TOYOTA BATTERY FORKLIFT 5FBCU15 1999. Please...

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 - 30 series, please refer to Repair Manual (Pub. No.CU305) for

the matters not covered herein.

This manual deals with the above models as of October 1999. Please under-

stand that disagreement can take place between the descriptions in the manual

and actual vehicles due 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 herewith indicate the titles of relevant manuals

TOYOTA INDUSTRIAL EQUIPMENT REPAIR MANUAL

5FBCU15 - 30 (No.CU305)

TOYOTA MOTOR CORPORATION

SECTION INDEX NAME I SECTION

GENERAL DRIVE UNIT (2.3 TON SERIES) FRONT AXLE (2.3 TON S E R I E S ) ~

-

REAR AXLE (2.3 TON SERIES) MAST (2.3 TON SERIES) CYLINDER (2.3 TON SERIES) OIL CONTROL VALVE APPENDIX

GENERAL

EXTERIOR VIEWS ....................................................... 0-2

VEHICLE MODEL ..................................................... 0-3

LUBRICATION CHART (2.3 TON SERIES) ............. 0-4

PERIODIC MAINTENANCE .......................................... 0-5

INFORMATION ON REFERENCE MANUAL ........... 0-6

MEANING OF LATEST MODIFICATION ON ...................... SFBCU 2 TON AND 3 TON SERIES 0-7

EXTERIOR VIEWS

VEHICLE MODEL

*: These high capacity (battery compartment) models are not established in EEC specification.

Note: Way and the position of the model and frame No. indications have been unchanged.

Types on Spec.

STD spec. models

Dust proof 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

Load center = 500mm (kg)

1500

1750

2000

2500

3000

2000

2500

1500

1750

2000

2500

3000

2000

2500

Capacity

Load center = 24in (Ibs)

3000

3500

4000

5000

6000

4000

5000

3000

3500

4000

5000

6000

4000

5000

STD capacity battery compartment

High capacity *

STD capacity battery 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

LUBRICATION CHART (2.3 TON SERIES)

I* 2* 3* 4* 5 6 7 8 9 lo* 11* 12* 13*

Chain Mast support bushing Tilt cylinder front pin Front wheel bearing Differential & transmission Brake fluid reservoir tank Tilt steering locking mechanism Tilt steering universal joint Oil tank Rear wheel bealing Steering knuckle king pin Tie rod end pin Rear axle cylinder end pin Rear axle beam front pin Rear axle beam rear pin Located on right and left sides

lnspect every 8 hours (daily) lnspect every 40 hours (weekly) lnspect every 170 hours (monthly) lnspect every 1000 hours (6 monthly) lnspect every 2000 hours (annually) lnspect and service Replace

MP grease Engine oil Hypoid gear oil Hydraulic oil Brake fluid Molybdenum disulfide grease

PERIODIC MAINTENANCE

INSPECTION METHOD

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.

Inspection Period

Item

Months

Hours

TRAVELING EQUIPMENT

6

1000

Rear axle

1

170

12

2000

3

500

Cracks, damage and deformation of beam

Looseness of axle beam in vehicle longitudinal direction (2.3 ton series: from October 1 999)

I

M*

0

0

-

INFORMATION ON REFERENCE MANUAL 3n and after October 1999 products of 5FBCU series, choose the reference publication for proper servic- ng in accordance with the following instructions:

0: Applicable reference

Remarks

Refer to Parts & Service News GE-8031 of Dec. 1998.

Refer to Parts & Service

News GE-8024 of Oct. 1 998

5FBCU15 - 30

Section

GENERAL

BAlTERY

CONTROLCIRCUIT

MULTIDISPLAY FUNCTIONS

ELECTRICAL SYSTEM TROUBLESHOOTING

MOTOR

Repair manual

Pub. No. CU305

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

DRIVE UNIT

FRONT AXLE

REAR AXLE

This book

0

0

0

0

0

0

0

0

1 ton series

2.3 ton series

1 ton series

2.3 ton series

1 ton series

2.3 ton series

STEERING

BRAKE

BODY & FRAME

MATERIAL HANDLING SYSTEM

1 ton series

2.3 ton series

1 ton series

2.3 ton series

MAST

Tilt cylinder

OIL PUMP

OIL CONTROLVALVE

APPENDIX

CYLINDER

Lift

MEANING OF LATEST MODIFICATION ON 5FBCU 2 TON AND 3 TON SERIES Accompanied by the model change - Development to 7FGCU 2 ton & 3 ton series from GFGCU 2 ton & 3 ton series -, several new design features of 7FGC 2 ton & 3 ton series have also been adapted for 5FBCU 2 ton & 3 ton series. As the effect that, several components have been standardized for the developments as well as for service efficiencies and conveniences. The major components involved are tabulated as follows:

Standardization between model series Meaning of Marks Used for List item 0 Standardized between 5FBCU series and 7FGCU series, or interchangeable.

