Toyota 30 5fbcu30 forklift service repair manual by 1636772

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

SECT1

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

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

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

Oil Pump Disassembly Procedure

Disassembly Procedure Remove the cover. [Point 11 1

Remove the bush [Point 2 l o O p e r a t i o n explained on a laterpage

Remove the gear.

Point operations

Explanation of key point for operation with an illustration

[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)

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

Left hand

STD

Standard

OPT

Option

T =

Tightening torque

01s

Oversize

0O T

Power steering

U IS

Undersize

Right hand

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.

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:

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

No continuity

Continuity shall exist

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

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.

0.1

0.2 0.3 0.4 0.5 0.6 0.7 0.8 Voltage in forward direction

(')

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.

Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.

The nut tightening torque can judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD 1.

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

Identification by part No.

Hexagon head bolt

Parts No.

91 61 1-40625 Length (mm) Diameter (mm)

iameter

Hexagon head bolt

Hexagon flange bolt

Two protruding lines

Two protruding ines

6T Stud bolt

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

Welded bolt

I Stud bolt

iameter No mark

Grooved

0-1 2

TIGHTENING TORQUE TABLE

1.5

1 .O

)

130

113

1150

1 1 I 1 I f I f

6.4

1.25

160

1.25

330

1.25

1 1 I 1 1 1

600

1.5

91 137

1.5

1 .O

1.25

1.5

14 6 8

1 .O 1.25

7.8

11 25

1 /

930 1400 80 195 730

1.25

110 260

1.25

530 1500

226

970

14 16 8T

1.5 1.5

147

43 67 101 69 in-lbf

8.8

123

8 19

12 28

1.25

300

1.25

620

1.25

110

1 1

1100

I I

I I I

I I

1 1

1 / /

I I

1 1 1

1 1

120

103

f 108

I I I I I

) 166

j I

I I

I I I

167

I I

1 I 1 I 1

2300

I I

1 1 I 1

1 I 1 1 1

56 in-lbf

400 I I I

1 1 1

78 in-lbf

1250

59 90

120

215 440 810

290 590

16 32

21 I

1050

1 1

1700

330 690 1250

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.

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.

When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.

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

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)

0-1 4

WlRE ROPE SUSPENSION ANGLE LIST Lifting angle

Tension

Compression

1.OO time

0 time

30 O

1.04 time

Suspension method

0.27 time

Lifting angle

Tension

Compression

90°

1.41 time

1.OO time

1.1 6 time

1 20°

2.00 time

1.73 time

0.58 time

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Rope diameter

A k0

by5

60 O

Suspension method

Single-rope Cutting suspension load

0O 3040 21380 6 mm (0.31) (2.18) (0.24 in) [48071 [683.6] 4410 31480 8 mm (0.45) (3.21) (0.32 in) [992.3] [70781 6960 49230 10 mm (0.71) (5.02) (0.4 in) [ I 1.691 [I 565.61 76880 10980 12.5 mm (1.12) (7.84) (0.5in) 1173871 [2469.5] 13730 96400 14 mm (9.83) (1.4) (0.56 in) [21675] [3087]

Two-rope suspension

0O 6080 (0.62) [ I 3671 8830 (0.9) [ I 9851 14020 (1.43) [3153] 21570 (2.2) 148511 27460 (2.8) [6174]

30 O 5880 (0.6) [ I 3231 8530 (0.87) [ I 91 81 13440 (1.37) [3021] 21280 (2.1) [4631] 26480 (2.7) [5954]

60 O 5200 (0.53) [ I 1691 7650 (0.78) [ I 7201 11770 (1.2) [2646] 18630 (1.9) [4190] 23540 (2.4) [5292]

Unit: N (ton) [Ibl

Four-rope suspension

60 O 30 O 90 O 0O 10400 4310 12160 11770 (1.06) (0.44) (1.24) (1.2) [970] [27341 [2646] 123371 17650 17060 15300 6280 (1.74) (1.56) (0.64) (1.8) [ I 41 11 [3969] [39371 [3440] 9810 27460 26480 23540 (2.4) (2.8) (2.7) (1.0) [2205] [6174] [5954] 152921 14710 43150 41 190 37270 (3.8) (4.2) (1.51 (4.4) 133081 [9702] 192611 [83791 18630 54920 52960 47070 (4.8) (5.6) (5.4) (1.9) [4190] [ I 23481 [ I 19071 [ I 05841

