Toyota Forklift 9FBE18T 2025 Repair Manual CE247

Description

Contents:
1 GENERAL
1.1 VEHICLE EXTERIOR VIEW​
1.1.1 DIN VEHICLE EXTERIOR VIEW (lead-acid battery)​
1.1.2 DIN VEHICLE EXTERIOR VIEW (lithium-ion battery)​
1.1.3 LIB VEHICLE EXTERIOR VIEW (lithium-ion battery)​
1.2 VEHICLE MODELS​
1.2.1 DIN VEHICLE MODELS​
1.2.2 LIB VEHICLE MODELS​
1.3 CHASSIS NUMBER​
1.3.1 DIN CHASSIS NUMBER​
1.3.2 LIB CHASSIS NUMBER​
1.4 HOW TO USE THIS MANUAL​
1.4.1 EXPLANATION METHOD​
1.4.2 TERMINOLOGY​
1.4.3 ABBREVIATIONS​
1.4.4 SI UNITS​
1.5 OPERATING TIPS​
1.5.1 JACK-UP POINTS​
1.5.2 SUPPORT POINTS​
1.5.3 JACKING UP THE VEHICLE​
1.6 WIRE ROPE SUSPENSION ANGLE LIST​
1.7 COMPONENT WEIGHTS​
1.7.1 DIN COMPONENT WEIGHTS​
1.7.2 LIB COMPONENT WEIGHTS​
1.8 TOWING THE TRUCK​
1.9 ELECTRICAL COMPONENTS INSPECTION​
1.10 NOTES ON STABILITY SYSTEM​
1.11 TABLE OF TIGHTENING TORQUES​
1.12 LUBRICATION CHART​
1.13 TABLE OF LUBRICANTS AND FLUIDS​
1.14 PERIODIC MAINTENANCE​
1.14.1 SERVICE INFORMATION​
1.14.2 PERIODIC REPLACEMENTS​
1.14.3 PERIODIC MAINTENANCE​
1.14.4 STABILITY SYSTEM PERIODIC MAINTENANCE​
1.15 CHECKING HYDRAULIC OIL LEVEL​
2 BATTERY
2.1 LEAD-ACID BATTERY​
2.1.1 BATTERY COMPARTMENT AND REQUIRED WEIGHT​
2.1.2 STANDARD SERVICE VALUES​
2.1.3 INSPECTION​
2.1.4 STATE OF BATTERY CHARGE​
2.1.5 BATTERY CAPACITY​
2.1.6 REPLACING BATTERY CONNECTOR TERMINALS​
2.2 LITHIUM BATTERY​
2.2.1 BATTERY COMPARTMENT AND REQUIRED WEIGHT​
2.2.2 STANDARD SERVICE VALUES​
2.2.3 SWITCHING OFF THE BATTERY​
2.2.4 BMS BOARD​
2.2.5 PMU BOARD​
2.2.6 POLES​
2.2.7 BRIX​
2.2.8 CHARGING THE BATTERY​
2.3 BATTERY EXTRACTION​
2.4 INTEGRATED LITHIUM-ION BATTERY​
2.4.1 INTEGRATED BATTERY COMPARTMENT AND REQUIRED LITHIUM WEIGHT​
2.4.2 STANDARD SERVICE VALUES​
2.4.3 SWITCHING OFF THE BATTERY​
2.4.4 OPENING THE BATTERY HOOD​
2.4.5 BMS BOARD​
2.4.6 PMU BOARD​
2.4.7 BRIX​
2.4.8 CHARGING THE BATTERY​
2.4.9 BATTERY EXTRACTION​
2.5 BATTERY CHARGE INDICATOR​
3 CONTROL SYSTEM
3.1 DIN VEHICLE FUSES AND RELAYS​
3.2 LIB VEHICLE FUSES AND RELAYS​
3.3 DIN VEHICLE DC/DC CONVERTERS​
3.4 LIB VEHICLE DC/DC CONVERTERs​
3.5 LOGIC UNITS​
3.5.2 MCB BOARD​
3.5.3 DISPLAY CARD​
3.5.4 DRIVE LOGIC UNIT​
3.5.5 PUMP LOGIC UNIT​
3.5.6 ARMREST BOARD​
3.5.7 LIGHT BOARD​
3.5.8 KEY BOARD​
3.6 STEERING POTENTIOMETER VEHICLE 3W​
3.6.1 DISASSEMBLY-ASSEMBLY​
3.7 STEERING POTENTIOMETER VEHICLE 4W​
3.7.1 DISASSEMBLY-ASSEMBLY​
