Toyota 30 Series User manual

This manual covers the service procedures for the modified portions of
TOYOTA BATTERY FORKLIFT 5FBCU15
- 30 series. Please use this
manual for quick accurate servicing of these vehicles and as the tool for
sales and service activities.
As this manual is edited as a supplement to Repair Manual for the
5FBCU15 - 30series, please refer to Repair Manual (Pub. No.CU305) for
the matters not covered herein.
Thismanualdeals withtheabovemodelsasof October
1999. Pleaseunder -
standthatdisagreementcantakeplacebetweenthedescriptionsinthemanual
and actual vehiclesdue to change in design and specifications.Any change
or modifications thereafter will be informed by Toyota Industrial Equipment
Parts
& Service News.
For your reference, we herewithindicatethetitles of relevantmanuals
TOYOTAINDUSTRIALEQUIPMENTREPAIR MANUAL
5FBCU15 - 30 (No.CU305)
TOYOTA MOTOR CORPORATION

SECTION INDEX
NAME I SECTION
GENERAL
DRIVE UNIT(2.3TON SERIES)
FRONT AXLE (2.3TON SERIES)~
-
REAR AXLE (2.3TON SERIES)
MAST
(2.3 TON SERIES)
CYLINDER (2.3TONSERIES)
OILCONTROLVALVE
APPENDIX

GENERAL
EXTERIOR VIEWS ....................................................... 0 - 2
VEHICLEMODEL ..................................................... 0 - 3
LUBRICATIONCHART (2.3 TON SERIES) ............. 0 - 4
PERIODICMAINTENANCE .......................................... 0 - 5
INFORMATIONON REFERENCEMANUAL ........... 0 - 6
MEANING OF LATEST MODIFICATION ON
......................
SFBCU 2 TON AND 3 TON SERIES
0-7

EXTERIOR VIEWS

VEHICLEMODEL
*: Thesehigh capacity (batterycompartment) models are not establishedin EEC specification.
Note: Way and the positionof the model and frame No. indicationshave been unchanged.
Typeson Spec.
STDspec.models
Dustproof models
Model
36Vl48V
5FBCU15
5FBCU18
5FBCU20
5FBCU25
5FBCU30
5FBCHU20
5FBCHU25
30-5FBCU15
30-5FBCU18
30-5FBCU20
30-5FBCU25
30-5FBCU30
30-5FBCHU20
30-5FBCHU25
Load
Loadcenter
= 500mm
(kg)
1500
1750
2000
2500
3000
2000
2500
1500
1750
2000
2500
3000
2000
2500
Capacity
Loadcenter
= 24in
(Ibs)
3000
3500
4000
5000
6000
4000
5000
3000
3500
4000
5000
6000
4000
5000
STD capacitybattery
compartment
High capacity
*
STD capacitybattery
compartment
High capacity
*
1 - ton
series
2
- ton
series
3
- ton
series
2
- ton
series
1 - ton
series
2
- ton
series
3
- ton
series
2
- ton
series

LUBRICATIONCHART (2.3 TON SERIES)
I*
2*
3*
4*
5
6
7
8
9
lo*
11*
12*
13*
Chain
Mastsupportbushing
Tiltcylinder frontpin
Frontwheelbearing
Differential
& transmission
Brakefluidreservoir tank
Tilt steering locking mechanism
Tiltsteeringuniversaljoint
Oiltank
Rear wheelbealing
Steeringknucklekingpin
Tie rod endpin
Rear axlecylinderend pin
Rear axlebeam front pin
Rear axlebeam rear pin
Located on right andleft sides
lnspect every
8 hours (daily)
lnspect every40 hours (weekly)
lnspect every170 hours (monthly)
lnspect every 1000hours (6monthly)
lnspectevery2000hours (annually)
lnspect and service
Replace
MPgrease
Engineoil
Hypoidgear oil
Hydraulicoil
Brakefluid
Molybdenumdisulfidegrease

PERIODICMAINTENANCE
INSPECTIONMETHOD
I: Inspection. Repair or replacement if required.
M: Measurement.Repair or adjustment if required.
T Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector
Note: This manual covers only the portions different from conventional models. Refer to the
Repair Manual (No.CU305) for the maintenance of other portions.
InspectionPeriod
Item
Months
Hours
TRAVELINGEQUIPMENT
6
1000
Rear axle
1
170
12
2000
3
500
Cracks,damageand
deformationof beam
Loosenessof axle beam in
vehiclelongitudinaldirection
(2.3 tonseries:from October
1 999)
I
M*
0
0

