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