Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 2 PDF

Description

Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 2 – PDF DOWNLOAD

FILE DETAILS:

Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 2 – PDF DOWNLOAD

Language : English
Pages : 462
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 2 – PDF DOWNLOAD

CONTROLLER 4
GENERAL 5
MAIN CONTROLLER 5
CONNECTOR-PIN ASSIGNMENT 6
DRIVE·MATERIAL HANDLING AC DRIVER 10
COMPONENTS 13
BEFORE REPAIR 14
INSPECTION 14
Disassembly Procedure 14
Caution for part replacement 14
CONNECTOR INSPECTION 15
TO USE SST 15
INSPECTION 15
MAIN CONTROLLER 16
DRIVE AC DRIVER 23
MATERIAL HANDLING AC DRIVER 24
CONTACTOR PANEL ASSY 25
DISPLAY 28
TEN-KEY (W/ PIN code entry system) 30
CHARGER SWITCH BOX (OPTION) 31
TRANSFORMER 32
BATTERY ELECTROLYTE LEVEL SENSOR 32
MAIN CONTROLLER 33
REMOVAL·INSTALLATION 33
Removal Procedure 33
Reassembly Procedure 35
MATERIAL HANDLING AC DRIVER 36
REMOVAL·INSTALLATION (1 ton series and 50-8FBN20) 36
Removal Procedure 36
Reassembly Procedure 37
REMOVAL·INSTALLATION (2 · 3 ton series, except 50-8FBN20) 39
Removal Procedure 39
Reassembly Procedure 39
DRIVE AC DRIVER 41
Removal·Installation Procedure 41
OCL MEASUREMENT 42
[For drive circuit] 42
DISPLAY FUNCTION 45
DISPLAY 46
GENERAL 46
SCREEN 47
DETAIL DESCRIPTION 49
SETTING FUNCTION 53
Power select function 53
SERVICE FUNCTIONS 54
General 54
Service Function List 54
Before Starting Matching 54
PASSWORD 55
Password Entry Procedure 55
Service Function Display 56
ANALYZER 57
General 57
Analyzer Screen Item List 58
ANALYZER MENU screen 60
Operation Procedure 60
“1 DIAG” (1 DIAG MEMORY) 61
“2 I01” (2 I/O monitor1 TEMP/VOLT) 61
“3 I02” (3 I/O monitor2 TRAVELING) 61
“4 I03” (4 I/O monitor3 MHANDLING) 61
“5 I04” (5 I/O monitor4 STEERING) 62
“6 I05” (6 I/O monitor5 OTHERS) 62
“7 ACT” (7 ACTIVE TEST) 62
“8 VER” (8 VERSION) 62
“E END” 63
Diagnostic Memory Function (DIAG MEMORY) 63
Operation Procedure 63
“1 DIAG: 1 01 to 1 10” 64
“1 DIAG: 1 E” 64
In/Out Monitor Function (I/O MONITOR) 65
In/Out Monitor (1) (I01) 65
Operation Procedure 65
“2 01” 66
“2 02” 66
“2 03” 66
“2 04” 66
“2 05” 66
“2 06” 66
“2 07” 66
“2 08” 66
“2 09” 66
“2 10” 66
“2 11” 67
“2 12” 67
“2 13” 67
“2 14” 67
“2 15” 67
“2 I01: 2 E” 67
In/Out Monitor (2) (I02) 68
Operation Procedure 68
“3 01” 68
“3 02” 69
“3 03” 69
“3 04” 69
“3 05” 69
“3 06” 70
“3 07 (1)” 70
“3 07 (2)” 70
“3 07 (3)” 70
“3 07 (4)” 70
“3 08” 71
“3 09” 71
“3 10” 71
“3 11” 71
“3 12” 71
“3 13” 71
“3 14” 71
“3 I02: 3 E” 72
In/Out Monitor (3) (I03) 72
Operation Procedure 72
“4 01 (1)” 73
“4 01 (2)” 73
“4 02” 73
“4 03” 73
“4 04” 73
“4 05” 73
“4 06” 74
“4 07” 74
“4 08” 74
“4 09” 74
“4 10” 74
“4 11” 74
“4 12” 75
“4 13” 75
“4 14” 75
“4 15” 75