3.8 TFD SENSOR – 3 WHEEL VEHICLE​
3.8.1 DISASSEMBLY-ASSEMBLY​
3.9 ACCELERATOR AND BRAKE POTENTIOMETERS​
3.9.1 DISASSEMBLY-ASSEMBLY​
3.10 TILT ANGLE POTENTIOMETER​
3.10.1 DISASSEMBLY-ASSEMBLY​
3.11 PRESSURE SENSOR​
3.11.1 DISASSEMBLY-ASSEMBLY​
3.12 MAST HEIGHT SWITCH​
3.12.1 DISASSEMBLY-ASSEMBLY​
4 MULTI-FUNCTION DISPLAY
4.1 GENERAL​
4.1.1 RESETTING TRUCK SERIAL NUMBER​
4.2 MENU MAP​
4.3 MULTI-FUNCTION DISPLAY​
4.3.1 INITIALIZING SCREEN​
4.3.2 OPERATOR MENU​
4.3.3 COUNTERS MENU​
4.3.4 ADMINISTRATOR MENU​
4.4 MULTI-FUNCTION TOUCH DISPLAY​
4.4.1 INITIALIZING SCREEN​
4.4.2 OPERATOR MENU​
4.4.3 ADMINISTRATOR MODE​
4.4.4 COUNTERS MENU​
4.4.5 UPDATING THE OPERATING SYSTEM MULTI-FUNCTION TOUCH DISPLAY​
4.4.6 UPDATING THE SOFTWARE MULTI-FUNCTION TOUCH DISPLAY​
4.5 CALIBRATIONS​
4.5.1 PUMP CALIBRATION (High Performance motor only)​
4.5.2 ACCELERATOR PEDAL CALIBRATION​
4.5.3 BRAKE PEDAL CALIBRATION​
4.5.4 MAST CALIBRATION​
4.5.5 RIGHT NEGATIVE BRAKE CALIBRATION​
4.5.6 LEFT NEGATIVE BRAKE CALIBRATION​
4.5.7 RESTORING NEGATIVE BRAKE CALIBRATION VALUES​
4.5.8 NEGATIVE BRAKE HOLDING TEST​
4.5.9 STEERING CALIBRATION (3 WHEELS)​
4.5.10 STEERING CALIBRATION (4 WHEELS)​
4.5.11 LIFT SENSOR CALIBRATION​
4.5.12 LOAD SENSOR CALIBRATION​
4.6 ADJUSTMENT MENU​
4.6.1 ANALYZER​
4.6.2 OPTIONS​
4.6.3 TUNING​
4.6.4 MATCHING​
4.7 LIGHT SETTING​
4.7.1 LIGHT BOARD PARAMETERS​
4.7.2 LIGHT BOARD CONNECTORS​
4.8 AUTOMATIC LIGHT RECOGNITION PROCEDURE​
4.9 ENABLING ACB AND SEnS+​
4.10 CONFIGURATION SEnS+ VIA CB TRUCKCOM​
4.11 SERVICE TEST SEnS+ VIA CB TRUCKCOM​
4.12 SEnS+ ADJUSTMENT FUNCTIONS VIA CB TRUCKCOM​
4.12.1 PEDESTRIAN DETECTION​
4.12.2 OBJECT DETECTION​
4.12.3 START CONTROL​
4.12.4 START SELECTION CONTROL​
4.12.5 DECELERATION​
4.13 REPLACING THE CAMERA​
5 TROUBLESHOOTING
5.1 CONNECTOR CHECK​
5.1.1 BEFORE TROUBLESHOOTING​
5.2 WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE​
5.2.1 CONTINUITY CHECK​
5.2.2 SHORT CIRCUIT CHECK​
5.2.3 VISUAL AND CONTACT PRESSURE CHECKS​
5.3 INSULATION CHECK PROCEDURE​
5.3.1 TRUCK INSULATION CHECK​
5.3.2 BATTERY INSULATION CHECK​
5.3.3 MOTOR INSULATION CHECK​
5.4 MOTOR WINDING CHECK PROCEDURE​
5.4.1 MOTOR PHASE CONTINUITY CHECK​
5.5 TEMPERATURE SENSOR CHECK PROCEDURE​
5.5.1 SENSOR INTEGRITY CHECK​
5.5.2 SENSOR INSULATION CHECK​
5.6 CAN-BUS CHECK PROCEDURE​
5.6.1 WIRING HARNESS AND CONNECTIONS CHECK​
5.7 WHEN AN ERROR CODE IS DISPLAYED​
