Toyota 60-9FB20T to 9FBK20T Repair Manual CE247 2025
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Toyota 60-9FB20T to 9FBK20T Repair Manual CE247 2025
Data Size: 171.64 MB
File Type: PDF
Language: English
Manufacturer: Toyota
Applicable Machine: Forklift
Document: Repair Manual, Electric and Hydraulic Diagrams
Machine Model: Toyota 60-9FB20T, 60-9FBE20T, 60-9FBEK16T, 9FB16T, 9FB18T, 9FB20T, 9FBE15T, 9FBE16T, 9FBE18T, 9FBE20T, 9FBEK16T, 9FBEK18T, 9FBK16T, 9FBK20T
Book Number: CE247
Publication Date: 05.2025
Page: 900 Pages
List 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