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 specifica-
tions. Any change or modifications thereafter will be informed by
Toyota Industrial Vehicles' Parts & Service News.

TOYOTA MOTOR CORPORATION

 SECTION INDEX
NAME 1 SECT1

e
x m
CC
MULTIDISPLAY FUNCTIONS
ELECTRICAL SYSTEM TRouBLEsHooTlNG m A

MOTOR
DRIVE UNIT
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY & FRAME
y
MAST
CYLINDER
OIL PUMP
p a

APPENDIX
 GENERAL
Page
EXTERIOR VIEWS ........................................ 0-2
VEHICLE MODEL ................................................ 0-3
FRAME NUMBER ............................................... 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
STANDARD BOLT & NUT TIGHTENING
TORQUE .......................................................... 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ........................................................ 0-11
TIGHTENING TORQUE TABLE ............................... 0-12
PRECOAT BOLTS ............................................... 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 ...................................... 0-16
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 capacity
battery
2-ton
compartment
STD spec. series
models

3-ton
series

High capacity 2-ton

% series

I -ton
series

STD capacity
battery
2-ton
compartment
Dust proof series
models

%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

Stamping Form
Models Remark
[( ) showing EEC specifications for ECI

5FBCU15-10011
1-ton series 5FBCU1 5
(5FBCU15 @ 10011)

5FBCU18
5FBCU25-10011
5FBCU20
(5FBCU25 @ 1001 1 )
2-ton series 5FBCU25

5FBCHU20 5FBCHU25-10011
5FBCHU25 (5FBCHU25 @ 1001 1)

5FBCU30-10011
3-ton series 5FBCU30
(5FBCU30 @ 1001 1 )

305FBCU15-10011
1-ton series 30-5FBCU 1 5
(305FBCU1 5 @1001
I 1)

30-5FBCU 1 8
305FBCU25-10011
30-5FBCU20
(305FBCU25 @ 1001 1)
2-ton series 30-5FBCU25

30-5FBCHU20 305FBCHU25-10011
30-5FBCHU25 (305FBCHU25 @ 1001 1 1

305FBCU30-10011
3-ton series 30-5FBCU30
(305FBCU30 @ 1001 1)
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, fol-
lowed 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 indi-

cated directly, the part name is
described on the either side of
the illustration.

Example: 1 Piping

I I

Oil Pump Disassembly Procedure

Disassembly Procedure
1 Remove the cover. [Point 11

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

[Point 1I 4
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)
2. How t o read components figures (Example)
( 1 ) The components figure use the illustra-
tion 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 FIG number in parts catalog
components figure indicates the Fig.
number in the parts catalog.

3. 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 re-
quiring 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 Number of teeth (00 )
PS Power steering U IS Undersize
RH Right hand W/ With
Society of Automotive
SAE
Engineers (USA)
- - - ---- -- -- - - - - - --
 0-7

LIST OF ABBREVIATIONS AND SYMBOLS

Symbol Name Symbol Name Symbol Name
BATT Battery FRY Flasher Relay MScH Charger Magnet Switch
Bz Buzzer H Horn MW Field Weakning Contactor
CADIP DriveIPump Absorber ,,,L Back-up Lamp, LH PBcpu Computer Print Board
Capacitor ,.L
,, Back-up Lamp, RH PBsps SPS Print Board
CH Charger LC-L Clearance Lamp, LH PL, Working Pilot Lamp
CHI, Forward Chime Clearance Lamp, RH RF Fan Resistor
CHI, Reverse Chime LF-L Flasher Lamp, LH RFW Field Weakning Resistor
CSDIP DriveIPump Current LF-,, Flasher Lamp, LH (Rear) RG Regenerative Resistor
Sensor LF-R Flasher Lamp, RH RADIP Drivelpump Absorber
CS, Power Steering Current L,-, Flasher Lamp, RH (Rear) Resistor
Sensor LH-L Head Lamp, LH SA Surge Absorber
DcH Charger Diode LH-R Head Lamp, RH SDD Drive SIT Driver
DC-SDD DC-DC Converter & LR-F Rotaly Forward Lamp SDP Pump SIT Driver
Source Drive (Drive) LR-R Rotaly Reverse Lamp SLL Lequid Level Sensor
DC-SDP DC-DC Converter & LSATT,,, Attachment Limit Switch SN 1 Snubber No. 1
Source Drive (Pump) No. 112 SSP Speed Sensor
DF112 FLY-WHEELDiode, LSB Brake Limit Switch SP Steering Pressure Sensor
No. 112 LSD Dead Man Limit Switch STH Thermo Sensor
DF314 FLY-WHEEL Diode No.314 LSL1/2 Lift Limit Switch No.112 SWAc Accel Switch
DG Regenerative Diode LS, Parking Brake Limit SW, Flasher Switch
DlSP Display Switch SW, Horn Switch
DMD,, DriveIPump Motor LS, Stop lamp limit Switch SW, Key Switch
DMps Power Steering Motor LST-, Stop Lamp, LH SW, Light Switch
DSBu Back-up Direction Switch LsT-, Stop Lamp, RH SW, Speed Control Switch
DSF Forward Direction Switch LS, Tilt Limit Switch TF Transformer
DSFo Forward Optional LT-L Tail Lamp, LH TG Regenerative Transistor
Direction Switch LT-R Tail Lamp, RH THR Thermal Relay
DSR Reverse Direction Switch ,L Working Lamp TM Main Transistor
F1 Drive Fuse MF Forward Contactor TMP Main Pump Transistor
F2 Pump Fuse MG Regenerative Contactor TMps Main Power Steering
F3 Power Steering Fuse MP Pump Contactor Transistor
F4 Lamp Fuse M PS Power Steering Contactor TU Timer Unit
F5 Control Circuit Fuse MR Reverse Contactor VRAD Accel Drive Vari-Ohm
F c ~ Charger Fuse MS Short Contactor
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
(1 Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure 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 accord-
ing 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 move-
ment.