Partly standardized between 5FBCU series and 7FGCU series, or Partly Interchangeable. x Exclusively for 5FBCU series

1

3 ton series

x

Components

Mast Assembly V. FV. FSV. Q FV

2 ton series

x

Front axle

Rear axle

Tire size

Forks

Seat belt

Differential housing

Axle housing

Axle bracket

Axle shaft

Wheel bearing

Wheel & hub drum

Differential case

Rear axle beam

Rear axle cylinder

Tie rod

Steering knuckle

Wheel bearing

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 Vehicle Series 2 ton Series

Item STD

3 ton Series

Dustproof STD Dustproof

Ring gear teeth

Drive pinion teeth

Gear ratio (Differential)

+

C

+

+-

C

+

+

Pinion gear

Side gear

22

60

2.727

35

6

5.833

4

10

2

14

Number of gears

Teeth

Number of gears

Teeth

17

65

3.824

22

60

2.727

Drive gear teeth

Output gear teeth

Gear ratio (Transmission)

Drive unit oil capacity J? ( (US gal) C

17

65

3.824

7.5 (1.98)

COMPONENTS

DRIVE UNIT ASSY REMOVAL-INSTALLATION

T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Remove the mast. (See page 4-7)

2 Remove the battery hood Wldriver seat.

3 Remove the battery ASSY.

4 Jack up the vehicle and remove the front wheels.

5 Drain differential oil. [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 Remove the front toe-board.

10 Disconnect the parking brake wires.

11 Remove the drive motor set bolts.

12 Support the front axle & drive motor ASSY with a hoist and garage jack. [Point 21

13 Remove the front axle bracket set bolts. [Point 31

14 Remove the front axle & drive motor ASSY.

15 Disconnect the drive unit and drive motor

16 Remove the front axle shaft. [Point 41

17 Remove the front axle housing Wlbrake.

18 Remove the speed sensor cover and the sensor.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note: Bleed air from the brake system after installation.

Point Operations

[Point 11 Installation:

After reassembly, fill hypoid gear oil to the specified level.

A = 15 mm (0.59 in) or less

[Point 21 Removal.lnstallation:

Install hub nuts on hub bolts on the left and right side, and sling wire at the tapered portion.

[Point 31 Removal:

Remove the reamer bolts. (2 pcs. each at top and bottom on one side) SST 0931 0-23320-71

[Point 41 Removal.Installation:

Operate carefully so as not to bring the axle shaft into contact with the oil seal lip to damage it.

N.m (kgf-cm) [ft-lbfl

Disassembly Procedure

1 Remove the differential cover. [Point 11

2 Measure the ring gear backlash. [Point 21

3 Remove the bearing cap and adjusting nut. [Point 31

4 Remove the differential case ASSY. (See page 1-1 4 for the disassembly, inspection and reassembly procedure.)

5 Remove the drive pinion ASSY. [Point 41

6 Remove the output gear. [Point 51

7 Remove the drive pinion, bearing, spacer and shim from the retainer. [Point 61

8 Remove the pilot bearing. [Point 71

9 Remove the drive pinion bearing inner race. [Point 81

10 Remove the drive gear

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Point Operations

[Point 11 Reassembly:

Apply sealing agent (Three Bond's No.1217C or the equiva- lent) on the mating surfaces of the differential cover and housing before reassembly.

[Point 21 Inspection:

Measure the ring gear backlash.

Standard: 0.2 - 0.3 mm (0.008 - 0.012 in)

[Point 31 Disassembly:

Put match marks on the bearing cap and differential housing.

Reassembly: Install the adjusting nuts and bearing cap. 1, Install the adjusting nuts. 2. Install the bearing cap by aligning the match marks and

temporarily tighten the set bolt. T = 19.6 N-m (200 kgf-cm) [I 4.5 ft-lbf]

3. Set the dial gauge in the thrust direction of the differential case.

4. Use the SST and tighten until the thrust clearance is elimi- nated. SST 09630-1 01 10-71

5. Tighten adjusting nuts on both sides by one notch each. 6. Set the dial gauge vertical to the ring gear tooth surface,

and measure the backlash.

