 535...............................................................................................293 536...............................................................................................293 537...............................................................................................293 538...............................................................................................294 539...............................................................................................295 53A...............................................................................................296 53B...............................................................................................296 53C...............................................................................................297 53D...............................................................................................297 53E...............................................................................................298 53F...............................................................................................298 540...............................................................................................298 541...............................................................................................299 542...............................................................................................299 543...............................................................................................299 544...............................................................................................300 545...............................................................................................300 546...............................................................................................301 547...............................................................................................301 551...............................................................................................302 553...............................................................................................302 554...............................................................................................303 555...............................................................................................303 556...............................................................................................304 557...............................................................................................304 558...............................................................................................305 55A...............................................................................................305 55B...............................................................................................306 55C...............................................................................................306 55D...............................................................................................306 560...............................................................................................307 561...............................................................................................307 562...............................................................................................307 MCB CARD (EVCB section)...............................................................................308 659...............................................................................................308 65A...............................................................................................309 65B...............................................................................................310 65D...............................................................................................311 65E...............................................................................................312 6A1...............................................................................................312 6A2...............................................................................................313 6A3...............................................................................................313 6A4...............................................................................................313 6A7...............................................................................................314 6A8...............................................................................................314 6A9...............................................................................................315 6AA...............................................................................................316 6AB...............................................................................................317 6AC...............................................................................................318 6AD...............................................................................................319 6AE...............................................................................................320 6AF...............................................................................................321 6B0...............................................................................................321 6B1...............................................................................................322 6B2...............................................................................................323 6B3...............................................................................................324 6B4...............................................................................................325 6B6...............................................................................................325 6B7...............................................................................................325 6B8...............................................................................................326 6BA...............................................................................................326 6BB...............................................................................................327 6BC...............................................................................................328 6BD...............................................................................................329 6BE...............................................................................................330 6E1...............................................................................................330 6EE...............................................................................................330 6F3...............................................................................................331 6F4...............................................................................................331 ARMREST CARD (section Master).........................................................................331 8E1...............................................................................................331 8E2...............................................................................................331 8E3...............................................................................................332 8E4...............................................................................................332 8E5...............................................................................................333 8E6...............................................................................................333 8E7...............................................................................................333 8E8...............................................................................................334 8E9...............................................................................................334 8EA...............................................................................................334 8EB...............................................................................................335 8EC...............................................................................................335 8ED...............................................................................................335 8EE...............................................................................................336 MULTI-DISPLAY FUNCTIONS...............................................................................336 C02...............................................................................................336 C04...............................................................................................337 