FOREWORD Thjs manual covers the service procedures of the TOYOTA BATTERY FORKLIFT 5FBCU15 -- 30 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of July 1995. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due t o change in disign and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles' Parts & Service News.
TOYOTA MOTOR CORPORATION
SECTION INDEX NAME
x
1
SECT1
e
m
C C
MULTIDISPLAY FUNCTIONS ELECTRICAL SYSTEM TRouBLEsHooTlNG MOTOR DRIVE UNIT FRONT AXLE REAR AXLE STEERING BRAKE BODY & FRAME
m A
y MAST CYLINDER OIL PUMP
p a
APPENDIX
GENERAL Page
EXTERIOR VIEWS ........................................ 0-2 VEHICLE MODEL ................................................ 0-3
............................................... 0-4 HOW TO READ THIS MANUAL ......................... 0-5 EXPLANATION METHOD ..................................... 0-5 TERMINOLOGY .................................................. 0-6 ABBREVIATIONS ................................................ 0-6 LIST OF ABBREVIATIONS AND SYMBOLS ............. 0-7 OPERATIONAL TIPS .......................................... 0-8 CIRCUIT TESTER ............................................... 0-9 FRAME NUMBER
STANDARD BOLT & NUT TIGHTENING TORQUE .......................................................... 0-11 BOLT STRENGTH TYPE IDENTIFICATION METHOD ........................................................ 0-11
............................... 0-12 PRECOAT BOLTS ............................................... 0-13 TIGHTENING TORQUE TABLE
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .................................... 0-13 WIRE ROPE SUSPENSION ANGLE LIST ............. 0-14 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ...................................... 0-14 COMPONENTS WEIGHT .................................... 0-15 RECOMMENDED LUBRICANTS AND CAPACITIES ...................................... 0-16 GREASE ON MICRO SWITCH FOR INSTALLATION ......................................... 0-17 INSTRUCTION OF OIL CHECK LEVEL IN HYDRAULIC OIL TANK ........................... 0-17 LUBRICATION CHART .................................. 0-18 PERIODIC MAINTENANCE ............................. 0-19 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ..................................... 0-24
EXTERIOR VIEWS
I
I
Front View
I Rear View
VEHICLE MODELS Load Capacity
Model
Types on Spec.
1-ton series
STD spec. models
STD capacity battery compartment
2-ton series
3-ton series
High capacity
%
2-ton series
I -ton series
Dust proof models
STD capacity battery compartment
2-ton series
%ton series
High capacity
2-ton series
% These high capacity (battery compartment) models are not established in EEC specification.
FRAME NUMBER
Above side frame of LH
7
Models
1-ton series
5FBCU1 5
Stamping Form [(
) showing EEC specifications for ECI
5FBCU15-10011 (5FBCU15 @ 10011)
5FBCU18 5FBCU20 2-ton series
5FBCU25-10011 (5FBCU25 @ 1001 1 )
5FBCU25 5FBCHU20 5FBCHU25
5FBCHU25-10011 (5FBCHU25 @ 1001 1)
3-ton series
5FBCU30
5FBCU30-10011 (5FBCU30 @ 1001 1 )
1-ton series
30-5FBCU 1 5
305FBCU15-10011 (305FBCU1 5 @ 1001 I 1)
30-5FBCU 1 8 30-5FBCU20 2-ton series
30-5FBCU25 30-5FBCHU20 30-5FBCHU25
3-ton series
305FBCU25-10011 (305FBCU25 @ 1001 1)
30-5FBCU30
305FBCHU25-10011 (305FBCHU25 @ 1001 1 1 305FBCU30-10011 (305FBCU30 @ 1001 1)
Remark
HOW TO READ THIS MANUAL EXPLANATION METHOD 1.
Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Ex~lanationof each ooeration step with a photo or illustration. Pattern B: ~xplanationof operatiin procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B DISASSEMBLY-INSPECTION-REASSEMBLY
Tightening torque unit T = N - m (kgf-cm) [ft-lbfl If a place or part cannot be indicated directly, the part name is described on the either side of the illustration. Example: 1 Piping
I
I
Oil Pump Disassembly Procedure
Disassembly Procedure Remove the cover. [Point 11 1
2
Remove the bush [Point 2 l o O p e r a t i o n explained on a laterpage
3
Remove the gear.
Point operations
Explanation of key point for operation with an illustration
4
[Point 1I Disassembly: Put a match mark when removing the pump cover. [Point 21 Inspection: Measure the bush inside diameter. Bush inside diameter limit:19.12 mm (0.7528 in)
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2.
3.
How t o read components figures ( 1 ) The components figure use the illustration in the parts catalog for the vehicle model. Please refer t o the catalog for checking the part name. The number at the right shoulder of each components figure indicates the Fig. number in the parts catalog.
(Example)
FIG number in parts catalog
Matters omitted in this manual (1) This manual omits description of the following jobs, but perform them in actual operation: Cleaning and washing of removed parts as required @ visual inspection (Partially described)
TERMINOLOGY Caution: lmportant matters of which negligence may cause accidents. Be sure to observe them. Note: Important items of which negligence may cause accidents or matters in operation procedure requiring special attention.
Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS Abbreviation (code)
Meaning
Abbreviation (code)
Meaning
ASSY
Assembly
SST
Special service Tool
LH
Left hand
STD
Standard
OPT
Option
T =
Tightening torque
01s
Oversize
0O T
PS
Power steering
U IS
Undersize
RH
Right hand
W/
With
SAE
Society of Automotive Engineers (USA)
-
-
--- --
-
--
-
Number of teeth
-
-
-
-
--
(00 )
0-7
LIST OF ABBREVIATIONS AND SYMBOLS Symbol Name Battery BATT Buzzer Bz CADIP DriveIPump Absorber Capacitor Charger CH Forward Chime CHI, Reverse Chime CHI, CSDIP DriveIPump Current Sensor Power Steering Current CS, Sensor Charger Diode DcH DC-SDD DC-DC Converter & Source Drive (Drive) DC-SDP DC-DC Converter & Source Drive (Pump) DF112 FLY-WHEELDiode, No. 112 DF314 FLY-WHEEL Diode No.314 DG Regenerative Diode Display DlSP DriveIPump Motor DMD,, Power Steering Motor DMps Back-up Direction Switch DSBu Forward Direction Switch DSF Forward Optional DSFo Direction Switch Reverse Direction Switch DSR F1 Drive Fuse F2 Pump Fuse F3 Power Steering Fuse F4 Lamp Fuse F5 Control Circuit Fuse Charger Fuse F c ~
Symbol FRY H ,,,L ,.L ,, LC-L LF-L LF-,, LF-R L,-, LH-L LH-R LR-F LR-R LSATT,,, LSB LSD LSL1/2 LS, LS, LST-, LsT-, LS, LT-L LT-R ,L MF MG MP M PS MR MS
Name Flasher Relay Horn Back-up Lamp, LH Back-up Lamp, RH Clearance Lamp, LH Clearance Lamp, RH Flasher Lamp, LH Flasher Lamp, LH (Rear) Flasher Lamp, RH Flasher Lamp, RH (Rear) Head Lamp, LH Head Lamp, RH Rotaly Forward Lamp Rotaly Reverse Lamp Attachment Limit Switch No. 112 Brake Limit Switch Dead Man Limit Switch Lift Limit Switch No.112 Parking Brake Limit Switch Stop lamp limit Switch Stop Lamp, LH Stop Lamp, RH Tilt Limit Switch Tail Lamp, LH Tail Lamp, RH Working Lamp Forward Contactor Regenerative Contactor Pump Contactor Power Steering Contactor Reverse Contactor Short Contactor
TMps
Name Charger Magnet Switch Field Weakning Contactor Computer Print Board SPS Print Board Working Pilot Lamp Fan Resistor Field Weakning Resistor Regenerative Resistor Drivelpump Absorber Resistor Surge Absorber Drive SIT Driver Pump SIT Driver Lequid Level Sensor Snubber No. 1 Speed Sensor Steering Pressure Sensor Thermo Sensor Accel Switch Flasher Switch Horn Switch Key Switch Light Switch Speed Control Switch Transformer Regenerative Transistor Thermal Relay Main Transistor Main Pump Transistor Main Power Steering
TU VRAD
Transistor Timer Unit Accel Drive Vari-Ohm
Symbol MScH MW PBcpu PBsps PL, RF RFW RG RADIP SA SDD SDP SLL SN 1 SSP SP STH SWAc SW, SW, SW, SW, SW, TF TG THR TM TMP
OPERATIONAL TIPS 1.