Standard: 0.2 - 0.3 mm (0.008 - 0.012 in)

Heeal contact

If the standard is not satisfied, adjust by turning the adjusting nut to move the differential case ASSY in the thrust direction.

(1) When the backlash is excessive: Loosen the adjusting nut on the ring gear teeth side and tighten the adjusting nut on the rear side as much to bring the ring gear closer to the drive pinion.

(2) When the backlash is insufficient: Loosen the adjusting nut of the rear side of the ring gear and tighten the adjusting nut on the teeth side as much to bring the ring gear away from the drive pinion.

7. Side bearing starting torque (Reference only): Measure the torque by turning the output gear lock nut with a torque wrench. Standard:

6.37 - 15.20 N-m (65 - 155 kgf-cm) [4.70 - 11.21 ft-lbf]

8. Tighten the adjusting nut on the rear side of the ring gear further by 1.5 to 2 notches.

9. Install the adjusting nut lock plate. 10.Finally tighten the bearing cap set bolts.

T = 11 7.7 - 137.3 N-m (1 200 - 1400 kgf-cm) [86.82 - 101.3 ft-lbfl

11. Check the tooth contact. (1) Uniformly coat red lead thinly on both faces of 7 to 8

gear teeth, and turn the ring gear forward and backward several times after installing a box wrench on the output gear lock nut. Judge the gear teeth contact by observing the pattern formed on the gear teeth. If the tooth contact is not correct, make adjustment according to the "Drive Pinion Protrusion Adjustment" and "Ring Gear Backlash and Differential Case Bear- ing Starting Torque Adjustment" procedures.

(2) Correct teeth contact The pattern should be slightly leaning to the inside circle of the ring gear with respect to the center of the tooth length, as shown.

(3) Heeal contact Move the drive pinion croser to the ring gear by decreasing the drive pinion adjusting shim thickness. Then move the ring gear away from the pinion to adjust the backlash.

(4) Toe contact Move the pinion away from the ring gear by increasing the drive pinion adjusting shim thickness. Then move the ring gear closer to the pinion to adjust the backlash.

Flank contact

Face contact

0 Good examples 0 Point contact

(5) Flank contact (low shallow contact) Move the pinion awayfrom the ring gear by increasing the drive pinion adjusting shim thickness. Then move the ring gear closer to the pinion to adjust the backlash.

(6) Face contact (high shallow contact) Move the pinion closer to the ring gear by decreasing the drive pinion adjusting shim thickness. Then move the ring gear away from the pinion to adjust the backlash.

[Point 41 Reassem biy:

Adjust the drive pinion protrusion by means of the drive pinion bearing retainer shims. Select the shim by teeth contact inspection. (See Point 3.)

Shim thickness: 0.10.0.15.0.35 and 0.45 mm (0.0039~0.0059~0.0138 and 0.01 77 in)


After the drive pinion bearing starting torque adjustment, caulk the output gear lock nut.

[Point 61 Reassembly: SST 09370-20270-7 1

SST

Reassembly: Adjust the drive pinion bearing starting torque.

1. Install the output gear and tighten the lock nut to the specified torque.

2. Set a torque wrench on the lock nut, and measure the starting torque.

Starting torque: 10.79 - 13.24 N-m (1 10 - 135 kg-cm) [7.96 - 9.77 ft-lb]

3. If the starting torque does not satisfy the standard make adjustment by changing the shim thickness.

Shim thickness: 0.03.0.1 0.0.1 5.0.35 and 0.45 mm (0.001 2~0.0039~0.0059~0.0138 and 0.01 77 in)


SST 09950-4001 1

Reassembly: Use the SST and install the pilot bearing. SST 09608-04031 Check the installed direction.


SST 09420-23000-71

Reassembly: SST 093 1 6-600 1 1

DIFFERENTIAL CASE ASSY DISASSEMBLY INSPECTION-REASSEMBLY T = N-m (kgf-cm) [ft-lbfl


1 Remove the differential case bearings. [Point I ]

2 Remove the differential upper case. [Point 21

3 Remove the side gear and pinion gear. [Point 31

4 Remove the ring gear. [Point 41



SST a

, SST @

Match marks

Point Operations

[Point I] Disassembly:

SST 09950-4001 1 --- @ 09950-6001 0 --- @

Reassembly: Install the side bearing.