C05...............................................................................................337 C06...............................................................................................338 C08...............................................................................................338 C0B...............................................................................................339 CB9...............................................................................................339 CD1...............................................................................................339 CD3...............................................................................................339 CD7...............................................................................................340 CD9...............................................................................................340 CDA...............................................................................................341 CDC...............................................................................................341 CDD...............................................................................................341 CDE...............................................................................................341 CDF...............................................................................................342 CF1...............................................................................................342 CF2...............................................................................................343 CF3...............................................................................................343 ARMREST CARD (section Slave)..........................................................................344 BE6...............................................................................................344 BE7...............................................................................................344 BE8...............................................................................................345 BE9...............................................................................................345 BEA...............................................................................................346 BEB...............................................................................................346 BEC...............................................................................................346 MOTOR.........................................................................................................347 SENSOR....................................................................................................348 GENERAL...............................................................................................348 SPECIFICATIONS........................................................................................348 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................349 Point Operations..................................................................................350 [Point 1].....................................................................................350 [Point 2].....................................................................................350 [Point 3].....................................................................................351 [Point 4].....................................................................................351 [Point 5].....................................................................................351 [Point 6].....................................................................................352 [Point 7].....................................................................................352 [Point 8].....................................................................................353 [Point 9].....................................................................................353 [Point 10]....................................................................................354 [Point 11]....................................................................................354 [Point 12]....................................................................................354 [Point 13]....................................................................................354 [Point 14]....................................................................................355 [Point 15]....................................................................................355 [Point 16]....................................................................................356 [Point 17]....................................................................................356 [Point 18]....................................................................................356 [Point 19]....................................................................................357 [Point 20]....................................................................................357 [Point 21]....................................................................................358 [Point 22]....................................................................................359 [Point 23]....................................................................................359 TEMPERATURE SENSOR REPLACING..........................................................................359 DISASSEMBLY-ASSEMBLY..............................................................................359 Point Operations..............................................................................360 [Point 1].................................................................................360 [Point 2].................................................................................360 PUMP MOTOR:...............................................................................................360 GENERAL...............................................................................................360 SPECIFICATIONS........................................................................................361 COMPONENTS............................................................................................361 DISASSEMBLY-ASSEMBLY..................................................................................362 Point Operations..................................................................................363 [Point 1].....................................................................................363 [Point 2].....................................................................................363 ENCODER REPLACING.....................................................................................364 TEMPERATURE SENSOR REPLACING..........................................................................364 Point Operations..................................................................................365 [Point 1].....................................................................................365 [Point 2].....................................................................................365 DRIVE UNIT & FRONT AXLE.......................................................................................367 GENERAL...................................................................................................368 COMPONENTS - STANDARD VERSION.............................................................................369 COMPONENTS - NEGATIVE BRAKE VERSION.......................................................................371 FRONT AXLE ASSEMBLY.......................................................................................373 DISASSEMBLY•ASSEMBLY..................................................................................373 Point Operations..................................................................................374 [Point 1].....................................................................................374 [Point 2].....................................................................................374 MAINTENANCE...............................................................................................375 OIL TOP-UP............................................................................................375 DRAINING AND CHANGING THE OIL.........................................................................375 REAR AXLE.....................................................................................................377 REAR AXLE ASSEMBLY........................................................................................378 GENERAL...............................................................................................378 