1. 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. Al-
ways use a circuit tester according t o its operation manual. Cautions when the polarities are dif-
ferent between the analog type and digital type are described below.

Circuit tester range: Analog type + kohm range Digital type + 2 Mohm range
Forward direction Reverse direction

Black Red
probe probe

Measurement result example

Analog type Digital type

Continuity
No continuity
Forward shall exist
11 Kn 1
Continuity
No continuity
Reverse shall exist
00 2 MSZ

As seen from the example above, the measurement results with the analog and digital types are re-
verse. In measurement with a digital type circuit tester, therefore, use the tester probes as shown be-
iow.
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 mea-

sured
with t w o types of circuit testers having different
Current power supply voltages are different.
in
forward This manual describes the results of measurement
direction
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. Identification by bolt shape 2. Identification by part No.

Shape and class Class Hexagon head bolt

4 = 4T

GD-
5 = 5T
Bolt head No. 6 = 6T
7 = 7T Parts No.
Hexagon 8 = 8T
91 61 1-40625
head bolt
Length (mm)
No mark 4T
Diameter (mm)

Hexagon
No mark 4T
flange bolt
iameter

Hexagon
head bolt 0 Two protruding
lines
5T

Hexagon Two protruding

6T
flange bolt ines
Stud bolt

Hexagon
head bolt 0 Three protruding
lines
7T

Parts No.
92 1 32-406 1 4
Hexagon
head bolt @ Four protruding
lines
8T Length (mm)
Diameter (mml

Welded bolt 4T

k
iameter
No mark 4T
I
Stud bolt

Grooved 6T
0-1 2

TIGHTENING TORQUE TABLE

13 ) 130 1 9

16 1.5 113 f 1150 1 83 - I

I
- I
I
-
6 1 .O 6.4 1 65 1 56 in-lbf I
I
I
I
I I I I
8 1.25 16 f
I
160 1 12 I
I
I
I
I I I
10 1.25 32 j 330 f 24 - I
I
- I
I
-
5T I I I I
12 1.25 59 1
I
600 f
I
43
I
I
I
I
I
I
14 1.5 91 1
I
930 1
I
67
I
I
I
I
I
I
16 1.5 137 1 1400 1 101
I
I
I
I

6 1 .O 7.8 1 80 1 69 in-lbf 8.8 1 90 1

I
78 in-lbf
8 1.25 19 1 195 1 14 21 1 215 1 16
6T 10 1.25 39 400 29 43 440 1 32
12 1.25 72 1 730 j 53 79 1 810 j 59
14 1.5 - I
I
I
- I
I
I
- 123 / 1250 / 90
6 1 .O 11 /
I
110 /
I
8 12 /
I
120 j 9
8 1.25 25 260 f 19 28 290 21
I I I I
10 1.25 52 j 530 j 38 58 1 590 f 43
7T \ I I I
12 1.25 95 1 970 j 70 103 1 1050 1 76
I I I I
14 1.5 147 1 1500 f 108 167 1 1700 1 123
I I I I
16 1.5 226 1 2300 ) 166 - I
I
- I
I
-
8 1.25 29 f 300 1 22 33 1 330 1 24
8T 10 1.25 61 1 620 1 45 68 1 690 1 50
12 1.25 110 1 1100 1 80 120 1250 1 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 fol-

lowing cases.
(a) After is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.