5.7.1 IDENTIFYING AN ERROR CODE​
5.7.2 LIST OF ERROR CODES​
6 MOTORS
6.1 DRIVE MOTOR​
6.1.1 COMPONENTS​
6.1.2 DISASSEMBLY-ASSEMBLY​
6.2 PUMP MOTOR:​
6.2.1 COMPONENTS​
6.2.2 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
6.2.3 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
7 DRIVE UNIT
7.1 COMPONENTS​
7.1.1 DRIVE UNIT​
7.2 DRAINING AND CHANGING THE OIL​
7.3 DRIVE UNIT​
7.3.1 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
7.3.2 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
7.4 FRONT WHEELS​
7.4.1 SPECIFICATIONS​
8 REAR AXLE
8.1 REAR AXLE ASSEMBLY 3W VEHICLE​
8.1.1 COMPONENTS​
8.1.2 3W VEHICLE DISASSEMBLY-ASSEMBLY​
8.2 REAR AXLE ASSEMBLY 4W VEHICLE​
8.2.1 COMPONENTS​
8.2.2 4W VEHICLE DISASSEMBLY-ASSEMBLY​
8.3 REAR WHEELS​
8.3.1 SPECIFICATIONS​
9 STEERING SYSTEM
9.1 STEERING COLUMN​
9.1.1 3W VEHICLE DISASSEMBLY-ASSEMBLY​
9.1.2 4W VEHICLE DISASSEMBLY-ASSEMBLY​
9.2 ORBITROL​
9.2.1 DISASSEMBLY-ASSEMBLY​
9.2.2 INSPECTION AND ADJUSTMENT​
9.3 PRIORITY VALVE​
9.3.1 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
9.3.2 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
10 BRAKE
10.1 GENERAL​
10.1.1 GENERAL DIN VEHICLE​
10.1.2 GENERAL LIB VEHICLE​
10.2 BRAKE PEDAL SYSTEM​
10.2.1 DISASSEMBLY-ASSEMBLY​
10.2.2 BRAKE PIPES DISASSEMBLY-ASSEMBLY​
10.2.3 BRAKE FLUID RESERVOIR​
10.2.4 BRAKE CIRCUIT BLEEDING​
10.3 PARKING BRAKE​
10.3.1 DISASSEMBLY-ASSEMBLY​
10.4 EMERGENCY RELEASE​
10.4.1 RELEASE PROCEDURE FOR LEAD-ACID BATTERIES​
10.4.2 RELEASE PROCEDURE FOR LITHIUM BATTERIES​
11 CHASSIS
11.1 COUNTERWEIGHT​
11.1.1 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
11.1.2 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
11.2 OPERATOR SEAT​
11.2.1 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
11.2.2 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
11.3 BATTERY HOOD​
11.3.1 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
11.4 OVERHEAD GUARD​
11.4.1 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
11.4.2 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
12 MATERIAL HANDLING SYSTEM
12.1 HYDRAULIC DIAGRAM​
12.1.1 3W VEHICLE​
12.1.2 4W VEHICLE​
12.2 COMPONENTS​
12.2.1 OIL TANK​
12.3 OIL FILTER AND AIR BREATHER PIPE​
12.3.1 DISASSEMBLY-ASSEMBLY​
12.4 NATURAL DROP TEST ON LIFTING​
12.5 NATURAL FORWARD TILTING TEST​
12.6 OIL LEAK TEST​
12.6.1 FOREWORD​
12.6.2 LIFT CYLINDER​
12.6.3 TILTING CYLINDER​
