FOREWORD This manual covers the service procedures of the TOYOTA BATTERY FORKLIFT 5FBE10-20 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of September 1998. Please understand that disagreement can take place between the descriptions i n the manual and actual vehicles due t o change i n design and specifications. Any change or modifications thereafter will be informed b y Toyota Industrial Vehicles' Parts & Service News.
TOYOTA Material Handling Company A Division of TOYOTA INWSRIES CORPORATION
SECTION INDEX SECTION
NAME
GENERAL BATTERY OTHER THAN U.S.A.] (1993.1 - 1998.8) CONTROL ClRCU IT [FOR IFOR u.s.A.1 (1993.1 -1999.1 OTHER THAN U.S.A.] (1998.9 CONTROL CIRCUIT [FOR [FOR UL. U.S.A.. CANADA] (1999.2 MULTI-DISPLAY FUNCTIONS )
-
-) -)
A
[FOR OTHER THAN U.S.A.] (1993.1 1998.8) [Fouu.s.A.j (1993.1 - )
ELECTRICAL SYSTEM TROUBLESHOOTING ELECTRICAL SYSTEM TROUBLESHOOTING
/
-
[FOR OTHER THAN U.S.A.] (1993.1 1998.8) [FoRu.s.A.1 (1993.1 -1
[FOR OTHERTHAN U.s.Ad(199889 -I
A
A
MOTOR FRONT AXLE & TRANSMISSION (lgg3.1 - lgg8-l) FRONT AXLE & DRIVE UNIT (1998-2-1 REAR AXLE (1993.1- 1998.1)
1 A
STEERING -
BRAKE (1998.2- I BODY & FRAME MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL ] APPENDIX
GENERAL Page
........................... VEHICLE MODEL ........................... FRAME NUMBER ........................... HOW TO USE THIS MANUAL ................
EXTERIOR VIEWS
0-2 0-3 0-3 0-4
.......................... 0-4 TERMINOLOGY .................................. 0-5 ABBREVIATIONS ................................. 0-5
EXPLANATION METHOD
.......... 0-6 OPERATIONAL TIPS ......................... 0-7 JACK-UP POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 CIRCUIT TESTER ............................ 0-9 LIST OF ABBREVIATIONS AND SYMBOLS
STANDARD BOLT & NUT TIGHTENING TORQUE ................................. 0-11 BOLT STRENGTH TYPE IDENTIFICATION METHOD ....................................... 0-11 TIGHTENING TORQUE TABLE
PRECOAT BOLTS
.....................
...........................
0-12 0-13
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 ......................... 0-15 LUBRICATION CHART ....................... 0-16 PERIODIC MAINTENANCE ................... 0-17 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ........................ 0-22
0-2
EXTERIOR VIEWS
VEHICLE MODEL Load capacity
Model
Battery capacity AH/5HR
Voltage V
Control circuit
1.0 ton
5FBE10
280
*36 or 48
MCS-IIIA
1.25 ton
5FBE13
t
t
1.5 ton
5FBE15
390
1.75 ton
5FBE18
t
1.815 ton
5FBE20
375
t t t t
t t t
*: 36 V is provided for UL specification.
FRAME NUMBER
Punching position
Upper face of side member of frame RH
Vehicle model 1 ton series
1.5 ton series 2.0 ton series
5FBE10 5FBE13 5FBE15 5FBE18 5FBE20
Punching format 5FBE13-10011 5FBE13E10011 (EEC spec.) (1993.1 1993.9) 5FBE130 10011 (EEC spec.) (1993.10 )
-
-
5FBE18-10011 5FBE18E10011 (EEC spec.) (1993.1 1993.9) 5FBE18010011 (EEC spec.) (1993.10 )
-
-
5FBE20-10011
HOW TO USE THIS MANUAL EXPLANATION METHOD 1.
Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with a photo or illustration. Pattern B: Explanation of operation 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
--
T = 46.09 48.05 (470 490) 134.00- 35.451
8
Disassembly Procedure 1
Remove the cover. [Point 11
2
Remove the bush [Point 21
3
Remove the gear.
Operation explained later
Point operations Explanation of key point for operation with an illustration [Point 11 Disassembly: [Point 21 Inspection:
J
Put a match mark when removing the pump cover. Measure the bush inside diameter. Bush inside diameter limit: 19.12 mm (0.7528 in)
2.