SPECIFICATIONS........................................................................................379 COMPONENTS............................................................................................379 WHEELS................................................................................................381 SPECIFICATIONS........................................................................................381 REAR AXLE.................................................................................................382 DISASSEMBLY-ASSEMBLY..................................................................................382 Point Operations..................................................................................383 [Point 1].....................................................................................383 REAR AXLE HUB - CAST ARTICULATED JOINT....................................................................384 DISASSEMBLY-ASSEMBLY..................................................................................384 Point Operations..................................................................................385 [Point 1].....................................................................................385 [Point 2].....................................................................................385 [Point 3].....................................................................................385 [Point 4].....................................................................................386 [Point 5].....................................................................................386 [Point 6].....................................................................................387 [Point 7].....................................................................................387 [Point 8].....................................................................................387 [Point 9].....................................................................................388 REAR AXLE CYLINDER........................................................................................388 DISASSEMBLY-ASSEMBLY-INSPECTION.......................................................................388 Point Operations..................................................................................389 [Point 1].....................................................................................389 [Point 2].....................................................................................389 [Point 3].....................................................................................390 [Point 4].....................................................................................390 [Point 5].....................................................................................390 STEERING......................................................................................................391 SCRAPER...................................................................................................392 STEERING COLUMN...........................................................................................393 DISASSEMBLY•ASSEMBLY..................................................................................393 Point Operations..................................................................................394 [Point 1].....................................................................................394 ORBITROL..................................................................................................395 DISASSEMBLY•ASSEMBLY..................................................................................395 Point Operations..................................................................................396 [Point 1].....................................................................................396 INSPECTION AND ADJUSTMENT.....................................................................396 TROUBLESHOOTING...........................................................................................397 BRAKE.........................................................................................................399 GENERAL...................................................................................................400 SPECIFICATIONS............................................................................................400 COMPONENTS................................................................................................401 BRAKE UNIT............................................................................................401 PARKING BRAKE.........................................................................................402 BRAKE PEDAL...........................................................................................403 BRAKE UNIT................................................................................................405 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................405 Point Operations......................................................................................407 [Point 1].........................................................................................407 [Point 2].........................................................................................407 [Point 3].........................................................................................408 [Point 4].........................................................................................408 [Point 5].........................................................................................408 [Point 6].........................................................................................409 [Point 7].........................................................................................409 [Point 8].........................................................................................409 [Point 9].........................................................................................409 [Point 10]........................................................................................410 [Point 11]........................................................................................410 [Point 12]........................................................................................410 [Point 13]........................................................................................410 [Point 14]........................................................................................411 [Point 15]........................................................................................411 [Point 16]........................................................................................411 [Point 17]........................................................................................411 [Point 18]........................................................................................412 [Point 19]........................................................................................412 [Point 20]........................................................................................413 [Point 21]........................................................................................413 [Point 22]........................................................................................413 [Point 23]........................................................................................414 [Point 24]........................................................................................414 [Point 25]........................................................................................415 [Point 26]........................................................................................415 [Point 27]........................................................................................415 [Point 28]........................................................................................415 [Point 29]........................................................................................416 [Point 30]........................................................................................416 [Point 31]........................................................................................416 [Point 32]........................................................................................417 [Point 33]........................................................................................417 [Point 34]........................................................................................417 [Point 35]........................................................................................418 [Point 36]........................................................................................418 [Point 