90 O 8630 (0.88) [ I 9401 12550 (1.28) [23221 19610 (2.0) 144101 29420 (3.0) 166151 37270 (3.8) 183791

COMPONENTS WEIGHT Item

Model

Approx Weight kg (Ibs) STD

6 6 (145)

Dust proof type

75 (165)

STD

1 0 4 (229)

Dust proof type

1 2 0 (264)

STD

1 0 4 (229)

Dust proof type

1 2 0 (264)

STD

3 8 (84)

Dust proof type

4 2 (92)

STD

75 (165)

Dust proof type

7 5 (165)

STD

7 5 (165)

Dust proof type

7 5 (165)

1 ton series

Drive Motor

2 ton series

3 ton series Motor 1 ton series

Pump Motor

2 ton series

3 ton series

Counter Weight

Mast WILift bracket (with Lift cylinder, less Back rest and forks). [Max. Fork height = 3000mm (118 in)]

Note:

5FBCU1 5

4 4 0 (970)

5FBCU1 8

4 1 0 (904)

5FBCU20

480 (1058)

5FBCU25

825 (1819)

5FBCU30

8 2 5 (18 1 9)

5FBCHU20

41 0 (904)

5FBCHU25

4 8 0 (1058)

1 ton series

3 9 0 (860)

2 ton series

4 6 0 (1014)

3 ton series

6 0 0 (1323)

Refer t o Page 1 - 2 for the battery weight.

RECOMMENDED LUBRICANTS AND CAPACITIES APPLICATION Differential & transmission

TYPE STD: 20s:

Hydraulic oil

STD: 20s:

Brake oil

Grease

***

CAPACITY (TOTAL)

Hypoid gear oil SAE85W-90 (VALVOLINE80W90) Hypoid gear oil W (VALVOLINE80W90)

1.5 ton

7.0 Q (1.85 US gal.)

1.8 -- 3 t o n

7.5 Q (1.98 US gal.)

STD: SAE J-1703 DOT-3 (INTAC AUTOMOTIVE PRODUCTS INC. GC325) 20s: GC325 STD: 20s:

Hydraulic oil I S 0 VG32 (Daph- 1.5 ton ne Fluid AW32) Auto Fluid 1.8- 3 t o n

1 6 Q (4.2 US gal.) * 2 1 Q (5.5 US gal.) * 2 0 Q (5.3 US gal.) * * 2 6 Q (6.9 US gal.)

Proper quantity

MP Grease No.2 (VALVOLINE BRB GRESE) Esso Beacon 3 2 5

Proper quantity

** * ***

For 3000 mrn ( 118 in) maximum fork height. For 6000 mm (236 in) maximum fork height. Use where unspeicified.

HYDRAULIC OIL CAPACITY DEPENDING ON FORK HEIGHT Model 5FBCU1 5 30-5FBCU1 5

[ Height Capacity

3000 or less

3300 -4000

4300 - 5000

5500 - 6000

Remarks

Total (Q1

17.5

Same as 5FB15 &

Oil tank (0) 5FBCU 18,20,25 5FBCUH20, H 2 5 5FBCU30 30-5FBCU 18, 20, 2 5 30-5FBCUH20,25 30-5FBCU30

Total (Q)

14.5

5FB20 series

Same as 5FB30 series Oil tank (Q

16.5

18.5

20.5

22.5

P.S. There are no capacity differences depending on the type of mast, such as V, FV, and FSV.

INSTRUCTION OF OIL CHECK LEVEL IN HYDRAULIC OIL TANK

To check the oil level, touch the lower threaded end portion of the cap t o retainer without screwed in.

Adjust oil amount within 0 -- 10 mm (0.39 in) difference from each of the height indication.

Fork Height 5500- 6500 Fork Height 4300- 5000 Fork Height 3300- 4000

Fork Height 3000 or less

GREASE ON MICRO SWITCH FOR INSTALLATION Put grease on roller.

LUBRICATION CHART

Chain

Inspect every 8 hours (daily)

Mast support bushing

lnspect every 40 hours (weekly)

Tilt cylinder front pin

111

lnspect every 170 hours (monthly)

Front wheel bearing

lnspect every 1000 hours (6monthly)

Differential & transmission

lnspect every 2000 hours (annually)

Brake fluid reservoir tank

lnspect and service

Tilt steering locking mechanism

Replace

Tilt steering universal joint

Oil tank

MP grease

10.