Safe operation (1) After jacking up, always support with rigid stands. (2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts. 2.
(1
Tactful operation Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly. (6) Replace, gaskets, packings and O-rings with new ones each time of disassembly. (7) Use genuine Toyota parts for replacement. (8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassembly. If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table. 3.
Grasping the troule state When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for remedying.
CIRCUIT TESTER Circuit testers are available in both the analog and digital types. The should be used selectively according t o the purpose of measurement. Analog type: This type is convenient for observing movement during operation, but the measured value should only be used for reference or rough judgement. Digital type:
1.
Fairly accurate reading is possible, but it is difficult t o observe the variation or movement.
Difference in measurement results with the digital type and analog type * The result may be different between measurements with the analog type and digital type. Always use a circuit tester according t o its operation manual. Cautions when the polarities are different between the analog type and digital type are described below. Circuit tester range: Analog type
kohm range Digital type
+
Forward direction
+
2 Mohm range
Reverse direction
Black probe
Red probe
Measurement result example
Forward
Reverse
Analog type
Digital type
Continuity shall exist
No continuity
11 Kn
1
No continuity
Continuity shall exist
00
2 MSZ
As seen from the example above, the measurement results with the analog and digital types are reverse. In measurement with a digital type circuit tester, therefore, use the tester probes as shown beiow. Forward direction
Reverse direction
2.
Difference in result of measurement with circuit tester The circuit tester power supply voltage depends on the tester type. 1.5V, 3.OV or 6.OV is used. The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. The diode characteristics are shown in the figure below. The resistance values of the same semiconductor measured with t w o types of circuit testers having different power supply voltages are different.
Current in forward direction
This manual describes the results of measurement with a circuit tester whose power supply voltage is 3.0 V.
0
0.1
0.2 0.3 0.4 0.5 0.6 0.7 0.8 Voltage in forward direction
3.
(')
Difference in measurement result by measurement range (analog type) In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the circuit resistance. Even when the same diode is measured, the measurement result varies with the measurement range. Always use the range described in the repair manual for measurement.
Variable resistor
Resistor
Range: x 10
Red
Black
0-1 1
STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below.
1.
Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2.
The nut tightening torque can judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD 1.
2.
Identification by bolt shape Shape and class
GD-
Hexagon head bolt
Hexagon flange bolt
Bolt head No.
Class 4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T
No mark
4T
No mark
4T
Identification by part No.
Hexagon head bolt
Parts No.
91 61 1-40625 Length (mm) Diameter (mm)
iameter
0
Hexagon head bolt
Hexagon flange bolt
Two protruding lines
5T
Two protruding ines
6T Stud bolt
0
Hexagon head bolt
Three protruding lines
7T Parts No.