3.
How to read components figures (1) The components figure use the illustration in the parts catalog for the vehicle model. Please refer to 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)
fl 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: lmportant 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
RR
Rear
EHPS
Electrical hydraulic power steering
SAE
Society of Automotive Engineers (USA)
FR
Front
SST
Special service Tool
I-/
Less
STD
Standard
LH
Left hand
T=
Tightening torque
0PT
Option
OOT
01s
Oversize
U/S
PS
Power steering
w/
RH
Right hand
Number of teeth Undersize With
(00)
LIST OF ABBREVIATIONS AND SYMBOLS Symbol BATT BZ CA CADIP
Name
Battery Buzzer Absorber Capacitor Drivelpump Absorber Capacitor Charger CH Forward Chime CHIF Reverse Chime CHIR CSDIP DriveIPump Current Sensor Power Steering Current CSps Sensor DADIP Drivelpump Absorber Diode Charger Diode DCH DC-SDD DC-DC Converter & Source Drive (Drive) DC-SDP DC-DC Converter & Source Drive (Pump) FLY-WHEEL Diode, DF112 No.112 DF314 FLY-WHEEL Diode No.314 DlSP Display DriveIPump Motor DMDlP 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 FCH
Symbol
Name
Flasher Relay Horn Wheel Position Indicator 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 LSB Dead Man Limit Switch LSD LSL1/2 Lift Limit Switch No.112 Stop lamp limit Switch LSsT L S T - ~ Stop Lamp, LH L s T - ~ Stop Lamp, RH Tilt Limit Switch LST Tail Lamp, LH LT-~ Tail Lamp, RH LT-~ Working Lamp Lw Forward Contactor, LH MFL Forward Contactor, RH MFR MP Pump Contactor Power Steering Contactor MPS Reverse Contactor, LH MRL Reverse Contactor, RH MRR Charger Magnet Switch MScH PBcpu Computer Print Board PBEHPs EHPS Print Board FRY H IWP LBU-~ LBU-~ LC-L LC-R LF-L L F - ~ LF-R LF-RR LH-L LH-~ LR-F LR-~ LSAnI2 l
Symbol
Name
Snubber Print Board Working Pilot Lamp Absorber Resistor Drivelpump Absorber Resistor PCKI I 2 Check Resistor No.112 SA Surge Absorber SLL Lequid Level Sensor Sunbber No.1 SN1 SNCI 12 Snubber Capacitor 112 SNR112 Snubber Resistor 112 SSP Steering Pressure Sensor Speed Sensor, LH SSL Speed Sensor, RH SSR Thermo Sensor STH SWAC Accel Switch Flasher Switch SWF Horn Switch SWH Key Switch SWKy Light Switch SWL SWPB Parking Brake Limit Switch Speed Control Switch SWsc Transformer TF Thermal Relay THR Main Transistor TM Main Drive Transistor TMD Main Pump Transistor TMP Main Power Steering TMps Transistor Timer Unit TU VRAD Accel Drive Variable resistor VRSP Steering Position Variable resistor (Steering potentiometer) PBsN PLw RA RADIP
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OPERATIONAL TIPS 1.
Safe operation (1) After jacking up, always support with wooden blocks on rigid stands. (2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve in load capacity. (3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2.
Tactful operation (1) 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, du not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for remedying.
4.
How to treat liquid waste When draining liquid waste from a vehicle, use a pan or other suitable container to collect the liquid. Do not throw away oil, fuel, cooling water, oil filters, batteries, or other injurious materials since these materials may adversely affect human health and the environment. Sort liquid waste into different types and seek the service of experts for proper disposal.
Hoisting the vehicle Loop wire ropes on the mast hook hole and the rear of the head guard to hoist the vehicle.
JACK-UP POINTS The vehicle often needs to be jacked up during assembly and reassembly. Be sure to jack up the vehicle at the right positions. Placing a jack in the wrong position or jacking up the vehicle in the wrong manner may cause an unexpected accident.
Front jack-up
Rear jack-up
Front jack-up If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with a bearing plate at least 80 m m long.
Rear jack-up When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the weight on the opposite side. The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle maintains its balance during jack-up.