37]........................................................................................418 [Point 38]........................................................................................419 [Point 39]........................................................................................420 [Point 40]........................................................................................420 [Point 41]........................................................................................420 [Point 42]........................................................................................420 [Point 43]........................................................................................421 [Point 44]........................................................................................421 [Point 45]........................................................................................421 [Point 46]........................................................................................422 [Point 47]........................................................................................422 [Point 48]........................................................................................422 [Point 49]........................................................................................423 [Point 50]........................................................................................423 [Point 51]........................................................................................423 [Point 52]........................................................................................424 [Point 53]........................................................................................424 [Point 54]........................................................................................424 [Point 55]........................................................................................424 [Point 56]........................................................................................425 [Point 57]........................................................................................425 [Point 58]........................................................................................425 [Point 59]........................................................................................426 [Point 60]........................................................................................426 PARKING BRAKE.............................................................................................427 DISASSEMBLY·ASSEMBLY·ADJUSTMENT.......................................................................427 NEGATIVE BRAKE VERSION....................................................................................428 COMPONENTS............................................................................................428 EMERGENCY NEGATIVE BRAKE RELEASE......................................................................428 BODY..........................................................................................................429 COMPONENTS................................................................................................430 OPERATOR’S SEAT...........................................................................................446 DISASSEMBLY-ASSEMBLY..................................................................................446 BATTERY COVER UNIT........................................................................................447 DISASSEMBLY-ASSEMBLY..................................................................................447 OVERHEAD GUARD............................................................................................448 DISASSEMBLY-ASSEMBLY..................................................................................448 COUNTERWEIGHT.............................................................................................449 DISASSEMBLY-ASSEMBLY..................................................................................449 REAR CHASSIS..............................................................................................450 DISASSEMBLY-ASSEMBLY..................................................................................450 MATERIAL HANDLING SYSTEM......................................................................................451 HYDRAULIC CIRCUIT.........................................................................................452 NEGATIVE BRAKE HYDRAULIC DIAGRAM..........................................................................453 COMPONENTS................................................................................................454 GENERAL...............................................................................................454 OIL TANK..............................................................................................454 CONTROL VALVE.........................................................................................455 STEERING SYSTEM.......................................................................................457 NEGATIVE BRAKE SYSTEM.................................................................................457 V MAST................................................................................................458 FV MAST...............................................................................................459 FSV MAST..............................................................................................460 FW MAST...............................................................................................461 FSW MAST..............................................................................................462 OIL TANK..................................................................................................463 REMOVAL• INSTALLATION.................................................................................463 OIL FILTER AND AIR BREATHER PIPE..........................................................................464 REMOVAL• INSTALLATION.................................................................................464 Point Operations..................................................................................465 [Point 1].....................................................................................465 [Point 2].....................................................................................465 HYDRAULIC OIL.............................................................................................466 REPLACEMENT...........................................................................................466 LIFTING LOAD DOWN TEST....................................................................................467 NATURAL FORWARD TILTING TEST..............................................................................467 OIL LEAK TEST.............................................................................................468 LIFT CYLINDER.........................................................................................468 TILTING CYLINDERS.....................................................................................468 MAST..........................................................................................................469 MAST......................................................................................................470 GENERAL...............................................................................................470 MAST SECTION (V - FV - FSV)...........................................................................473 MAST SECTION (FW - FSW)...............................................................................474 COMPONENTS............................................................................................475 MAST GROUP (V) (4.0 - 5.0 t)......................................................................475 MAST GROUP (FV) (4.0 - 4.5 t).....................................................................475 MAST GROUP (FV) (5.0 t)...........................................................................476 MAST GROUP (FSV) (4.0 - 4.5 t)....................................................................476 MAST GROUP (FSV) (5.0 t)..........................................................................477 MAST GROUP (FW) (4.0 - 4.5 t).....................................................................477 MAST GROUP (FW) (5.0 t)...........................................................................478 MAST GROUP (FSW) (4.0 - 4.5 t)....................................................................478 MAST GROUP (FSW) (4.0 - 4.5 t)....................................................................479 MAST GROUP (FSW) (5.0 t)..........................................................................479 