Note:
For torque check, use the lower limit of the allowable tight-
ening 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.

Standard tightening torque N-m (kgf-cm) [ft-lbfl Hose inside

Nominal diameter
diameter
of screw Standard Tightening range mm (in).
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 -- 52 ( 480 - 530) [34.7 - 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 118 ( 1 2 0 0 ) [ 86.81 112-123(1140--12501[82.5- 90.41 19 (0.75)
1.511 6 - 12UNF 137 (1400) [101.3] 130 - 144 (1330 -
1470) 196.2 - 106.41 25 (0.98)
PF1 14 25 ( 250) [ 18.1I 24 -- 26 1 240 - 270) I17.4 -- 19.51 6 (0.24)
PF318 49 ( 500) [ 36.21 47 - 52 ( 480 -- 530) [34.7 - 38.31 9 (0.35)
PFI I 2 59 ( 600) [ 43.41 56 -- 62 ( 570 - 630) 141.2 -- 45.61 12 (0.47)
PF314 1 18 (1200) [ 86.81 1 12 -- 123 (1140 - 1250) 182.5 - 90.41 19 (0.75)
PF 1 137 (1400) [101.31 130 - 144 (1330 -- 1470) 196.2 -- 106.41 25 (0.98)
0-1 4

WlRE ROPE SUSPENSION ANGLE LIST

Lifting Compres- Suspension Lifting Compres- Suspension
Tension Tension
angle sion method angle sion method

0O 1.OO time 0 time

L1
- 90° 1.41 time 1.OO time
by5
2' A
30 O 1.04 time 0.27 time
%

h0 1 20° 2.00 time 1.73 time

2% k0
60 O 1.1 6 time 0.58 time

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (ton) [Ibl

Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0O 0O 30 O 60 O 90 O 0O 30 O 60 O 90 O
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in) [ I 9401
[48071 [683.6] [ I 3671 [ I 3231 [ I 1691 [970] [27341 [2646] 123371
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm (1.74) (1.56) (1.28)
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8)
(0.32 in)
[70781 [992.3] [ I 9851 [ I 91 81 [ I 7201 [ I 41 11 [3969] [39371 [3440] [23221
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[ I 1.691 [I 565.61 [3153] [3021] [2646] [2205] [6174] [5954] 152921 144101 -

76880 10980 21570 21280 18630 14710 43150 41 190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.51 (4.4) (4.2) (3.8) (3.0)
(0.5in)
1173871 [2469.5] 148511 [4631] [4190] 133081 [9702] 192611 [83791 166151
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [ I 23481 [ I 19071 [ I 05841 183791
COMPONENTS WEIGHT
Item Model Approx Weight kg (Ibs)

STD 6 6 (145)
1 ton series
Dust proof type 75 (165)

STD 1 0 4 (229)
Drive Motor 2 ton series
Dust proof type 1 2 0 (264)

STD 1 0 4 (229)
3 ton series
Dust proof type 1 2 0 (264)
Motor
STD 3 8 (84)
1 ton series
Dust proof type 4 2 (92)

STD 75 (165)
Pump Motor 2 ton series
Dust proof type 7 5 (165)

STD 7 5 (165)
3 ton series
Dust proof type 7 5 (165)

5FBCU1 5 4 4 0 (970)

5FBCU1 8 4 1 0 (904)

5FBCU20 480 (1058)

Counter Weight 5FBCU25 825 (1819)

5FBCU30 8 2 5 (18 1 9)

5FBCHU20 41 0 (904)

5FBCHU25 4 8 0 (1058)

Mast WILift bracket (with Lift cylinder,

1 ton series 3 9 0 (860)
less Back rest and forks).
[Max. Fork height = 3000mm (118 in)]
2 ton series 4 6 0 (1014)

3 ton series 6 0 0 (1323)

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

RECOMMENDED LUBRICANTS AND CAPACITIES
APPLICATION TYPE CAPACITY (TOTAL)
Differential & transmission STD: Hypoid gear oil SAE85W-90 1.5 ton 7.0 Q
(VALVOLINE80W90) (1.85 US gal.)
20s: Hypoid gear oil W
(VALVOLINE80W90) 1.8 -- 3 t o n 7.5 Q
(1.98 US gal.)

Hydraulic oil STD: Hydraulic oil I S 0 VG32 (Daph- 1.5 ton

ne Fluid AW32)
* 1 6 Q (4.2 US gal.)
* 2 1 Q (5.5 US gal.)
20s: Auto Fluid
1.8- 3 t o n * 2 0 Q (5.3 US gal.)
* * 2 6 Q (6.9 US gal.)