“4 16” 76
“4 17” 76
“4 18” 76
“4 19” 77
“4 20” 77
“4 21” 77
“4 I03: 4 E” 77
In/Out Monitor (4) (I04) 78
Operation Procedure 78
“5 01” 78
“5 02” 79
“5 03” 79
“5 04” 79
“5 05” 79
“5 06” 80
“5 I04: 5 E” 80
In/Out Monitor (5) (I05) 80
Operation Procedure 80
“6 01” 81
“6 02” 81
“6 I05: 6 E” 81
ACTIVE TEST (Active Test) 82
Active Test Item List 82
Operation Procedure 82
“7 01” 83
“7 02” 83
“7 03” 83
“7 04” 84
“7 05” 84
“7 06” 84
“7 ACT: 7 E” 84
VERSION (Program Version) 84
Operation Procedure 84
“8 d” 85
“8 c” 85
“8 T” 85
“8 P” 86
“8 E” 86
TUNING 87
General 87
Tuning Item List 87
TUNING MENU screen 90
Operation Procedure 90
“1 GENERA” (1 GENERAL) 90
“2 L LIFT” 91
“3 L TILT” 91
“4 L ATT1” 91
“5 L ATT2” 91
“E END” 92
TUNING (GENERAL) 92
Operation Procedure 92
“1 01 to 1 35” 92
“1 E” 93
TUNING (2 L LIFT) 93
Operation Procedure 93
“2 01 to 2 10” 94
“2 E” 94
TUNING (3 L TILT) 94
Operation Procedure 94
“3 01 to 3 10” 95
“3 E” 95
TUNING (4 L ATT1) 96
Operation Procedure 96
“4 01 to 4 10” 96
“4 E” 97
TUNING (5 L ATT2) 97
Operation Procedure 97
“5 01 to 5 10” 98
“5 E” 98
OPTION SET 99
General 99
Option Set Item List 99
OPTION SET MENU screen100
Operation Procedure100
“1 OPT SET”100
“E END”100
MATCHING101
General101
Matching Items and Prerequisite for Implementation101
Before Starting Matching102
MATCHING MENU screen103
Operation Procedure103
“1 DRIVE”103
“2 SAS”103
“3 LEVER”104
“4 OCV”104
“5 TIRE”104
“6 PWR OFF”104
“7 SPEED”105
“E End”105
MATCHING (1 DRIVE)106
“1 01”107
“1 02”107
“1 03”107
“1 04”108
“1 E”108
MATCHING (2 SAS)108
“2 01”109
“2 E”109
MATCHING (3 LEVER)109
“3 01 to 3 04”110
“3 E”111
MATCHING (4 OCV)111
“4 A1 to 4 B4”112
“4 E”112
MATCHING (5 TIRE)113
“5 01”113
“5 E”113
Tire Data List114
POWER OFF (6 PWR OFF)115
“6 01”115
“6 E”115
SPEED (7 SPEED)116
“7 01”116
“7 E”116
OTHERS MENU117
OTHERS MENU screen117
Operation Procedure117
“1 METER”117
“2 DEMO”117
“E END”118
HOUR METER START118
“1 01”118
“1 E”119
DEMO MODE120
“2 01”120
“2 E”121
MULTI-FUNCTION DISPLAY122
GENERAL122
FEATURES LIST123
ADMINISTRATOR FUNCTIONS125
Administrator menu list125
Password Entry Procedure127
ADMINISTRATOR MENU screen (Except PIN code entry)128
Operation Procedure129
Setting Screen130
ADMINISTRATOR MENU screen (With PIN code entry)139
SERVICE FUNCTIONS142
Service Function List142
Before Starting Matching143
PASSWORD144
Password Entry Procedure144
SERVICE MENU Screen145
ANALYZER146
General146
Analyzer Screen Item List146
ANALYZER MENU screen149
Operation Procedure149
“1 DIAG MEMORY”149
“2 I/O TEMP/VOLT”149
“3 I/O TRAVELING”149
“4 I/O MHANDLING”149
“5 I/O STEERING”149
“6 I/O OTHERS”149
“7 ACTIVE TEST”149
“8 VERSION”149
Diagnostic Memory Function (DIAG MEMORY)150
Operation Procedure150
“DIAG MEMORY 1/2”150