LIFTING BRACKET GROUP (V) (4.0 - 5.0 t)...........................................................480 LIFTING BRACKET GROUP (FV) (4.0 - 4.5 t)..........................................................480 LIFTING BRACKET GROUP (FV) (5.0 t)................................................................481 LIFTING BRACKET GROUP (FSV) (4.0 - 4.5 t).........................................................481 LIFTING BRACKET GROUP (FSV) (5.0 t)...............................................................482 LIFTING BRACKET GROUP (FW) (4.0 - 5.0 t)..........................................................482 LIFTING BRACKET GROUP (FSW) (4.0 - 5.0 t).........................................................483 SIDESHIFT FORK CARRIAGE GROUP (V) (4.0 - 5.0 t)...................................................483 SIDESHIFT FORK CARRIAGE GROUP (FV) (4.0 - 4.5 t)..................................................484 SIDESHIFT FORK CARRIAGE GROUP (FV) (5.0 t)........................................................484 SIDESHIFT FORK CARRIAGE GROUP (FSV) (4.0 - 4.5 t).................................................485 SIDESHIFT FORK CARRIAGE GROUP (FSV) (5.0 t).......................................................485 SIDESHIFT FORK CARRIAGE GROUP (FW) (4.0 - 5.0 t)..................................................486 SIDESHIFT FORK CARRIAGE GROUP (FSW) (4.0 - 5.0 t).................................................486 CHAIN AND CHAIN PULLEY GROUP (V) (4.0 - 5.0 t)....................................................487 CHAIN AND CHAIN PULLEY GROUP (FV) (4.0 - 4.5 t)...................................................487 CHAIN AND CHAIN PULLEY GROUP (FV) (5.0 t).........................................................488 CHAIN AND CHAIN PULLEY GROUP (FSV) (4.0 - 4.5 t)..................................................488 CHAIN AND CHAIN PULLEY GROUP (FSV) (5.0 t)........................................................489 CHAIN AND CHAIN PULLEY GROUP (FW) (4.0 - 5.0 t)...................................................489 CHAIN AND CHAIN PULLEY GROUP (FSW) (4.0 - 5.0 t)..................................................490 FORK CARRIAGE ASSEMBLY AND MAST REMOVAL...................................................................490 DISASSEMBLY-ASSEMBLY..................................................................................490 Point Operations......................................................................................491 [Point 1].........................................................................................491 [Point 3].........................................................................................493 [Point 4].........................................................................................493 [Point 5].........................................................................................493 MAST GROUP (WITH FORK CARRIAGE)...........................................................................494 DISASSEMBLY-ASSEMBLY..................................................................................494 Point Operations......................................................................................495 [Point 1].........................................................................................495 [Point 2].........................................................................................495 [Point 3].........................................................................................495 MAST ASSEMBLY V...........................................................................................496 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................496 Point Operations......................................................................................497 [Point 1].........................................................................................497 [Point 2].........................................................................................497 MAST GROUP FV.............................................................................................498 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................498 Point Operations......................................................................................499 [Point 1].........................................................................................499 [Point 2].........................................................................................499 MAST GROUP FSV............................................................................................500 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................500 Point Operations......................................................................................501 [Point 1].........................................................................................501 [Point 2].........................................................................................501 FW MAST GROUP.............................................................................................502 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................502 Point Operations......................................................................................503 [Point 1].........................................................................................503 FSW MAST GROUP............................................................................................503 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................503 Point Operations......................................................................................504 [Point 1].........................................................................................504 LIFTING BRACKET V - FV - FSV..............................................................................505 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................505 Point Operations......................................................................................505 [Point 1].........................................................................................505 LIFTING BRACKET - FW - FSW................................................................................506 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................506 Point Operations......................................................................................507 [Point 1].........................................................................................507 REPLACING THE FORK CARRIAGE GUIDE PADS....................................................................507 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................507 Point Operations......................................................................................508 [Point 1].........................................................................................508 [Point 2].........................................................................................509 ADJUSTING THE MAST V • FV • FSV...........................................................................510 Adjusting the lifting roller on the mast..............................................................510 Adjusting the play on the inner mast roller (V - FV - FSV) and central mast lower roller (FSV)....510 Adjusting the play on the outer mast roller (V - FV - FSV) and central mast upper roller (FSV)....511 Adjusting the roller on the fork plate................................................................512 Adjusting the play on the lower/central/upper lifting roller......................................512 Adjusting the lifting roller on the mast..............................................................513 Adjusting the clearance of the inner mast roller..................................................513 STANDARD FOR SELECTING AN OVERSIZE ROLLER.................................................................514 MAST ROLLER...............................................................................................514 DISASSEMBLY-ASSEMBLY..................................................................................514 CHAINS....................................................................................................515 INSPECTIONS - INSTALLATION - TUNING ..................................................................515 Standard values of the chain pitch distance...........................................................515 Assembly..............................................................................................515 Adjustment............................................................................................518 FORK......................................................................................................519 