Rear wheel bealing

Engine oil

1 1.

Steering knuckle king pin

Hypoid gear oil

12.

Rear axle beam front

Hydraulic oil

13.

Rear axle cylicder rod joint (1 ton series)

Brake fluid

14.

Rear axle beam rear

Located on right and left sides

1 Lubrication Chart

PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required. M: Measurement. Repair or adjustment if required. T : Retightening C: Cleaning L: Lubrication 1 * : Flaw detector Months

Hours

170

500

1000

2000

Abnormal sound during revolution

Loose terminal

0 0

Insulation resistance

0 0 0

Brush wear and sliding contact status

Commutator fouling and damage

0 0 0 0 0

0 0 0 0

0 0 0 0 0 0 0 0 0 0

Inspection Period Item ELECTRICAL SYSTEM

Motor

Brush spring fatigue

Charge

Battery fluid level

Battery fluid specific gravity Battery

Charger

Magnet contactor

Microswitch

Loose terminal

Abnormality at top of battery and battery case

Insulation resistance

Cell voltage measurement after charging

Timer operation

Terminal loosening

Operating voltage measurement

Magnet switch function, contact fouling and roughening

Loose contact, damage and wear

Auxiliary contact function, fouling and wear

Arc chute installation status

Timing and functioning

Loose coil installation

Loose main circuit lead installation

Timing and operating function

Damage and loose installation

0 0 0

0 0 0 0

0 0

0 0 0 0 0 0

0 0

I-

Months

Hours

170

500

1000

2000

Operating conditions and damage

Operation

Inside fouling and damage

0 0 0

Overcurrent limit valve

Loosening

0 0 0 0 0

Inspection Period

Item Direction lever

Controller

Fuse

Damage of wiring harness and loose Wiring (including charging cord)

Accelerator

clamp

Loose connection and taping status

Battery connector damage and connection status

Operating and damage

Oil leak

Oil level

0 0

Loosening of nuts and bolts

0 0 0

POWER TRAIN Differential, Transmission

TRAVELING EQUIPMENT

Wheels

Front axle Rear axle

Tire cuts, damage and uneven wearing

Loose rim and hub nuts

Tire groove depth

Metal chips, pebbles and other foreign matter trapped in tire grooves

Rim and disc wheel damage

Abnormal sound and looseness of front wheel bearing

Abnormal sound and looseness of rear wheel bearing

Cracks, damage and deformation of housing

Cracks, damage and deformation of beam

Months

Hours

170

500

1000

2000

Play and looseness

Function

Oil leak

Looseness of mounting

Oil leak

0 0 0 0 0

Damage of power steering hose

King pin looseness

Cracks and deformation

0 0 0 0 0 0 0 0

0 0 0 0 0

0 0 0 0 0 0

Inspection Period Item STEERING SYSTEM Steering wheel

Steering valve

Power steering

Knuckle

BRAKING SYSTEM Brake pedal

Play and reserve

Braking effect

Pull margin

Braking effect

Rod and cable looseness and damage

Ratchet wear and damage

Brake pipe and hose

Leakage, damage and mounting status

Brake fluid

Fluid level

Master cylinder or brake valve and wheel cylinder

Function, wear, damage, leak and mounting looseness

Clearance between drum and lining

Wear of shoe sliding portion and lining

Drum wear and damage

Shoe operation condition

Anchor pin rusting

Parking brake

Brake drum and brake shoe

Backing plate

Return spring fatigue

Automatic adjuster function

Deformation, cracks and damage

Loose mounting

0 0

0 0 0 0 0 0 0 0 0

Inspection Period Item

Months

Hours

170

500

1000

2000

MATERIAL HANDLING SYSTEM

I Abnormality of fork and stopper pin /

Forks

Misalignment between left and right fork fingers

Cracks at fork root and welded part

0 0

Deformation and damage of each part and crack at welded part Mast and lift bracket looseness Mast and fork bracket

Wear and damage of mast support bush Wear, damage and rotating condition of rollers Wear and damage of roller pins Wear and damage of mast strip Tension, deformation and damage of chain

Chain and chain wheel

Chain lubrication Abnormality of chain anchor bolt Wear, damage and rotating condition of chain wheel

Various attachments

Abnormality and mounting condition of each part

HYDRAULIC SYSTEM Loosening and damage of cylinder mounting Cylinder

Deformation and damage of rod, rod screw and rod end Cylinder operation Natural drop and natural forward tilt (hydraulic drift)