@
Hexagon head bolt
92 1 32-406 1 4 Four protruding lines
Length (mm) Diameter (mml
4T
Welded bolt
I Stud bolt
8T
k
iameter No mark
4T
Grooved
6T
0-1 2
TIGHTENING TORQUE TABLE
16
1.5
6
1 .O
13
)
130
1
9
113
f
1150
83
1
65
1 1 I 1 I f I f
24
6.4
I
8
1.25
16
f
160
I
5T
10
1.25
32
j
330
I
12
1.25
59
1 1 I 1 1 1
600
I
14
6T
1.5
91 137
16
1.5
6
1 .O
8
1.25
19
10
1.25
39
12
1.25
72
1.5
-
14 6 8
1 .O 1.25
7.8
11 25
1 /
I
930 1400 80 195 730
-
10
1.25
52
110 260
j
1.25
530 1500
226
970
I
14 16 8T
1.5 1.5
147
-
j
I
I
/
I
f
43 67 101 69 in-lbf
8.8
14
21
29
43
53
79
-
123
8 19
12 28
1.25
29
f
300
10
1.25
61
620
12
1.25
110
1 1
1100
I I
I I
I I I
-
I I
I I
I
I
I I
I I
I
I
1 1
1 / /
I I
1 1 1
22
33
45
68
1 1
80
120
103
f 108
I
I
-
70
I I I I I
) 166
j I
8
I
I I
I I I
58
I
I
167
38
I
I I
1 I 1 I 1
j
-
I
I
2300
I I
I
I
1 1 I 1
95
12
I
\
12
1 I 1 1 1
I
I
7T
56 in-lbf
I
400 I I I
-
-
-
1 1 1
78 in-lbf
j
1250
/
59 90
120
j
9
90
I
215 440 810
290 590
16 32
21 I
f
43
I
1050
1 1
76
I
1700
330 690 1250
I I
I
1 1 1
123
24 50 90
PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1.
Do not use the precoat bolt as it is in either of the following cases. (a) After is removed. (b) When the precoat bolt is moved (loosened or tightened) by tightness check, etc.
Note: For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it according to the steps below.
2.
Method for reuse of precoat bolts ( 1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.) (2) Parfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent to the threaded portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1.
When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth t o remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation.
2.
When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3.
The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter of screw
Hose inside diameter mm (in).
Standard tightening torque N-m (kgf-cm) [ft-lbfl Tightening range
Standard
7116 - 20UNF
25 ( 250) [ 18.11
24 -- 26 ( 240 -- 270) [ I 7.4 --
19.51
6 (0.24)
9116 - 18UNF
49 ( 500) [ 36.21
47 --
38.31
9 (0.35)
314 - 16UNF
59 ( 600) [ 43.41
56 -- 62 ( 570
630) [41.2 -- 45.61
12 (0.47)
718 - 14UNF
59 ( 600) [ 43.41
56 -- 62 ( 570
630) 141.2 -- 45.61
12 (0.47)
718 - 14UNF
78 ( 800) [ 57.91
74
82 1 760 -- 840) 155.0 -- 60.81
1 5 (0.59)
1-1116-12UNF
-
52 ( 480
PF1 14
25 ( 250) [ 18.1I
PF318
49 ( 500) [ 36.21
PFI I 2
59 ( 600) [ 43.41
56 -- 62 ( 570
PF314 PF 1
530) [34.7
118 ( 1 2 0 0 ) [ 86.81 112-123(1140--12501[82.5144 (1330 1470) 196.2 137 (1400) [101.3] 130
24 -47 -
1.511 6 - 12UNF
--
26 1 240
270) I17.4
52 ( 480 -- 530) [34.7
1 18 (1200) [ 86.81 1 12 -- 123 (1140 137 (1400) [101.31 130
-
-
-
630) 141.2 1250) 182.5
---
90.41
19 (0.75)
106.41
25 (0.98)
19.51
6 (0.24)
38.31
9 (0.35)
45.61
12 (0.47)
90.41
19 (0.75)
- 144 (1330 -- 1470) 196.2 -- 106.41
25 (0.98)