Brake oil STD: SAE J-1703 DOT-3

(INTAC AUTOMOTIVE PRODUCTS
INC. GC325) Proper quantity
20s: GC325

Grease *** STD: MP Grease No.2

(VALVOLINE BRB GRESE)
20s: 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
Height [ 3000 3300 4300 5500
Remarks
Capacity or less -4000 - 5000 - 6000
5FBCU1 5 Total
16 17.5 19 21 Same as 5FB15
30-5FBCU1 5 (Q1
&
Oil tank
13 14.5 16 18 5FB20 series
(0)

5FBCU 18,20,25
5FBCUH20, H 2 5
5FBCU30 Total
20 22 24 26
(Q)
30-5FBCU 18, 20, 2 5
30-5FBCUH20,25 Same as 5FB30
30-5FBCU30
series

Oil tank
16.5 18.5 20.5 22.5
(Q 1

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

2. +
Adjust oil amount within 0 -- 10 mm (0.39 in) dif-
ference 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

I 1. Chain I Inspect every 8 hours (daily)

2. Mast support bushing I1 lnspect every 40 hours (weekly)

3. Tilt cylinder front pin 111 lnspect every 170 hours (monthly)
4. Front wheel bearing IV lnspect every 1000 hours (6monthly)
5. Differential & transmission V lnspect every 2000 hours (annually)
6. Brake fluid reservoir tank 0 lnspect and service
7. Tilt steering locking mechanism Replace
8. Tilt steering universal joint
9. Oil tank 1. MP grease
10. Rear wheel bealing 2. Engine oil
1 1. Steering knuckle king pin 3. Hypoid gear oil
12. Rear axle beam front 4. Hydraulic oil
13. Rear axle cylicder rod joint (1 ton series) 5. 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

Inspection Period Months 1 3 6 12

Item Hours 170 500 1000 2000
ELECTRICAL SYSTEM
Abnormal sound during revolution I 0 0 0 0
Loose terminal T 0 0 0 0
Insulation resistance M 0 0 0
Motor
Brush wear and sliding contact status I 0 0
Commutator fouling and damage I 0 0
Brush spring fatigue M 0
Charge I 0 0 0 0
Battery fluid level I 0 0 0 0
Battery fluid specific gravity M 0 0 0 0
Loose terminal I 0 0 0 0
Battery Abnormality at top of battery and
battery case
I 0 0 0 0
Insulation resistance M 0 0 0
Cell voltage measurement after
charging
M 0
Timer operation I 0 0 0 0
Terminal loosening I 0 0 0 0
Charger Operating voltage measurement M 0 0 0
Magnet switch function, contact
fouling and roughening
I 0
Loose contact, damage and wear I 0 0 0 0
Auxiliary contact function, fouling and
I 0 0 0 0
wear
Magnet
Arc chute installation status I 0
contactor
Timing and functioning I 0
Loose coil installation I 0
Loose main circuit lead installation I 0
Timing and operating function I ' 0 0 0 0
Microswitch
Damage and loose installation I 0 0 0 0
I-
Inspection Period Months 1 3 6 12
Item - Hours 170 500 1000 2000
Direction lever Operating conditions and damage I 0 0 0 0
Operation I 0 0 0 0
Controller Inside fouling and damage C 0 0 0 0
Overcurrent limit valve M 0
Fuse Loosening I 0 0 0 0
Damage of wiring harness and loose
clamp
I 0 0 0 0
Wiring
(including Loose connection and taping status I 0 0 0 0
charging cord) Battery connector damage and
connection status
I 0 0 0 0
Accelerator Operating and damage I 0 0 0 0
POWER TRAIN
Oil leak I 0 0 0 0
Differential,
Oil level I 0 0 0 0
Transmission
Loosening of nuts and bolts T 0
TRAVELING EQUIPMENT
Tire cuts, damage and uneven wearing I 0 0 0 0
Loose rim and hub nuts T 0 0 0 0
Tire groove depth M 0 0 0 0
Metal chips, pebbles and other foreign
matter trapped in tire grooves
I 0 0 0 0
Wheels
Rim and disc wheel damage I 0 0 0 0
Abnormal sound and looseness of
I 0 0 0 0
front wheel bearing
Abnormal sound and looseness of rear
wheel bearing
I 0 0 0 0
Cracks, damage and deformation of
Front axle I 0
housing
Cracks, damage and deformation of
Rear axle I 0
beam
 Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000
STEERING SYSTEM
Play and looseness I 0 0 0 0
Steering wheel
Function I 0 0 0 0
Oil leak I 0 0 0 0
Steering valve
Looseness of mounting T 0 0 0 0
Oil leak I 0 0 0 0
Power steering
Damage of power steering hose I 0
King pin looseness I 0 0 0 0
Knuckle
Cracks and deformation I 0
BRAKING SYSTEM
Play and reserve M 0 0 0 0
Brake pedal
Braking effect I 0 0 0 0
Pull margin I 0 0 0 0
Braking effect I 0 0 0 0
Parking brake
Rod and cable looseness and damage I 0 0 0 0
Ratchet wear and damage I 0
Brake pipe and
hose
Leakage, damage and mounting status I 0 0 0 0
Brake fluid Fluid level I 0 0 0 0
Master cylinder
or brake valve Function, wear, damage, leak and
I 0
and wheel cyl- mounting looseness
inder
Clearance between drum and lining M 0 0 0 0
Wear of shoe sliding portion and lining I 0
Drum wear and damage I 0
Brake drum
Shoe operation condition I 0
and brake shoe
Anchor pin rusting I 0
Return spring fatigue M 0
Automatic adjuster function I 0
Deformation, cracks and damage I 0
Backing plate
Loose mounting T 0
 Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000
MATERIAL HANDLING SYSTEM
I Abnormality of fork and stopper pin / I 1 0
Misalignment between left and right
/ Forks
fork fingers
I 0

