Toyota 7FBEF 15 User manual

Index
< Tillbaka till Servicemanual 7FBEF 15-20

FOREWORD
This manual mainly describes the development objectives of new Toyota forklift
7FBEF15 to 20 models, outlines of main component units, structures and functions of
new mechanisms and other technical features.
Please read it carefully for sales and service activities.
This manual has been edited for the vehicles launched into the market in May
2003.
Any later change shall be informed through Toyota Industrial Equipment Parts &
Service News.
Please refer to the repair manual and parts catalog for the matters necessary
for servicing.
TOYOTA Material Handling Company
A Division of TOYOTA INDUSTRIES CORPORATION

SECTION INDEX
NAME SECTION
GENERAL 0
DEVELOPMENT OBJECTIVE 1
ELECTRICAL SYSTEM 2
POWER TRAIN 3
TRAVELING, STEERING AND BRAKE SYSTEMS
4
INSTRUMENTS 5
FRAME AND AUXILIARY EQUIPMENT 6
MATERIAL HANDLING AND HYDRAULIC SYSTEM
7
SAS CONTROL SYSTEM 8
OUTLINE OF MAJOR OPTIONS 9
APPENDIX 10

0-1
GENERAL
Page
VEHICLE EXTERIOR VIEWS ...................................... 0-2
MODEL LINEUP.............................................................. 0-3
2
3
0
3

0-2
VEHICLE EXTERIOR VIEWS
■ Vehicle exterior views
Front View
Rear View

0-3
MODEL LINEUP
■Vehicle model lineup
L.C.: Load center
Payload
(L.C. 500 mm) New model Previous model Voltage
1.5 ton 7FBEF15 5FBE15 48V
1.6 ton 7FBEF16 −48V
1.8 ton 7FBEF18 5FBE18 48V
2.0 ton 7FBEF20 −48V
2
3
0
3

0-4

1-1
DEVELOPMENT OBJECTIVE
Page
DEVELOPMENT OBJECTIVE..................................... 1-2
FEATURES (SELLING POINTS) ................................ 1-3
MAJOR DIFFERENCES BETWEEN NEW AND
PREVIOUS MODELS ................................................. 1-9
2
3
1

1-2
DEVELOPMENT OBJECTIVE
■Development objective
Toyota 5FBE series, 1,500-kg to 1,800-kg three-wheel, counter battery type forklift have favorably been
accepted by a large number of customers thanks to their ease of use and reliability since the model
change in 1993.
After the model changes by competitors in later years, however, disparities in specifications and
equipment compared to 7FB series and 7FBR series have been pointed out.
Growing environmental concerns in the market, on the other hand, has been adding to the importance of
battery vehicles.
■Development concepts
The AC drive system, especially was implemented in 1999 ahead of other companies by consolidation of
our time-tested technologies. Its features have fully been utilized not only in performances but also in
operating feel.
We propose these models as three-wheel counter battery forklift trucks without an equal in performance
and operating feel.
1Optimum material handling operation matching each customer's needs by making the most of
the features of AC-motor drive system.
2
Adoption of the SAS (mast control and steering synchronizer) developed in the 7 series and
highly evaluated in the market for realization of high stability comparable with that of the 7
series.
3Easier ingress and egress by adoption of the open step, small-diameter steering wheel and tilt
steering with memory.
4Addition of 1,600- and 2,000-kgf models to the 1,500- and 1,800-kgf models in the previous
series.

1-3
FEATURES (SELLING POINTS)
■Major selling points
The greatest feature of the new models is adoption of the AC motor drive system. New features of the 7FB
series have also been adopted in many places.
1. Adoption of AC Motor Drive System
What is AC motor drive system?
The conventional DC motor drive system uses a controller for battery current chopping (ON and OFF)
to control the motor power by changing the chopping ratio to realize from inching at the time of starting
up to the maximum power.
The controller in the AC motor drive system converts the battery current to a three-phase alternate
current, whose sine wave form (frequency and waveform height) varies to control the motor power.
The table below compares the motor voltage, motor structure and the controller between the AC
system and DC system.
Comparison between the DC and AC systems
Motor voltage Motor structure Controller
DC
sys-
tem
• Conversion from battery DC
voltage into the mean volt-
age by the chopper
• Need of brush and commu-
tator maintenance
• Complicated structure
• Relatively easy by mean DC
voltage control
• Need of contactor for rotat-
ing direction change
AC
sys-
tem
• Conversion from battery DC
voltage into the AC voltage
by the controller
• No brush and commutator
(maintenance-free)
• Compact and lightweight
• Conversion from DC into
three-phase AC by the mod-
ule
• No need of contactor for
rotating direction change
Battery voltage Motor voltage
Con-
troller
Mean voltage
ON ON ON
Commutator Brush M
Motor
Contactor
Microcomputer
control
Battery
Battery voltage
Con-
troller
Motor voltage
Sine wave Stator core Stator coil
M
Microcomputer
control
Motor
1 Phase
Battery
2
3
1