I Oil leak and damage Cylinder

Oil pump

Wear and damage of pin and cylinder bearing

/ Lifting speed

I " I o o I o

Uneven movement

Oil leak and abnormal sound

0 0

1 0

Oil level and contamination Hydraulic oil tank

Tank and oil strainer

I Oil leak

Months

Hours

170

500

1000

2000

Loose linkage

Operation

Oil leak

0 0 0

0 0 0 0

Inspection Period

Item Control lever

Oil control valve

+ +

Relief pressure measurement

Relief valve and tilt lock valve functions

Oil leak

Hydraulic

Deformation and damage

piping

Loose joint

Hoise tension and twisting

0 0 0 0

SAFETY DEVICES, ETC. Cracks at welded portion

Deformation and damage

Loosening of mounting

Deformation, crack and damage

Lighting system

Function and mounting condition

Horn

Function and mounting condition

Direction indicator

Function and mounting condition

Instruments

Functions

Back u p buzzer

Function and mounting condition

Rear-view mirror

Dirt, damage

Rear reflection status

Seat

Loosening and damage of mounting

0 0 0 0 0

Body

Damage and cracks of frame, cross members, etc.

Bolt looseness

Grease up

Head guard

Back-rest

Other

0 0 0

0-24

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS Inspection (operating hours or months, whichever is earlier)

Months

Hours

170

500

1000

2000

• •

Brake fluid Hydraulic oil Hydraulic oil return filter Differential and transmission oil Wheel bearing grease Master cylinder rubber parts Wheel cylinder rubber parts Reserve tank hose Power steering hose Internal rubber parts of power steering system Material handling hose Chain -

a (New veh~cle)

• • • • a (Every 2 years)

a (Every 2 years)

a (Every 3 years)

BATTERY Page

............................................................1-2 CAPACITY ON SPEC .......................................... 1-2 WEIGHT OF BATTERY WICASE ............................. 1-2 RECOMMENDED BATTERIES ................................. 1-2

GENERAL

BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED

.......................

1-5

BATTERY COMPARTMENT SIZE ADJUSTMENT ................................................. 1-6 BATTERIES SUITABLE TO BATTERY ROLL OUT SPEC. COMPARTMENT BATTERY WEIGHT SUPPLEMENT ADJUSTMENT BY SUB-WEIGHT

................ 1-8

..................... 1-9 TROUBLE SHOOTING ......................................... 1-12 SERVICE STANDARDS ....................................... 1-I3 BATTERY ASSY .................................................. 1-I4 REMOVAL.INSTALLATION ................................... 1.14 INSPECTION ....................................................... 1-15

1-2

GENERAL CAPACITY ON SPECIFICATIONS STD battery

Model

36 V

48 V

36 V

48 V

5FBCU1 5 30-5FBCU1 5

595

425

680

51 0

5FBCU1 8 30-5FBCU1 8

680

51 0

935

680

510

935

610

5FBCU25

680

557

935

680

5FBCU25 (Compact model)

680

935

5FBCU30 30-5FBCU30 ' 5FBCHU20 30-5FBCHU20 . 5FBCHU25 30-5FBCHU25

935

5FBCHU25 (Compact model)

935

5FBCU20 30-5FBCU20 Capacity AH16HR

High capacity

1020

WEIGHT OF BATTERY WICASE Model

Approx. weight battery ASSY Wlcase kg (Ibs)

Model

Approx. weight battery ASSY Wlcase kg (Ibs)

5FBCU1 5 30-5FBCU1 5

830 (1840)

5FBCHU20 30-5FBCHU20

1360 (3000)

5FBCU20 30-5F BCU20

1090 (2400)

5FBCHU25 30-5FBCHU25

1360 (3000)

5FBCU25 30-5FBCU25

1090 (2400)

5FBCU30 30-5FBCU30

1360 (3000)

RECOMMENDED BATTERIES The recommended Batteries are shown in the next table. Those batteries satisfy the minimum weight required for counter balance. For that reason, the sub-weight are unnecessary. (The maximum capacity batteries are also given for reference.)