Cracks at fork root and welded part I*

Deformation and damage of each part
and crack at welded part
Mast and lift bracket looseness
Wear and damage of mast support
Mast and fork
bush
bracket
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 lubrication
chain wheel Abnormality of chain anchor bolt
Wear, damage and rotating condition
of chain wheel
Various Abnormality and mounting condition
I 0 0 0 0
attachments of each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
mounting
Deformation and damage of rod, rod
Cylinder screw and rod end
Cylinder operation
Natural drop and natural forward tilt
(hydraulic drift)
I Oil leak and damage I I I o ~ o I o I o
Wear and damage of pin and cylinder
Cylinder bearing
/ Lifting speed / I " I o o I o
Uneven movement I 0 0 0 0
Oil pump Oil leak and abnormal sound I 0 0 0 0
Oil level and contamination
Hydraulic oil
Tank and oil strainer
tank
I Oil leak I 0 0 0 1 0
-
- Inspection Period Months 1 3 6 12
Item --++ Hours 170 500 1000 2000
Loose linkage I 0 0 0 0
Control lever
Operation I 0 0 0 0
Oil leak I 0 0 0 0
Oil control Relief pressure measurement M 0
valve Relief valve and tilt lock valve
I 0 0 0 0
functions
Oil leak I 0 0 0 0
Hydraulic Deformation and damage I 0 0 0 0
piping Loose joint T 0 0 0 0
Hoise tension and twisting I 0 0 0 0
SAFETY DEVICES, ETC.
Cracks at welded portion I 0 0 0 0
Head guard
Deformation and damage I 0 0 0 0
Loosening of mounting T 0 0 0 0
Back-rest
Deformation, crack and damage I 0 0 0 0
Lighting
Function and mounting condition I 0 0 0 3
system
Horn Function and mounting condition I 0 0 0 0
Direction
Function and mounting condition I 0 0 0 0
indicator
Instruments Functions I 0 0 0 0
Back u p buzzer Function and mounting condition I 0 0 0 0
Rear-view Dirt, damage I 0 0 0 0
mirror Rear reflection status I 0 0 0 0
Seat Loosening and damage of mounting I 0 0 0 0
Damage and cracks of frame, cross
I 0
Body members, etc.
Bolt looseness T 0
Other Grease up L 0 0 0 C
0-24

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Inspection (operating hours or Months 1 3 6 12
months, whichever is earlier) Hours 170 500 1000 2000
Brake fluid • •
Hydraulic oil • •
Hydraulic oil return filter
a a a
(New veh~cle)

Differential and transmission oil •

Wheel bearing grease •
Master cylinder rubber parts •
Wheel cylinder rubber parts •
Reserve tank hose
a
(Every 2 years)

Power steering hose

a
(Every 2 years)

Internal rubber parts of power steering system

a
(Every 2 years)

Material handling hose

a
(Every 2 years)