DISASSEMBLY·INSPECTION·ASSEMBLY.......................................................................519 ADJUSTING THE ADJUSTING RINGS ON THE LIFT CYLINDER ROD (TO AVOID IRREGULAR LIFTING).......................521 CYLINDER......................................................................................................523 LIFTING CYLINDERS.........................................................................................524 GENERAL...............................................................................................524 SPECIFICATIONS........................................................................................526 PARACHUTE VALVE (LOWERING SAFETY VALVE)...............................................................528 LOWERING VALVE........................................................................................528 COMPONENTS............................................................................................529 SIDE LIFTING CYLINDERS V MAST (4.0 - 4.5 t).......................................................529 SIDE LIFTING CYLINDERS V MAST (5.0 t).............................................................529 SIDE LIFTING CYLINDERS FV MAST (4.0 - 4.5 t)......................................................530 CENTRAL LIFTING CYLINDERS FV MAST (4.0 - 4.5 t)...................................................530 SIDE LIFTING CYLINDERS FV MAST (5.0 t)............................................................531 CENTRAL LIFTING CYLINDERS FV MAST (5.0 t).........................................................531 SIDE LIFTING CYLINDERS FSV MAST (4.0 - 4.5 t).....................................................532 CENTRAL LIFTING CYLINDERS FSV MAST (4.0 - 4.5 t)..................................................532 SIDE LIFTING CYLINDERS FSV MAST (5.0 t)...........................................................533 CENTRAL LIFTING CYLINDERS FSV MAST (5.0 t)........................................................533 FW MAST SIDE LIFTING CYLINDERS (4.0 - 4.5 t)......................................................534 FW MAST CENTRAL LIFTING CYLINDERS (4.0 - 4.5 t)...................................................534 FW MAST SIDE LIFTING CYLINDERS (5.0 t)...........................................................535 FW MAST CENTRAL LIFTING CYLINDERS (5.0 t).........................................................535 FSW MAST SIDE LIFTING CYLINDER (4.0 - 4.5 t)......................................................536 FSW MAST CENTRAL LIFTING CYLINDER (4.0 - 4.5 t)...................................................536 FSW MAST SIDE LIFTING CYLINDERS (5.0 t)..........................................................537 FSW MAST CENTRAL LIFTING CYLINDERS (5.0 t)........................................................537 SIDE LIFTING CYLINDER ASSEMBLY........................................................................538 DISASSEMBLY•ASSEMBLY..............................................................................538 Point Operations..............................................................................539 [Point 1].................................................................................539 [Point 2].................................................................................540 CYLINDER (V - FSV) (FSW)..............................................................................541 REMOVAL - INSPECTION - INSTALLATION...............................................................541 Point Operations..................................................................................542 [Point 1].....................................................................................542 [Point 2].....................................................................................543 [Point 3].....................................................................................544 [Point 4].....................................................................................544 [Point 5].....................................................................................544 CYLINDER (FV) (FW)....................................................................................545 REMOVAL - INSPECTION - INSTALLATION...............................................................545 Point Operations..................................................................................545 [Point 1].....................................................................................545 [Point 2].....................................................................................548 [Point 3].....................................................................................548 [Point 4].....................................................................................549 [Point 5].....................................................................................550 [Point 6].....................................................................................550 CENTRAL LIFTING CYLINDER ASSEMBLY.....................................................................551 DISASSEMBLY•ASSEMBLY..............................................................................551 CYLINDER (FV - FSV) (FW - FSW)........................................................................553 REMOVAL - INSPECTION - INSTALLATION...............................................................553 Point Operations..............................................................................554 [Point 1].................................................................................554 [Point 2].................................................................................556 [Point 3].................................................................................556 [Point 4].................................................................................556 [Point 5].................................................................................557 TILTING CYLINDERS.........................................................................................558 GENERAL...............................................................................................558 SPECIFICATIONS........................................................................................558 COMPONENTS............................................................................................559 DISASSEMBLY•ASSEMBLY..................................................................................560 Adjusting.............................................................................................561 DISASSEMBLY•INSPECTION•ASSEMBLY.......................................................................561 Point Operations..................................................................................562 [Point 1].....................................................................................562 [Point 2].....................................................................................562 [Point 3].....................................................................................563 [Point 4].....................................................................................564 OIL PUMP......................................................................................................565 SCRAPER...................................................................................................566 COMPONENTS................................................................................................567 DISASSEMBLY-ASSEMBLY......................................................................................568 Point Operations......................................................................................569 [Point 1].........................................................................................569 [Point 2].........................................................................................569 [Point 3].........................................................................................570 [Point 4].........................................................................................570 OIL CONTROL VALVE.............................................................................................571 HYDRAULIC DIAGRAM.........................................................................................572 COMPONENTS................................................................................................573 SPECIFICATIONS............................................................................................577 DISASSEMBLY-ASSEMBLY......................................................................................578 MAXIMUM PRESSURE ADJUSTMENT...............................................................................578 SAS