Note: In UL-EE specifications, a battery side cover and an insulated cover on the rear of the battery hood are installed; thereby it is unnecessary to use a battery (with cover) for EE use. Battery case

Installed battery Type

Voltage

Manufacturer

Model

5FBCU1 5

Single cell dimensions mm (in)

Capacity AH16HR

Inside dimensions mm (in)

Length Width Height Length Width Height 575 862 575 660 (22.64) (25.98) (33.94) (22.64)

EXlDE

18E85-17

680

159 (6.26)

165 (6.50)

18E100-17

800

578 (22.76) 554 (21.81

GNB

18-75C-17

600

1 8-85C- 1 7

680

C&D

18C75-17

600

160 (6.30)

166 (6.54)

575 (22.64)

1 8C85-17

680

EXlDE

24E75-13

450

127 (5.00)

24E 1 00- 1 3

600

GNB

24-75C-13

450

574 (22.60) 578 (22.76) 554 (22.60)

24-85C-13

510

C&D

24C75-13

450

158 (6.18)

128 (5.04)

575 (22.64)

24C85-13

510

EXlDE

8E1 low-'

880

159 (6.26)

165 (6.50)

578 (22.76)

157 (6.18)

[MAXI

24c85-17

680

166 (6.54)

160 (6.30)

Installed battery Type

Voltage

Single cell dimensions Inside dimensions Capacity mm (in) mm (in) AHI6HR . Length Width Height Length Width Height

Manufacturer

Mode'

EXlDE

18E75-23

825

222 (8 74)

159 (6 26)

18E85-23

935

5FBCU20

575 (22 64)

t 554 (21 81)

GNB

18-75C-23

825

18-85C-23

935

160 (6 30)

575 (22 64)

C&D

18C85-2 1

850

18C85-23

935

204 (8 03) 223 (8 78)

159 (6 26)

EXlDE

24E75-17

600

165 (6 50)

24E85-17

600

t 554 (21 81)

GNB

24-75C- 17

600

C&D

24C85-19

765

(7 28,

24C85-21

850

(iz)

(6 30)

(22 64)

[MAXI ~ F B C H U ~ 3~6 5FBCU30

Battery case

EXlDE A

8E 24E 1 1OW-2 1

540 1 100

279 159 ( 10 98) , (6 26) 203 159 ( 7 99, (6 26,

578 (22 76)

BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED When purchasing the battery locally, adjust its weight t o satisfy the minimum required weight by referring t o the table below. Compartment dimensions Front to rear length X

mm (in)

Width Y

Height

Minimum required battery weight (with case) kg (Ib) 830 (1840)

Battery Compartment Shape

Maximum battery weight (with case) kg (Ib)

1-6

BATTERY COMPARTMENT SIZE ADJUSTMENT The battery compartment is made adjustable in both the length and width direction. 1.

Length (To front and back)

Since TI 6 plate is mounted with a bolt, the compartment length is adjustable in t w o stages by removing this plate.

With TI6 Plate mounted: Compartment length = 691 mm (27.20") Without T I6 Plate: Compartment length = 698 mm (27.48")

Note: Adjust so the space between the battery compartment and the battery is under 12.7 mm (112" )

Width (To right and left)

W (Battery compartment width)

r C

Battery Stopper RH Battery stopper LH (Bolted to frame)

Battery compartment width: W is adjustable in 6 stages with different combinations of battery stopper LH.

Note:

Adjust so the space between the battery and battery compartment is under 12.7 mm (112")

BATTEROES SUITABLE TO BATTERY ROLL OUT SPEC. COMPARTMENT The batteries mountable on battery-rollout specification are limited since the battery compartment length and width differ from standard models. A recommended list of mountable batteries are shown in the table below. Voltage

Manufacturer

TYpe

Capacity (AHI6HR)

18E75-23

Length

Width

Height

mm (in)

825

690.6 (27.19)

982.7 (38.69)

574.8(22.63)

18E85-23

935

690.6 (27.19)

982.7 (38.69)

574.8 (22.63)

18C85-23

935

684.3 (26.94)

979.4 (38.56)

574.8 (22.63)

18-75C-23

825

685.8 (27.00)

973.1 (38.31

574.8 (22.63)

18-85C-23

935

685.8 (27.00)

973.1 (38.31

574.8 (22.63)

24E75-17

600

685.8 (27.00)

982.7 (38.69)

574.8 (22.63)

24E85-17

680

685.8 (27.00)

982.7 (38.69)

574.8 (22.63)

24C75-17

600

684.3 (26.94)

979.4 (38.56)

574.8 (22.63)