“DIAG MEMORY 2/2”150
In/Out Monitor Function (I/O MONITOR)151
In/Out Monitor (1) (I/O TEMP/VOLT)151
Operation Procedure151
“I/O TEMP/VOLT 1/5”151
“I/O TEMP/VOLT 2/5”152
“I/O TEMP/VOLT 3/5”152
“I/O TEMP/VOLT 4/5”152
“I/O TEMP/VOLT 5/5”152
In/Out Monitor (2) (I/O TRAVELING)153
Operation Procedure153
“I/O TRAVELING 1/5”153
“I/O TRAVELING 2/5”154
“I/O TRAVELING 3/5”155
“I/O TRAVELING 4/5”156
“I/O TRAVELING 5/5”156
In/Out Monitor (3) (I/O MHANDLING)156
Operation Procedure156
“I/O MHANDLING 1/8”157
“I/O MHANDLING 2/8”158
“I/O MHANDLING 3/8”159
“I/O MHANDLING 4/8”159
“I/O MHANDLING 5/8”160
“I/O MHANDLING 6/8”161
“I/O MHANDLING 7/8”162
“I/O MHANDLING 8/8”163
In/Out Monitor (4) (I/O STEERING)164
Operation Procedure164
“I/O STEERING 1/1”164
In/Out Monitor (5) (I/O OTHERS)166
Operation Procedure166
“I/O OTHERS 1/1”166
Active Test (ACTIVE TEST)167
Active Test Item List167
Operation Procedure168
“ACTIVE TEST 1/2”168
“ACTIVE TEST 2/2”169
VERSION (Program Version)169
Operation Procedure169
“VERSION 1/2”169
“VERSION 2/2”170
TUNING171
General171
Tuning Item List171
TUNING MENU Screen174
Operation Procedure174
“1 GENERAL”174
“2 LIFT LEVER”174
“3 TILT LEVER”174
“4 ATT1 LEVER”174
“5 ATT2 LEVER”174
GENERAL175
Operation Procedure175
“TUNE GEN”175
LIFT LEVER (TUNING LIFT LEVER)176
Operation Procedure176
“LIFT DOWN”176
“LIFT UP”176
TILT LEVER (TUNING TILT LEVER)177
Operation Procedure177
“TILT FWD”177
“TILT BWD”177
ATTACHMENT 1 LEVER (TUNING ATT1 LEVER)178
Operation Procedure178
“ATT1 PUSH”178
“ATT1 PULL”178
ATTACHMENT 2 LEVER (TUNING ATT2 LEVER)179
Operation Procedure179
“ATT2 PUSH”179
“ATT2 PULL”179
OPTION SET180
General180
Option Set Item List180
OPTION SET MENU Screen182
Operation Procedure182
“OPTION SET” Screen 1182
“OPTION SET” Screen 2182
“OPTION SET” Screen 3182
“OPTION SET” Screen 4183
“OPTION SET” Screen 5183
“OPTION SET” Screen 6183
“OPTION SET” Screen 7183
“OPTION SET” Screen 8184
MATCHING185
General185
Matching Items and Prerequisite for Implementation186
Before Starting Matching188
MATCHING MENU Screen189
Operation Procedure189
“1 DRIVE”189
“2 SAS”189
“3 LEVER”189
“4 OCV”189
“5 LOAD METER”189
“6 TIRE DATA”189
DRIVE (MATCHING DRIVE)190
Operation Procedure190
“ACCEL OFF” Screen190
“ACCEL ON” Screen191
“BRAKE OFF” Screen191
“BRAKE ACT” Screen191
SAS (MATCHING SAS)192
Operation Procedure192
“TILT LEVEL” Screen (Models with SAS)192
“TILT FWD LIMIT” Screen (Models with SAS)192
“TIRE POSITION” Screen (Models with SAS or synchronized steering)193
“MAST TYPE” Screen (W/ Height sensor)193
“HEIGHT SENSOR” Screen193
LEVER (MATCHING LEVER)194
Operation Procedure194
“LEVER1” Screen194
“LEVER2” Screen195
“LEVER3” Screen195
“LEVER4” Screen195
OCV (MATCHING OIL CONTROL VALVE)196
Operation Procedure196