Chain
a
(Every 3 years)
-
 BATTERY
Page
GENERAL ............................................................1-2
CAPACITY ON SPEC .......................................... 1-2
WEIGHT OF BATTERY WICASE ............................. 1-2
RECOMMENDED BATTERIES ................................. 1-2
BATTERY COMPARTMENT &
MINIMUM WEIGHT REQUIRED ....................... 1-5
BATTERY COMPARTMENT SIZE
ADJUSTMENT ................................................. 1-6
BATTERIES SUITABLE TO BATTERY
ROLL OUT SPEC. COMPARTMENT ................ 1-8
BATTERY WEIGHT SUPPLEMENT
ADJUSTMENT BY SUB-WEIGHT ..................... 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 High capacity
Model
36 V 48 V 36 V 48 V
5FBCU1 5
595 425 680 51 0
30-5FBCU1 5
5FBCU1 8
680 51 0 935 680
30-5FBCU1 8
5FBCU20
. 680 510 935 610
30-5FBCU20
5FBCU25 680 557 935 680
Capacity 5FBCU25 - -
680 935
AH16HR (Compact model)
5FBCU30
30-5FBCU30 '
5FBCHU20
935 1020
30-5FBCHU20
. 5FBCHU25
30-5FBCHU25
5FBCHU25 - -
935 1020
(Compact model)

WEIGHT OF BATTERY WICASE

Approx. weight battery Approx. weight battery
Model ASSY Wlcase Model ASSY Wlcase
kg (Ibs) kg (Ibs)
5FBCU1 5 5FBCHU20
830 (1840) 1360 (3000)
30-5FBCU1 5 30-5FBCHU20
5FBCU20 5FBCHU25
1090 (2400) 1360 (3000)
30-5F BCU20 30-5FBCHU25
5FBCU25
1090 (2400)
30-5FBCU25
5FBCU30
1360 (3000)
30-5FBCU30

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.

Installed battery Battery case

Single cell dimensions Inside dimensions
Type Voltage Capacity
Manufacturer Model mm (in) mm (in)
AH16HR
V Length Width Height Length Width Height
159 165 575 660 862 575
36 EXlDE 18E85-17 680 (6.26) (6.50) (22.64) (25.98) (33.94) (22.64)

t t 18E100-17 800 t 578

(22.76)
. 1

554
t GNB 18-75C-17 600 t (21.81

t t 1 8-85C- 1 7 680 t T t
160 166 575
5FBCU1 5 t C&D 18C75-17 600 (6.30) (6.54) (22.64)

t t 1 8C85-17 680 t t t
157 127 574
48 EXlDE 24E75-13 450 (6.18) (5.00) (22.60)
578
t t 24E 1 00- 1 3 600 t (22.76)
554
t GNB 24-75C-13 450 t t (22.60)

t t 24-85C-13 510 t t t
158 128 575
T C&D 24C75-13 450 (6.18) (5.04) (22.64)

t t 24C85-13 510 t t t
[MAXI
159 165 578
36 EXlDE 8E1 low-' 880 (6.26) (6.50) (22.76)

t t 24c85-17 1 680 1 166

(6.54) / 160
(6.30) / 1
 Installed battery Battery case
Single cell dimensions Inside dimensions
Type Voltage Capacity
Manufacturer Mode' mm (in) mm (in)
AHI6HR .
V Length Width Height Length Width Height
222 159 575
36 EXlDE 18E75-23 825 (8 74) (6 26) (22 64)

t t 18E85-23 935 t t t
554
t GNB 18-75C-23 825 T (21 81)

t t 18-85C-23 935 t t t
204 160 575
t C&D 18C85-2 1 850 (8 03) (6 30) (22 64)
223
5FBCU20 t t 18C85-23 935 (8 78) t
165 159 575
25 48 EXlDE 24E75-17 600 (6 50) (6 26) (22 64)

T t 24E85-17 600 t t t
554
t GNB 24-75C- 17 600 t (21 81)

C&D 24C85-19 765 (7 28, (6 30) (22 64)

A *
24C85-21 850 (iz) t t
[MAXI 1
279 159 578
~ F B C H U ~ 3~6 EXlDE 8E 540 ( 10 98) , (6 26) (22 76)
203 159
5FBCU30 48
A
24E 1 1OW-2 1 1 100 ( 7 99, (6 26, T 7
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight t o satisfy the minimum required weight by refer-
ring t o the table below.

Compartment dimensions mm (in) Minimum required

Maximum battery
Front to rear
length X
I
I

Width Y /
I

Height Z
battery weight
(with case)
kg (Ib)
weight (with case)
kg (Ib)

830
(1840)

Battery Compartment Shape

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 compart-
ment 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" )

2. Width (To right and left)

W (Battery compartment width)

+

r
a 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.