24C85-17

680

684.3 (26.94)

979.4 (38.56)

574.8 (22.63)

24-75C-17

600

679.5 (26.75)

973.1 (38.31)

574.8 (22.63)

24-85C- 17

680

679.5 (26.75)

973.1 (38.311

574.8 (22.63)

EXlDE

36 V

C&D

GNB

EXlDE

48 V

C&C

GNB

A X

36 V

EXIDE

18E11OW-23

1210

690.6 (27.19)

982.7 (38.69)

577.9 (22.75)

48 V

EXlDE

24E110W-17

880

690.6 (27.19)

982.7 (38.69)

577.9 (22.75)

Note:

The following matters must be observed when mounting batteries other than the above. 1. Battery weight: Over 1090 kg (2403.45 Ib) 2. Space between battery and battery compartment (UL Standards) to be under 12.7 mm (112")

BATTERY WEIGHT SUPPLEMENT ADJUSTMENT BY SUBWEIGHT It will be possible to mount a battery that does not satisfy minimum battery weight by adding a subweight in the battery compartment. The subweight must be procured locally and will not be optionally set. Taps are provided at two places on the forklift body for attaching the subweight. Subweight reference diagrams, mounting methods, principal battery subweights and required weights are shown:

Unit:

Sub-weight reference diagram

Nozzle way for welding flame cutting.

Thickness T19mm (0.748 in) T 50 mm (1.969 in)

dl/

400

o m

(15.748) I

20 -

(0.7W&

b 6 +* .J

@F , 0

*+ 3 be. OO?.@~~

i i i

P P

0 r\

CO b

-2 0

i i i i i i i i I

500 (19 685)

870 (34.252)

f-'

mm (in)

Weight 72 kg (158.76 192 kg (423.36

Unit:

Mounting method

h x 1

(in)

\i (Frame) (Sub-weight)

(Sub-weight)

A-A section for T 1 9 mm (0.748) sub-weight

A-A section for T 50 mm (1.969 in) sub-weight

* Tapped holes were already bored in frame.

3. Principal Battery Sub-weight and Required Weight. A: T I 9 mm (0.748 in) 72 kg (158.76 Ib) B: T 5 0 mm (1.969 in) 192 kg (423.361b)

Vehicle tY Pe

Minimum battery weight kg (~bs)

Mounted-Battery (Subweight required)

Battery Size

W x L x H mm (W x L x H in1

Manufacturer

Voltage Battery type (V)

36 30-5FBCU15

5FBCU 30-5FBCU18

830 (18401

(2000)

18-75C-15

811 X597x575 131,93x 23,50x 22,641

18-85C-15

811x597~575 i31,g3x23,50x22,64)

GNB

i $ ~ ~ , " ~ ~ ~ ~ ' ~ 0 3 )

992x710~585 (39.06 x 27.95 x 23.03)

5FBCU20 30-5FBCu20 992X710x585 OgO (2400) (39.06 x 27.95 x 23.03) 5FBCU25 30-5FBCU25

GNB

Battery Case Size W X L x H mm IWxLXHin)

8-75B-1

weight kg (~bs)

725 (1598) 790 (1741)

Weight lacking kg (Ibs)

Loadable subweight width mm

(in1

105 (231)

83 13.27)

40 (88)

83 13.27)

83 r3,27,

81 1 x 597x 575 131.93X23.50~22.64)

725 (1598)

105 (231

778 (1716)

52 (114)

24-85C-11

685 x 848 x 575 126.18x25.51 x22,64)

18-85C-17

970X 508x 575 ~38,19x20,00x22,64,

899 (1981)

11 (24)

8-85C-1

970X 508 x 575 (38.19X 2 0 . 0 0 ~22.641

899 (1981)

191 (420)

li.gl

18-75C-19

973X 568x 575 138,31 22,36x 22,641

152 (334)

76 12.99)

18-85C-19

973 x 568 x 575 ,38,31 22,36x 22.64)

67 (147)

76 (2,991

152 (334)

76 (2,99,

36 18-75B-1

GNB 8-75c-21 8-75B-21

938 (2069)

1023 (2256)

973 x 568 x 575 138.31 X22.36x22.64)

938 (2069)

973 x 629x 575 138.31x -24.76%22.64)

1041 (2294)

973x629x575 138.31 X 24.76X 22.64)

1041 (2294)

49 (108)