-
INFORMATIONON REFERENCEMANUAL
3nandafter October 1999 productsof 5FBCU series,choosethe referencepublicationfor proper servic-
ng in accordance with the following instructions:
0: Applicablereference
Remarks
RefertoParts
& Service
NewsGE - 8031of Dec.
1998.
Referto Parts
& Service
NewsGE
- 8024of Oct.
1998
5FBCU15 - 30
Section
GENERAL
BAlTERY
CONTROLCIRCUIT
MULTIDISPLAYFUNCTIONS
ELECTRICALSYSTEMTROUBLESHOOTING
MOTOR
Repairmanual
Pub.No.CU305
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
DRIVE UNIT
FRONTAXLE
REARAXLE
Thisbook
0
0
0
0
0
0
0
0
1 ton series
2.3 ton series
1 tonseries
2.3 ton series
1 tonseries
2.3 ton series
STEERING
BRAKE
BODY
& FRAME
MATERIALHANDLINGSYSTEM
1 ton series
2.3 ton series
1 ton series
2.3 ton series
MAST
Tiltcylinder
OILPUMP
OILCONTROLVALVE
APPENDIX
CYLINDER
Lift

MEANING OF LATEST MODIFICATION ON 5FBCU
2 TON AND 3 TON SERIES
Accompanied by the model change - Developmentto 7FGCU 2 ton & 3 ton series from GFGCU 2 ton & 3
ton series - , severalnew designfeatures of 7FGC 2 ton & 3 ton series havealso been adaptedfor 5FBCU
2 ton & 3 ton series. As the effect that, severalcomponentshavebeen standardizedfor the developments
as well as for service efficiencies and conveniences.
The major componentsinvolvedare tabulated as follows:
Standardization between model series
Meaningof MarksUsed for Listitem
0
Standardizedbetween 5FBCUseriesand 7FGCUseries, or interchangeable.
Partly standardizedbetween 5FBCUseries and 7FGCUseries,or PartlyInterchangeable.
x Exclusivelyfor 5FBCUseries
1
3 ton series
x
Components
Mast Assembly V.FV.FSV.
Q FV
2 ton series
x
Frontaxle
Rear axle
Tiresize
Forks
Seat belt
Differentialhousing
Axle housing
Axle bracket
Axle shaft
Wheelbearing
Wheel
& hubdrum
Differentialcase
Rear axlebeam
Rear axle cylinder
Tie
rod
Steeringknuckle
Wheelbearing
Mount rubber
or bushing
Front tire
Rear tire
x
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
x
0
0
0

DRIVE UNIT
(2.3 TON SERIES)
page m
GENERAL ........................................................................ 1-2
..........................................................
SPECIFICATIONS 1 - 3
..............................................................
COMPONENTS 1 - 4
DRIVE UNIT ASSY ......................................................... 1 - 5
...............................................
REMOVAL*INSTALLATION 1 - 5
DISASSEMBLY*INSPECTION*REASSEMBLY ................... 1 - 8
DIFFERENTIAL CASE ASSY ....................................... 1 - 14
..................
DISASSEMBLY - INSPECTION - REASSEMBLY 1 - 14

GENERAL

SPECIFICATIONS
VehicleSeries 2 ton Series
Item STD
3 ton Series
Dustproof STD Dustproof
Ringgear teeth
Drivepinionteeth
Gear ratio (Differential)
+
C
+
+-
C
+
+
Piniongear
Sidegear
22
60
2.727
35
6
5.833
4
10
2
14
Numberof gears
Teeth
Numberof gears
Teeth
17
65
3.824
22
60
2.727
Drivegearteeth
Output gearteeth
Gearratio(Transmission)
Drive unit oil capacity
J? ( (USgal)
C
17
65
3.824
7.5(1.98)

COMPONENTS

DRIVE UNIT ASSY
REMOVAL - INSTALLATION
T = N-m (kgf - cm) [ft-lbfl

RemovalProcedure
1 Removethe mast. (Seepage 4 - 7)
2 Removethe batteryhood Wldriver seat.
3 Removethe batteryASSY.
4 Jack up the vehicleand removethe front wheels.
5
Draindifferentialoil. [Point 11
6
Disconnect the drive motor wiring.
7 Disconnect the speed sensor sub - harness connector.
8 Disconnect the brake pipe (from the wheel cylinder).
9 Removethe front toe
- board.
10 Disconnect the parking brake wires.
11 Remove the drive motor set bolts.
12 Support the front axle
& drivemotor ASSY with a hoist and garage jack. [Point 21
13 Remove the front axle bracket set bolts. [Point 31
14 Removethe front axle & drivemotor ASSY.
15 Disconnectthe drive unit and drivemotor
16 Remove the front axle shaft.
[Point 41
17 Remove the front axlehousingWlbrake.
18 Remove the speed sensor cover and the sensor.
InstallationProcedure
The installationprocedureis the reverse of the removalprocedure.
Note:
Bleed air from the brake system after installation.
Point Operations
[Point 11
Installation:
After reassembly,fill hypoidgear oilto the specifiedlevel.
A
= 15 mm (0.59in) or less

[Point 21
Removal.lnstallation:
Installhub nuts on hub bolts on the left and right side, and
sling wireat the taperedportion.
[Point 31
Removal:
Remove the reamer bolts. (2pcs. each at top and bottom
on one side)
SST09310
- 23320 - 71
[Point 41
Removal.Installation:
Operatecarefullyso as nottobringthe axleshaft intocon -
tact with the oil seal lip to damage it.