13 MASTS
13.1 MAST​
13.1.1 GENERAL​
13.1.2 MAST SECTION (V – FV – FSV)​
13.1.3 MAST SECTION (FW – FSW)​
13.1.4 COMPONENTS​
13.2 FORK CARRIAGE ASSY AND MAST REMOVAL​
13.2.1 DISASSEMBLY-ASSEMBLY​
13.3 MAST ASSEMBLY (W/FORK CARRIAGE)​
13.3.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.4 MAST ASSEMBLY V​
13.4.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.5 MAST FV​
13.5.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.6 MAST FSV​
13.6.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.7 FW MAST GROUP​
13.7.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.8 FSW MAST GROUP​
13.8.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.9 FORK CARRIAGE V – FV – FSV​
13.9.1 DISASSEMBLY-INSPECTION-REASSEMBLY (V-FV-FSV)​
13.10 FORK CARRIAGE FW – FSW​
13.10.1 DISASSEMBLY-INSPECTION-REASSEMBLY (FW- FSW)​
13.10.2 DISASSEMBLY-INSPECTION-REASSEMBLY (V-FV-FSV)​
13.11 REPLACING THE FORK CARRIAGE GUIDE SHOES (FW – FSW)​
13.11.1 DISASSEMBLY-INSPECTION-REASSEMBLY (FW- FSW)​
13.12 MAST ADJUSTMENT (FW – FSW)​
13.12.1 ADJUSTING THE MAST AND FORK CARRIAGE PADS​
13.13 STANDARD FOR SELECTING AN OVERSIZE ROLLER​
13.14 MAST ROLLER​
13.14.1 DISASSEMBLY-ASSEMBLY​
13.15 SIDESHIFT CYLINDER​
13.15.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.16 CHAINS​
13.17 FORK​
13.17.1 DISASSEMBLY-INSPECTION-REASSEMBLY​
13.18 ADJUSTING THE ADJUSTING RINGS ON THE LIFT CYLINDER ROD (TO AVOID IRREGULAR LIFTING)​
14 CYLINDERS
14.1 LIFTING CYLINDERS​
14.1.1 GENERAL​
14.1.2 SPECIFICATIONS​
14.1.3 PARACHUTE VALVE (LOWERING SAFETY VALVE)​
14.1.4 LOWERING VALVE​
14.1.5 COMPONENTS​
14.1.6 SIDE LIFTING CYLINDERS ASSEMBLY​
14.1.7 CENTRAL LIFTING CYLINDER ASSEMBLY​
14.2 TILTING CYLINDERS​
14.2.1 GENERAL​
14.2.2 SPECIFICATIONS​
14.2.3 COMPONENTS​
14.2.4 DISASSEMBLY-ASSEMBLY​
14.2.5 ADJUSTMENT​
14.2.6 DISASSEMBLY-INSPECTION-REASSEMBLY​
15 OIL PUMP
15.1 GENERAL​
15.1.1 OIL PUMP​
15.1.2 SPECIFICATIONS​
15.2 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
15.3 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
16 OIL CONTROL VALVE
16.1 HYDRAULIC DIAGRAM​
16.1.1 3W VEHICLE​
16.1.2 4W VEHICLE​
16.2 COMPONENTS​
16.2.1 TYPE OF OIL CONTROL VALVE​
16.3 SPECIFICATIONS​
16.4 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
16.5 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
16.6 HYDRAULIC CIRCUIT PRESSURE CHECK​
16.7 MANUAL LOWERING VALVE​