100

13,941

45.5

A A

24-75C-15

970x 597x 575 958 138,19x23,50x22,64~

24-85C-15

970 x 597 x 575 138,1gx 23,50, 22,641

24-75B-1

970x 597 x 575 (38.19~ 23.50~22.64)

(2111)

1044 (2302) 958 (21 )

49 (108)

45.5

132 (2901

61.5 12,42)

46 (101

61.5 (2.42)

32 (290)

61.5 12.42)

TROUBLESHOOTING Pole plate corrosion \

lnsufflc~entcharge \-No

operation for

Shorting between cells

Repetillon of overdischarge and overcharge Excessive charg~ng current

temperature

Improper water supply

Deposition of fallen -acting substance In

Short circuit and decrease

Incomplete terminal connection

Overcharge

Duty terminal or plug-

Loosened or corroded connections

1-13

SERVICE STANDARDS Specific gravity in fully charged state

(OC)

1.280 (20)

Specific gravity in fully discharged state

(OC)

1.150 (20)

Discharge end voltage

36 V specification

32.0

48 V specification

42.5 Sulfuric acid diluted with distilled water

Electrolyte

Distilled (deionized) Water

Fluid t o be spplied

Insulation resistance

I or more

DISPLAY INDICATION 1.

The display indicates the remaining battery charge level in 1 0 stages. When the remaining charge drops below 20 %, the indication flashes the warn the timing for charging.

When the battery is discharged fully ( 1 0 0 %), the overdischarge alarm function operates as follows:

OVERDISCHARGE ALARM FUNCTION 1.

Material handling with traveling becomes impossible. If simultaneous operation is attempted, priority is given t o traveling and material handling is not effected. (For prevention of battery from damage by large current flow)

When material handling is attempted, all indicators on the display flash and the buzzer sounds t o alarm overdischarge.

Note: Material handling operation becomes impossible on the vehicle with chopperless material handling circuit. For thirty seconds after the key switch is turned on however, material handling operation can be performed.

BATTERY ASSY REMOVAL. INSTALLATION

Removal Procedure 1

Place the mast in vertical position.

Disconnect the battery plug.

Pull the-steering unlocking lever to tilt the steering forward

Place the seat t o the foremost position. (When the deadman seat is used, remove the seat together with the seat stand.)

Release the battery hood catch. (For the battery roll-out spec. model, release the battery stoppeer. For the dust-proof spec. model, remove the battery side cover, too.)

Open the battery hood as holding the handle on RHS and hook the hood stay.

Hoist the battery Assy W/Case to relocate. (Case of the battery roll out spec., removable sidewise.)

Installation Procedure Follow the reverse sequences of the removal.

INSPECTION 1

Electrolyte inspection ( 1 ) The battery electrolyte should be colorless and transparent in normal state. Check turbidity, etc. at the time of specific gravity inspection. If clear confirmation is impossible, put in a beaker for inspection.

Inspection o f electrolyte specific gravity ( 1 ) Use a hydrometer and measure the specific gravity of the electrolyte Specific gravity in fully charged state: 1.280 (at 2 0 O C) Specific gravity in fully discharged state: 1.150 (at 2 0 OC) The specific gravity of the electrolyte is expressed by the value at 2 0 O C as the standard. Specific gravity conversion equation ,S, = S t + 0.0007'(t-20) :S ,, Specific gravity at 2 0 O C S t : Specific gravity at t O C t : Temperature at the time of measurement

Hydrometer

1 Duter tube

H o w t o use the hydrometer @ Insert the nozzle of the hydrometer into the water supply port and suck the electrolyte into the outer cylinder. @ Let the hydrometer in the outer cylinder float correctly without contact with the top, bottom and side wall of the outer cylinder, and read the graduation at the using electrolyte surface as shown at left after disappearance of bubbles in the sucked electrolyte. @ After the measurement wash outside and inside of the hydrometer with clear water and wipe thoroughly with clean cloth for storage.

Insulation resistance inspection Use an insulation resistance meter (megger) and measure the resistance between the battery and battery case. Insulation resistance: 1 M Q or more Note: If the insulation resistance is less than 1 MQ, remove the battery from the vehicle and wash it with water. Dry the battery case the roughly, and measure the insulation resistance again. Install the battery on the vehicle after checking that the insulation resistance is 1 M Q or more.

* Battery control table Prepare the control table for each battery t o record and retain the inspection result.