Capacity Length Width Height

Voltage Manufacturer TYpe (AHI6HR) mm (in) mm (in) mm (in)
690.6 982.7 574.8-
18E75-23 825
(27.19) (38.69) (22.63)
EXlDE
690.6 982.7 574.8
18E85-23 935
(27.19) (38.69) (22.63)
684.3 979.4 574.8
36 V C&D 18C85-23 935
(26.94) (38.56) (22.63)
685.8 973.1 574.8
18-75C-23 825
(27.00) (38.31 (22.63)
GNB
685.8 973.1 574.8
18-85C-23 935
(27.00) (38.31 (22.63)
685.8 982.7 574.8
24E75-17 600
(27.00) (38.69) (22.63)
EXlDE
685.8 982.7 574.8
24E85-17 680
(27.00) (38.69) (22.63)
684.3 979.4 574.8
24C75-17 600
(26.94) (38.56) (22.63)
48 V C&C
684.3 979.4 574.8
24C85-17 680
(26.94) (38.56) (22.63)
679.5 973.1 574.8
24-75C-17 600
(26.75) (38.31) (22.63)
GNB
679.5 973.1 574.8
24-85C- 17 680
(26.75) (38.311 (22.63)

36 690.6 982.7 577.9

EXIDE 18E11OW-23 1210
V (27.19) (38.69) (22.75)
A
X 48 690.6 982.7 577.9
EXlDE 24E110W-17 880
V (27.19) (38.69) (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 bat-
tery compartment.

The subweight must be procured locally and will not be op-

tionally set.

Taps are provided at two places on the forklift body for at-
taching the subweight. Subweight reference diagrams,
mounting methods, principal battery subweights and required
weights are shown:

1. Sub-weight reference diagram Unit: mm

(in)

Thickness Weight
T19mm 72 kg
(0.748 in) (158.76
T 50 mm 192 kg
(1.969 in) (423.36
Nozzle way for
welding flame
cutting.
dl/ o
400
(15.748)
m
I
L
f-'
20 -
7 I
-
(0.7W& b
6 +*
i
.J
@F
,
0
*+ 3 be. i
OO?.@~~
3s
i
d
P
P

-
fu
N i
0
r\
m - i
0
CO
b
i
-2 i
0
m
m i
i
i
i
I

500 (19 685)

870 (34.252)
2. Mounting method Unit: mm
(in)

h x 1 \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)

Minimum Battery Mounted-Battery (Subweight required) Loadable

Weight subweight
Vehicle battery Battery Case
Size Voltage weight lacking width
tY Pe weight W x L x H mm Manufacturer Battery type Size mm
(W x L x H in1 (V) W X L x H mm kg (~bs) kg (Ibs) (in1
kg (~bs) IWxLXHin)

811 X597x575 83
18-75C-15 131,93x 23,50x 22,641 725 (1598) 105 (231) 13.27)
B
811x597~575 83
36 18-85C-15 i31,g3x23,50x22,64) 790 (1741) 40 (88) 13.27)
A
830 (18401 GNB
30-5FBCU15 i $ ~ ~ , " ~ ~ ~ ~ ' ~ 0 3 ) 81 1 x 597x 575 83
8-75B-1 131.93X23.50~22.64)
725 (1598) 105 (231 r3,27,
B
685 x 848 x 575 32
48 24-85C-11 126.18x25.51 x22,64)
778 (1716) 52 (114) A

5FBCU 992x710~585 970X 508x 575 100

(2000) (39.06 x 27.95 x 23.03) GNB 36 18-85C-17 ~38,19x20,00x22,64,
899 (1981) 11 (24) 13,941
A
30-5FBCU18
970X 508 x 575
8-85C-1 (38.19X 2 0 . 0 0 ~22.641
899 (1981) 191 (420)
li.gl B
973X 568x 575 76
18-75C-19 ,
138,31 22,36x 22,641
938 (2069) 152 (334) 12.99)
B
973 x 568 x 575 76
18-85C-19 ,38,31 22,36x 22.64)
1023 (2256) 67 (147) (2,991
A
5FBCU20 36
973 x 568 x 575 76
30-5FBCu20 18-75B-1 938 (2069) 152 (334) (2,99,
B
992X710x585 138.31 X22.36x22.64)
OgO (2400) (39.06 x 27.95 x 23.03) GNB
5FBCU25 973 x 629x 575 45.5
8-75c-21 1041 (2294) 49 (108) A
30-5FBCU25 138.31x --
24.76%22.64) ~-

973x629x575 45.5
8-75B-21 1041 (2294) 49 (108)
138.31 X 24.76X 22.64) A
970x 597x 575 61.5
24-75C-15 138,19x23,50x22,64~
958 (2111) 132 (2901 12,42)
970 x 597 x 575 61.5
48 24-85C-15 138,1gx 23,50, 22,641
1044 (2302) 46 (101 (2.42)
A
970x 597 x 575 61.5
24-75B-1 (38.19~23.50~22.64) 958 (21 ) 32 (290) 12.42)
TROUBLESHOOTING

Pole plate corrosion

\

\\ lnsufflc~entcharge

\-No operation for \ Repetillon of

overdischarge
Shorting between
and overcharge
cells
Excessive
charg~ng
current

temperature

Incomplete
terminal
Improper water
connection
supply
Overcharge

Deposition of fallen
-acting substance In Duty terminal or plug-

Short circuit Loosened or corroded

and decrease 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
V 48 V specification 42.5
Electrolyte Sulfuric acid diluted with distilled water
Fluid t o be spplied Distilled (deionized) Water
Insulation resistance MO 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.