CIRCUIT TESTER Circuit testers are available in both the analog and digital types. They should be used selectively according to 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 to 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 to its operation manual. Cautions when the polarities are different between the analog type and digital type are described below. (1) Analog circuit tester
I Measurement result example Forward direction
Reverse direction
Tester range:
I
KR range Analog type Continuity Forward I shall exist
I
No continuity
Reverse
(2) Digital circuit tester Forward direction
Reverse direction
Measurement result example Tester range: 2 M Q range Digital type
I
I
I
Forward
Reverse
NO continuity 1 Continuity shall exist 2 MR
I
2. Difference i n result of measurement with circuit tester The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V 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. (m~)
The resistance values of the same semiconductor measured with t w o types of circuit testers having different power supply voltages are different.
5 Current 4 in forward direction
This manual describes the results of measurement with a circuit tester whose power supply voltage is
3.0 V.
2 1
0
0.1
0.3 0.4
0.2
0.5
0.7 0.8
0.6
Voltage in forward direction
lV)
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.
Current flow
I
Variable resistor
,
Resistor
,-
Range: x 10
,,
(SW 1)
Resistor 41
TEwer
4
,
(SW2)
Range: x 1
source: 1.5 V
"0 Red
6@ Black
STANDARD BOLT AND NUT TIGHTENING TORQUE How to judge tightening torque of a standard bolt or nut. 1.
How to judge tightening torque of a standard bolt. Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table.
2. How to judge tightening torque of a standard nut. The nut tightening torque can be judged from the bolt type. (See the item above.)
BOLT STRENGTH TYPE IDENTIFICATION METHOD 1. Identification by bolt shape Shape and class
2. Class 4=4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T
@-
Bolt head No.
0
No mark
4T
Hexagon flange bolt
No mark
4T
Hexagon head bolt
Two protruding lines
5T
Hexagon head bolt
Identification by part No.
Hexagon head bolt
I
Part No. 91611-40625 T L e n g t h (mml Diameter (mm)
iameter
Stud bolt Two protruding
Part No. 921 32-40614 Four protruding
Length (mm) Diameter (mm)
0-12
TIGHTENING TORQUE TABLE
I
I
14
1.5
75
1
16
1.5
113
j
760 1150
6
1 .O
1
65
8
1.25
j j j
160 330 600
i
930
6.4 16
I
5T
10
1.25
32
12
1.25
59
1.5
91
1.5
6
1 .O
137 7.8
1 1400
j
80
I
8
1.25
19
1
10
1.25
38
j
195
1.25
72
1
7T
1.5
16
1.5
6
1.O
8
1.25
10
1.25
110
730
14
1.5
67
100
1 101 69 in-lbf
1 14 29
1 53
11750
1127
l1 I1 1 1 0 25 1260
8 119
52
i
95
1
226
6
1.O
12
j
8
1.25
29
10
1.25
61
12
1.25
108
14
1.5
172 265
1
38
970
1 70 I
1500
i 108
I
I
1 2300
1 166
L
i
125
_
1
75
j j j
175
300
j
620
21 43 79
65 in-lbf
I
I
1 1050
1
76
9
360 670
26 48
11600
j I
1
90 215
1 1
ill6
j I
1
78 in-lbf 16
I
440
j
32
I
1810
159
I
I
1 1250
j I
191
11950
1141
12
j
120 1290
9 121
I
I
I
28 58
j
590
I
103
-
1 1050
j
l4 1I
43
:
76
I
11700 , I I I
j
I
I
I
167
90
-
j123 I I I
145
9
I
1 22
I
j
13
I
I
j
_
I
123
45
32
I
I
11100
180
68 123
i 127
196
1750
I I
j j j j
I
1
I
8.8
I
I
147
157
I
j
I I
I
I
530
I
161
I
i 8 0
170
65
I
I
1.5
1.5
i
j1100
16
16
36
I
I
8T
24 43
1
I
1850
I
I
I
1.25
18
I
I
12
12
j j
400
I
14
7.5
I
I
12
56 in-lbf
-
I
I
6T
83
I
I
16
i i
55 83
I
I
14
j
I
I
1 2700
1 195
1
330
1
690
I
24
j
50
I
1 1250 ,1 2000 1 3050
I
299
1I 1
90
j
145
I
1 221