1. Use the SST and drive in the side bearing to the end surface. SST 09950-60020 --- O

09950-7001 0 --- @ 2. Use a striking driver and fully drive in the bearing.

[Point 21 Disassem bly-Reassembly:

Check the match marks.

Reassembly: Apply locking agent (08833-00070) on the set bolt threaded portion before reassembly.


Measure the inside diameter of the differential pinion. Standard: 22.12 mm (0.8709 in) Limit: 22.22 mm (0.8748 in)

Inspection: Measure the spider outside diameter Standard: 22.00 mm (0.8661 in) Limit: 21.75 mm (0.8563 in)

Inspection: Measure the side gear thrust washer thickness.

Standard: 1.6 mm (0.063 in) Limit: 1.3 mm (0.051 in)

Inspection: Measure the pinion gear thrust washer thickness.


Reassembly: Install the side gear thrust washer with its oil groove facing the gear.

Reassembly: Apply chassis grease (molybdenum disulfide grease) on both sides of the spider pinion thrust washer before reassembly.


Apply locking agent (08833-00070) on the set bolt threaded portion before reassembly. Tighten the set bolts gradually in the diagonal order, and finally tighten in the circular order to the specified torque.

FRONT AXLE (2.3 TON SERIES)

Page

........................................................................ GENERAL 2-2

.......................................................... SPECIFICATIONS 2 9

.............................................................. COMPONENTS 2 4

FRONT AXLE SHAFTmAXLE HUB ............................. 2-5

REMOVAL*INSTALLATION ............................................... 2-5

FRONT AXLE BRACKETmAXLE HOUSING ............ 2-9


2-2

GENERAL 2 ton series

3 ton series

SPECIFICATIONS

3 ton series

+ +

+

+

e

Vehicle model 2 ton series

Item

Front axle type

Suspension type

Axle shaft diameter mm (in)

Axle shaft diameter (spline portion) mm (in)

Full-floating

Fixed to frame

40 (1.57)

40 (1.57)

COMPONENTS 2 ton series

3 ton series

FRONT AXLE SHAFTeAXLE HUB REMOVAL- INSTALLATION T = N.m (kgf-cm) [I?-lbfl

Removal Procedure

1 Drain differential oil. [Point I]

2 Jack up the vehicle and remove front wheel

3 Remove the front axle shaft. [Point 21

4 Remove the axle shaft oil seal. [Point 31

5 Remove the bearing lock nut and plate. [Point 41

6 Remove the outer bearing roller and front axle hub. [Point 51

7 Remove the oil seal and inner bearing roller. [Point 61

8 Remove the bearing outer race. [Point 71

9 Remove the hub bolt.



Note: Apply thread tightener (08833-00070) on the hub bolt set nut before tightening.

Point Operations

[Point I ] Installation:

Fill Hypoid gear oil to the specified level after installation. A = 15 mm (0.59 in) or less

[Point 21 Removal.lnstallation:

Carefully operate so as not to damage the oil seal by contact with the axle shaft.

[Point 31 Removal:

SST 09320-23000-71

Installation: SST 09950-6001 0 --- O

09950-7001 0 --- @

[Point 41 Removal.Installation:

SST 09509-55020

Installation: Adjust the front axle hub starting force. 1. Install the plate. 2. Fully tighten the bearing lock nut, and rotate the hub by 4

to 5 turns to run in the bearing. 3. Return the bearing lock nut by 1/12 to 116 turn (30 to

60°), and rotate the hub by 4 to 5 turns again. 4. Set a spring scale on a hub bolt, and measure the start-

ing force.

Standard: 25.5 - 72.6 N (2.6 - 7.4 kg9 [5.7 - 16.3 Ibf]

5. If the standard is not satisfied, adjust the degree of bearing lock nut tightening for adjustment.

6. Install the nut lock bolt. Coat thread tightener (08833-00070) on the nut lock bolt before tightening.


Fill MP grease in the hub before installing the front axle hub.

Installation: SST 09370- 1041 0-7 1

[Point 61 Removal:

Use a screwdriver or the like to remove the oil seal.

Installation: SST 09950-60020 --- @I

09950-7001 0 --- @

[Point 71 Removal:

Use a brass bar to remove the bearing outer race.