N.m (kgf - cm) [ft-lbfl
DisassemblyProcedure
1 Removethe differentialcover. [Point 11
2
Measurethe ring gear backlash. [Point 21
3 Removethe bearing cap and adjusting nut. [Point 31
4
Remove the differentialcase ASSY. (Seepage 1 - 1 4 for the disassembly,inspectionandreassembly
procedure.)
5
Removethe drivepinion ASSY. [Point 41
6
Removethe output gear. [Point 51
7 Removethe drive pinion,bearing, spacer and shimfrom the retainer. [Point 61
8 Remove the pilot bearing. [Point 71
9
Removethe drive pinionbearing inner race. [Point 81
10 Removethe drive gear
ReassemblyProcedure
The reassembly procedure is the reverse of the disassemblyprocedure.

PointOperations
[Point 11
Reassembly:
Applysealingagent (ThreeBond'sNo.1217Cor theequiva
-
lent) on the mating surfaces of the differential cover and
housingbefore reassembly.
[Point 21
Inspection:
Measurethe ringgear backlash.
Standard:0.2 - 0.3 mm (0.008 - 0.012 in)
[Point 31
Disassembly:
Put matchmarks onthe bearingcapanddifferential hous
-
ing.
Reassembly:
Installtheadjustingnuts andbearingcap.
1, Installthe adjustingnuts.
2. Installthe bearing cap by aligningthe match marks and
temporarilytightenthe setbolt.
T = 19.6 N-m (200 kgf - cm) [I 4.5 ft-lbf]
3. Setthedialgauge inthethrustdirectionof thedifferential
case.
4. Usethe SST andtightenuntilthethrustclearanceis elimi -
nated.
SST09630
- 10110 - 71
5. Tightenadjustingnuts onboth sidesby onenotcheach.
6. Setthe dialgaugeverticalto thering gear toothsurface,
and measurethe backlash.
Standard:0.2 - 0.3 mm (0.008 - 0.012in)

Heeal
contact
If the standardis notsatisfied,adjustbyturningthe adjust -
ing nut to move the differential case ASSY in the thrust di -
rection.
(1)When the backlash is excessive:
Loosen the adjusting nut on the ring gear teeth side
andtightentheadjustingnutontherear sideas much
to bring the ring gear closertothe drive pinion.
(2)When the backlash is insufficient:
Loosen the adjusting nut of the rear side of the ring
gear and tightentheadjustingnutontheteethsideas
much to bring the ring gear away from the drive pin
-
ion.
7. Sidebearingstartingtorque (Referenceonly):
Measurethe torque by turning the output gear lock nut
with a torque wrench.
Standard:
6.37 - 15.20 N-m(65 - 155kgf - cm)
[4.70 - 11.21 ft - lbf]
8. Tightenthe adjustingnutontherear side of thering gear
further by 1.5 to
2 notches.
9. Installtheadjustingnutlockplate.
10.Finallytightenthe bearingcapset bolts.
T = 117.7 - 137.3 N-m (1200 - 1400kgf - cm)
[86.82 - 101.3 ft-lbfl
11. Check the tooth contact.
(1) Uniformlycoat red lead thinly on both faces of
7 to 8
gear teeth, and turn the ring gear forward and back -
ward several times after installing a box wrench on
the output gear lock nut. Judgethe gear teethcontact
by observingthe pattern formed on the gear teeth. If
the tooth contact is not correct, make adjustment ac
-
cording to the " Drive Pinion Protrusion Adjustment "
and " RingGear BacklashandDifferentialCase Bear -
ingStartingTorqueAdjustment " procedures.
(2) Correctteeth contact
Thepatternshouldbeslightlyleaningtotheinsidecircle
of the ring gear with respectto the center of the tooth
length, as shown.
(3) Heealcontact
Move the drive pinion croser to the ring gear by de
-
creasing the drive pinion adjusting shim thickness.
Then move the ring gear away from the pinion to ad
-
justthe backlash.
(4) Toe contact
Movethepinionawayfromthering gearby increasing
the drivepinion adjustingshimthickness.Then move
the ring gear closer to the pinion to adjust the back
-
lash.

Flank
contact
Face
contact
0 Good examples 0
Point contact
(5) Flank contact (lowshallow contact)
Movethepinionawayfrom theringgearbyincreasing
thedrivepinionadjustingshimthickness.Then move
the ring gear closer to the pinion to adjust the back
-
lash.
(6) Face contact (high shallow contact)
Movethe pinion closer to the ring gear by decreasing
the drivepinionadjustingshimthickness.Then move
the ringgear awayfrom the pinionto adjustthe back
-
lash.
[Point 41
Reassembiy:
Adjustthedrivepinionprotrusionbymeansof thedrivepin -
ion bearing retainer shims. Select the shim by teeth con -
tact inspection.(See Point 3.)
Shimthickness:
0.10.0.15.0.35and 0.45 mm
(0.0039~0.0059~0.0138and 0.01 77 in)
[Point 51
Reassembly:
After the drive pinion bearing starting torque adjustment,
caulk the outputgear lock nut.
[Point 61
Reassembly:
SST 09370 - 20270 - 7 1