“OCV A01 to OCV A04” Screen196
“OCV B01 to OCV B04” Screen196
LOAD METER (MATCHING LOAD METER: DX ONLY)197
Operation Procedure197
“MAST TYPE” Screen197
“CYL SIZE” Screen (V mast only)197
“CYL SIZE 1” Screen (Except V mast)197
“CYL SIZE 2” Screen (Except V mast)198
Cylinder Diameter List198
“ZERO SET” Screen (V mast only)198
“ZERO SET 1” Screen (Except V mast)198
“ZERO SET 2” Screen (Except V mast)199
“CONPENSATION” Screen199
TIRE DATA (MATCHING TIRE DATA)200
Operation Procedure200
“TIRE DATA” Screen200
Tire Data List201
OTHERS MENU202
Operation Procedure202
“1 METER START”203
“2 DEMO MODE”203
“3 TO DEFAULT SET”203
“4 MASK PASSWORD”203
“5 MANAGER PASS CLR”203
“6 CHARGER CNT CLR”203
“7 CONTRAST”203
METER START (HOUR METER START)203
Operation Procedure204
“METER START” Screen204
DEMO MODE205
Operation Procedure205
“DEMO MODE” Screen206
TO DEFAULT SET206
Operation Procedure207
“TO DEFAULT SET” Screen207
SERVICE SECOND PASSWORD SETTING (MASK PASSWORD)208
Operation Procedure208
“Service second password clear”208
“Service second password set”209
ADMINISTRATOR’S SECOND PASSWORD CLEAR (MANAGER PASS CLR)210
Operation Procedure210
“MANAGER PASS CLR” Screen210
CHARGER COUNTER CLEAR (WITH ON-VEHICLE CHARGER ONLY)211
Operation Procedure211
“CHARGER CNT CLR” Screen211
LCD CONTRAST ADJUSTMENT212
Operation Procedure212
“CONTRAST” Screen212
TROUBLESHOOTING213
BEFORE TROUBLESHOOTING214
CONNECTOR HANDLING214
WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE214
Short circuit check215
Visual and contact pressure checks215
TROUBLESHOOTING METHOD216
Explanation of Frames216
TO USE SST217
DIAGNOSIS CODE LIST218
WHEN ERROR CODE IS DISPLAYED234
Related portion234
Probable cause:234
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WHEN NO ERROR CODE IS DISPLAYED417
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DESCRIPTION:

Toyota Forklift 8FBN15-30 50-8FBN15 50-8FBN18 50-8FBN20 Repair Manual Vol 2 – PDF DOWNLOAD

FOREWORD:

• This Manual (Volume 2) contains diagnosis, service procedures of electrical
  controller and display of the TOYOTA ELECTRICAL POWERED FORKLIFT
  8FBN15 to 30, 50-8FBN15·18·20 series.
• For maintenance, specifications and repair procedure for the chassis, body
  and material handling system, refer to Volume 1 (Pub. No. CE349).
  Please use these manuals for providing quick, correct servicing of the corresponding
  forklift models.
• This manual deals with the above models as of January, 2012. Please understand
  that disagreement can take place between the descriptions in the manual
  and actual vehicles due to change in design and specifications. Any
  change or modifications thereafter will be informed by Toyota Industrial
  Equipment Parts & Service News.

S.V 27/02/2025