2. 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 ef-
fected. (For prevention of battery from damage by
large current flow)

2. When material handling is attempted, all indicators on

the display flash and the buzzer sounds t o alarm over-
discharge.

Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on how-
ever, material handling operation can be performed.
BATTERY ASSY
REMOVAL. INSTALLATION

Removal Procedure
1 Place the mast in vertical position.

2 Disconnect the battery plug.

3 Pull the-steering unlocking lever to tilt the steering forward

4 Place the seat t o the foremost position.

(When the deadman seat is used, remove the seat together with the seat stand.)

5 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.)

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

7 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.

2 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

H o w t o use the hydrometer

@ Insert the nozzle of the hydrometer into the wa-
ter 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 in-
Hydrometer side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.
1
3 Insulation resistance inspection
Duter tube - Use an insulation resistance meter (megger) and mea-
sure 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
GENERAL ........................................................... 2-2
SPECIFICATIONS ................................................. 2-3
COMPONENTS ................................................... 2-4
CONTROL PANEL ASSY ...................................... 2-9
OCL VALUE (OVER CURRENT LIMIT VALUE) .......... 2-39
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 ................................... 2-45
DISASSEMBLY -ASSEMBLY .................................. 2-46
INSPECTION ...................................................... 2-47
POWER STEERING CONTROLLER ..................... 2-48
COMPONENTS ................................................... 2-48
REMOVAL.INSPECTION.INSTALLATlON (STD) ....... 2-49
REMOVAL-INSPECTION-
INSTALLATION (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 ac-
celerator and sensors to sound the buzzer (peep, peep) and to display the abnormal portion by the cor-
responding 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 1 t o n series 2 t o n series 3 ton series
F1 (Drive circuit) 275 A 325 A t

F 2 (Material handling circuit) 1 225 A I 325 A I c 1

Fuses F 3 (PS circuit) I 75 A I t I + 1
F 4 (For lamps) I 10 A I C
I t
I
F5 (Control circuit) I 10 A 1 t I t 1
T M (For traveling)

Transistors TMP (For material handling: OPT) TSM 0 0 3 (3 pcs.) c c

TG (For regeneration preexcitation) E T I8 8 c t

TM ,,(For PS : OPT) # IM1100H-025 t c

DAD (For traveling) 30MF40 t t

DAP (For material handling: OPT) 30MF40 t t

IDG (For regeneration)

D F I (DM flywheel) SR250L-6s + C

Diodes
DF2 (DM flywheel) SR250L-6s +- C

I D F ~(PM flywheel) 1 20M30 I t I 4- 1

/ D F (PM
~ flvwheel: OPT) I 70M30 1 +- I +- I
I D F ~ (PS flywheel) I # IM1100H-025 I + I t I
CSD (For traveling) HS800RT c c
Current
CSP (For material handling: OPT) HS800RT t c
sensors
CS, (For PS: OPT) MBP20A-1 OMJN C +-

CAD (Absorber for traveling) I 60pF ( 2 pcs.) 1 +- +-

I
I I
Capacitors CAP
(Absorber for material handling: OPT)
RAD (Absorber for traveling)
60pF ( 2 pcs.)

1 .5Q 2 2 0 W t c

RG (For regeneration) 0.6Q 120W t t

Resistors
RAP
1.5Q 220W c c
(Absorber for material handling: OPT)
MF.MR
(For forwardireverse traveling)
1 ME250
1
MG (For regeneration) ME251 c t

MS (Bypass) ME251 +- t

M W (For field weakening) ME251 +- +

MP (For material handling) 1 ME251 I

MPS (For PS) ME252 +- t

# : The PS transistor and diode are integrated.

COMPONENTS
Drive Control Panel Components

240 1
Resistor Panel Components
2401
Material Handling Contactor Components
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E
I
al
3
-
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Q
3
(C1

0
0
3
B
2
z
z
\

0
z
0
'El
u
e
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0
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MF-MR Contactor Components

MG-MS.MPsMW Contactor Components

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for your reading.
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