FUNCTION..................................................................................................581 GENERAL...................................................................................................582 FOR REPAIR WORK...........................................................................................583 HAND GRIP POSITION CORRECTION VALVE.......................................................................584 DISASSEMBLY-ASSEMBLY..................................................................................584 STEERING POTENTIOMETER....................................................................................585 DISASSEMBLY-ASSEMBLY..................................................................................585 Point Operations..................................................................................586 [Point 1].....................................................................................586 [Point 2].....................................................................................586 TILT ANGLE POTENTIOMETER..................................................................................587 DISASSEMBLY-ASSEMBLY..................................................................................587 Point Operations..................................................................................588 [Point 1].....................................................................................588 MAST PRESSURE SENSOR......................................................................................588 DISASSEMBLY-ASSEMBLY..................................................................................588 MAST HEIGHT SWITCH........................................................................................589 DISASSEMBLY-ASSEMBLY..................................................................................589 YAW RATE SENSOR...........................................................................................590 DISASSEMBLY-ASSEMBLY..................................................................................590 OSCILLATION LOCK CYLINDER.................................................................................591 DISASSEMBLY-ASSEMBLY..................................................................................591 Point Operations..................................................................................592 [Point 1].....................................................................................592 ADJUSTMENT................................................................................................593 GENERAL...............................................................................................593 MAIN OPTIONS..................................................................................................595 DC/DC CONVERTERS..........................................................................................596 REAR COMPARTMENT FUSES....................................................................................597 FUSES UNDER DASHBOARD.....................................................................................598 HEIGHT SELECTOR...........................................................................................599 COMPONENTS............................................................................................599 FUNCTIONS.............................................................................................600 MAXIMUM HEIGHT LIMITER............................................................................600 HEIGHT LIMITER....................................................................................601 AUTOMATIC HEIGHT CONTROL..........................................................................602 Target selection before lift-up operation.....................................................602 BUMP SENSOR - DHU - KEYPAD................................................................................604 COMPONENTS............................................................................................604 FLASH - ROTATING LAMP.....................................................................................605 COMPONENTS............................................................................................605 WORK SPOTLIGHTS...........................................................................................606 COMPONENTS............................................................................................606 COMBINED LIGHTS...........................................................................................607 COMPONENTS............................................................................................607 HEATER - HEATED REAR WINDOW...............................................................................608 COMPONENTS............................................................................................608 WINDSCREEN WIPERS - RADIO - CAB LIGHT.....................................................................609 COMPONENTS............................................................................................609 APPENDIX......................................................................................................611 COMPONENTS................................................................................................612 IMAGE 1...............................................................................................620 IMAGE 2...............................................................................................621 IMAGE 3...............................................................................................622 IMAGE 4...............................................................................................623 IMAGE 5...............................................................................................624 IMAGE 6...............................................................................................625 IMAGE 7...............................................................................................626 WIRING DIAGRAM............................................................................................627 WIRING....................................................................................................635 READING METHOD........................................................................................635 MAIN HARNESS..........................................................................................636 REMOTE CONTROL SWITCHES WIRING HARNESS................................................................659 STEERING COLUMN WIRING HARNESS WITH KEY...............................................................663 STEERING COLUMN WIRING HARNESS WITH KEYPAD............................................................666 STANDARD ARMREST WIRING HARNESS.......................................................................669 MAST PRESSURE SENSOR WIRING HARNESS...................................................................674 5th WAY VALVE HARNESS.................................................................................674 TILTING PEDAL WIRING..................................................................................675 TWIS SYSTEM WIRING HARNESS............................................................................676 WINDSCREEN WASHER TANK HARNESS........................................................................678 FLASH / ROTATING LAMP WIRING..........................................................................679 FRONT LIGHTS WIRING HARNESS...........................................................................680 FRONT LED LIGHTS WIRING...............................................................................681 REAR LIGHTS WIRING HARNESS............................................................................683 FRONT WORKING LIGHTS WIRING HARNESS...................................................................685 REAR WORKING LIGHTS WIRING HARNESS....................................................................686 WIRING HARNESS FOR LIGHTS ON MAST.....................................................................687 FRONT AND REAR WINDSCREEN WIPER WIRING................................................................689 HEATER UNIT WIRING....................................................................................690 CAR RADIO WIRING......................................................................................691 OVERHEAD LIGHT WIRING HARNESS.........................................................................693 CIGARETTE LIGHTER WIRING HARNESS......................................................................694
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