CONTROL CIRCUIT Page

MCS I11 CONTROLLER ....................................... 2-2

........................................................... 2-2 SPECIFICATIONS ................................................. 2-3 COMPONENTS ................................................... 2-4 CONTROL PANEL ASSY ...................................... 2-9 OCL VALUE (OVER CURRENT LIMIT VALUE) .......... 2-39 GENERAL

ACCELERATOR POTENTIOMETER ADJUSTMENT ................................................2-41 BRAKE SWITCH & STOP LAMP SWITCH ADJUSTMENT ................................................ 2-41 PARKING BRAKE SWITCH ADJUSTMENT ....... 2-42 SEAT SWITCH ADJUSTMENT FOR BATTERY ROLL OUT (OPT) ......................... 2-43 MATERIAL HANDLING SWITCH ADJUSTMENT ................................................ 2-43 MATERIAL HANDLING CHOPPER SWITCH (OPT) ADJUSTMENT ............................................... 2-44 DIRECTION SWITCH .......................................... 2-45 REMOVAL-INSTALLATION DISASSEMBLY -ASSEMBLY INSPECTION

................................... ..................................

2-45 2-46

...................................................... 2-47

POWER STEERING CONTROLLER

.....................

2-48

................................................... 2-48 REMOVAL.INSPECTION.INSTALLATlON (STD) ....... 2-49

COMPONENTS

REMOVAL-INSPECTIONINSTALLATION (WIEHPS)

................................. 2-51

MCS-I11 CONTROLLER GENERAL The 5FBCU series is provided with the diagnostic (self-diagnosis) function for automatically detecting any abnormality in the main travelinglmaterial handling circuit, operating system such as the accelerator and sensors to sound the buzzer (peep, peep) and to display the abnormal portion by the corresponding error code on the multidisplay. A t the same time, such an action as traveling stop, material handling stop or traveling speed restriction is taken to ensure safety. When the display is set to the analyzer (fault analysis) mode, defect detection and functional check of the main drivelmaterial handling circuit, operating systems, and sensors are performed. See the Multidisplay section (page 3-3) for the diagnosis. See the Multidisplay section (page 3-71 for the analyzer.

Drive Control Panel ASSY

Material Handling Control Panel ASSY

Material Handling Control Panel ASSY (with Chopper)

SPECIFICATIONS Portion F1 (Drive circuit)

1 I I I

F 2 (Material handling circuit) F 3 (PS circuit)

Fuses

F 4 (For lamps)

F5 (Control circuit)

1 t o n series

2 t o n series

3 ton series

275 A

325 A

I I I 1

225 A 75 A 10 A 10 A

I I I I

325 A t C

c + t

1 1 I 1

T M (For traveling) Transistors TMP (For material handling: OPT)

TSM 0 0 3 (3 pcs.)

E T I8 8

# IM1100H-025

DAD (For traveling)

30MF40

DAP (For material handling: OPT)

30MF40

D F I (DM flywheel)

SR250L-6s

DF2 (DM flywheel)

SR250L-6s

TG (For regeneration preexcitation) TM

,,(For PS : OPT)

IDG (For regeneration) Diodes

I D F ~(PM flywheel)

/ D F (PM ~ flvwheel: OPT)

I I

I D F ~ (PS flywheel) Current sensors

I I I

CSP (For material handling: OPT)

HS800RT

MBP20A-1 OMJN

(For PS: OPT)

Capacitors CAP

Resistors

# IM1100H-025

1 I

HS800RT

CAD (Absorber for traveling)

70M30

CSD (For traveling)

CS,

20M30

60pF ( 2 pcs.)

(Absorber for material handling: OPT) RAD (Absorber for traveling)

1 .5Q 2 2 0 W

RG (For regeneration)

0.6Q 120W

1.5Q 220W

RAP (Absorber for material handling: OPT) MF.MR (For forwardireverse traveling)

ME250

MG (For regeneration)

ME251

MS (Bypass)

ME251

M W (For field weakening)

ME251

MP (For material handling) MPS (For PS)

# : The PS transistor and diode are integrated.

ME251 ME252

1 I I

COMPONENTS Drive Control Panel Components

240 1

Resistor Panel Components

2401

Material Handling Contactor Components

z ?.

E I al 3

-. -

(C1

0 3

B 2

z z

0 z

'El

e 0

'El

0 3 tD

MF-MR Contactor Components

MG-MS.MPsMW Contactor Components

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