17 STABILITY SYSTEM
17.1 DIN VEHICLE COMPONENTS​
17.2 LIB VEHICLE COMPONENTS​
17.3 FUNCTIONS​
17.4 AXLE OSCILLATION LOCK CYLINDER​
17.4.1 DIN VEHICLE DISASSEMBLY-ASSEMBLY​
17.4.2 LIB VEHICLE DISASSEMBLY-ASSEMBLY​
18 MAIN OPTIONS
18.1 DC/DC CONVERTERS​
18.1.1 OPTIONAL EQUIPMENT CONSUMPTION​
18.2 OPTIONAL EQUIPMENT FUSES AND RELAYS​
18.3 HEIGHT SELECTOR​
18.3.1 COMPONENTS​
18.3.2 FUNCTIONS​
18.4 WIRINGS LIST​
18.4.1 HOW TO READ A WIRING DIAGRAM​
18.4.2 WORK LIGHTS ON MAST​
18.4.3 RIGHT FRONT WORKING LIGHT​
18.4.4 COMBINED FRONT LIGHTS RH​
18.4.5 COMBINED FRONT LIGHTS LH​
18.4.6 FRONT LEFT WORK LIGHT AND BLUE LIGHT​
18.4.7 COMPLETE COMBINED REAR LIGHTS​
18.4.8 FRONT LED LIGHTS SENS+​
18.4.9 ADDITIONAL WORK LIGHTS​
18.4.10 HEATER​
18.4.11 HEATED REAR WINDOW​
18.4.12 FRONT WINDSCREEN WIPER​
18.4.13 REAR WINDSCREEN WIPER​
18.4.14 UPPER WINDSCREEN WIPER​
18.4.15 FRONT AND REAR WASHER RESERVOIR​
18.4.16 CAB LIGHTS​
18.4.17 READING LIGHTS​
18.4.18 BLUETOOTH SPEAKER​
18.4.19 USB SOCKET​
18.4.20 REAR VIEW CAMERA​
18.5 DHU​
18.5.1 DHU3s​
18.5.2 DHU3s CONFIGURATION PROCEDURE VIA CB TRUCKCOM​
18.6 MULTIFUNCTION JOYSTICK​
18.7 OPERATOR ASSIST SYSTEM (SEnS+)​
19 APPENDIX
19.1 HOW TO READ A WIRING DIAGRAM​
19.2 COLOUR CODE TABLE​
19.3 WIRING DIAGRAMS​
19.3.1 WIRING DIAGRAM 15-20 3W DIN VEHICLE​
19.3.2 WIRING DIAGRAM 15-20 3W HIGH PERFORMANCE DIN VEHICLE​
19.3.3 WIRING DIAGRAM 16-20 4W DIN VEHICLE​
19.3.4 WIRING DIAGRAM 16-20 4W HIGH PERFORMANCE DIN VEHICLE​
19.3.5 WIRING DIAGRAM 16K-20 3W LIB VEHICLE​
19.3.6 WIRING DIAGRAM 16K-20 3W HIGH PERFORMANCE LIB VEHICLE​
19.3.7 WIRING DIAGRAM 20 4W LIB VEHICLE​
19.3.8 WIRING DIAGRAM 20 4W HIGH PERFORMANCE LIB VEHICLE​
19.3.9 ARMREST WIRING DIAGRAM​
19.3.10 SENS+ WIRING DIAGRAM​
19.3.11 LITHIUM WIRING DIAGRAM​
19.4 WIRINGS LIST​
19.4.1 STANDARD CHASSIS 3W DIN VEHICLE​
19.4.2 LOW OPTIONS CHASSIS 3W DIN VEHICLE​
19.4.3 FULL OPTIONS CHASSIS 3W DIN VEHICLE​
19.4.4 STANDARD CHASSIS 4W DIN VEHICLE​
19.4.5 LOW OPTIONS CHASSIS 4W DIN VERSION​
19.4.6 FULL OPTIONS CHASSIS 4W DIN VEHICLE​
19.4.7 STANDARD OHG DIN VEHICLE​
19.4.8 LOW OPTIONS OHG DIN VEHICLE​
19.4.9 FULL OPTIONS OHG DIN VEHICLE​
19.4.10 STANDARD CHASSIS 3W LIB VEHICLE​
19.4.11 FULL OPTIONS CHASSIS 3W LIB VEHICLE​
19.4.12 STANDARD CHASSIS 4W LIB VEHICLE​
19.4.13 FULL OPTIONS CHASSIS 4W LIB VEHICLE​
19.4.14 STANDARD OHG LIB VEHICLE​
19.4.15 FULL OPTIONS OHG LIB VEHICLE​