Installation: SST 09950-60020 --- @I

09950-7001 0 --- @

FRONT AXLE BRACKET*AXLE HOUSING

REMOVAL. INSTALLATION T = N.m (kgf-cm) [ft-lbfl

T = 265 - 343 (2700 - 3500) [195.3 - 253.21

T = 107.9 - 137.3 (1100 - 1400) 179.59 - 101.3]

T = 118 - 137 (1200 - 1400) [86.8 - 101.31

Removal Procedure

1 Remove the front axle & drive motor ASSY. (See page 1-5)

2 Remove the front axle shaft and axle hub. (See page 2-5)

3 Remove the brake ASSY. [Point 11

4 Remove the front axle bracket and O-ring.

5 Remove the axle hosing and O-ring.



Note: Apply grease on the O-ring before installation.

Point Operations

[Point I ] Installation:

Apply sealing agent (08826-00080) on the mating surfaces of the brake backing plate and front axle bracket before installation.

Installation: Apply locking agent (08833-00070) on the set bolts before tightening.

REAR AXLE (2.3 TON SERIES)

Page

GENERAL ........................................................................ 3-2

SPECIFICATIONS ......................................................... 3-3

.............................................................. COMPONENTS 39

REAR AXLE ASSY ....................................................... 3-5


.................................................. STEERING KNUCKLE 3-7

REMOVALINSTALLATION ............................................... 3-7

REAR AXLE CYLINDER ............................................... 3-11


.................. DISASSEMBLVINSPECTION~REASSEMBLY 3-13

....................................... REAR WHEEL ALIGNMENT 3-15

GENERAL

Rear Axle Cylinder

SPECIFICATIONS

Rear axle type

Rear axle suspension type

Wheel alignment

Elliot type

Center-supported right-left rocking type

0 (0)

1.5"

0"

0"

Toe-in mm (in)

Camber degree

Caster degree

King pin angle

5FBCU18,30 - 5FBCU18




5FBCHU20,30 - 5FBCHU20

5FBCHU25,30 - 5FBCHU25

1 740 (68.5)

1 765 (69.5)

1790 (70.5)

1 960 (66.0)

1 920 (75.5)

1 940 (76.0)

Double acting

50.0 (1.969)

76.0 (2.992)

Minimum turning radius (outermost) mm (in)

Rear axle cylinder

Cylinder type

Piston rod outside diameter mm (in)

Cylinder bore mm (in)

COMPONENTS

4302

I

I

L... ...a

4302-024

REAR AXLE ASSY REMOVAL- INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Remove the counter weight.

2 Apply the parking brake and chock the front wheels.

3 Jack up the frame and support it with the wooden block.

4 Remove the rear wheels (See removal procedure steps 2 to 4 in steering knuckle removal section on page 3-7).

5 Disconnect the rear axle cylinder hose.

6 Support the rear axle ASSY with a garage jack.

7 Remove the rear axle ASSY. [Point I]

8 Remove the center pin bushing. [Point 21



Note: After installation, add grease through each grease fitting. Add genuine molybdenum disulfide grease at the rear axle beam center pins (two places). Use MP grease to other grease fittings.

L I j First

I I : I Second

t ;I

-rI I I

Grease fitting

Point Operations

[Point I ] Inspection:

Measure the rear axle front to rear clearance. 1. Before removing the rear axle ASSY, measure the front

to rear clearance on the rear side.

Standard clearance: 0.7 mm (0.028 in) or less

2. If the measured value does not satisfy the standard, remove the rear axle ASSY and make adjustment by se- lecting the spacer.

Spacer thickness: 1.2.2.3.3.0.3.5.4.0.4.5 and 5.0 mm (0.047~0.091~0.118~0.138~0.157~0.177 and 0.1 97 in)

3, Install the spacer at the rear side center pin. The first spacer shall be installed with its chamfered at the inside diameter in contact with the center pin boss.


Inspect the inside diameter of the rear axle center pin bushing.

Limit: 52.0 mm (2.047 in)

Installation: Apply molybdenum disulfide grease on the bushing and install the bushing by aligning the grease groove in the bushing with the grease fitting position.

STEERING KNUCKLE REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Jack up the vehicle.

2 Remove the hub cap. [Point 11

3 Remove the castle nut and claw washer. [Point 21

4 Remove the outer bearing and rear wheel. [Point 31

5 Remove the bearing outer race from the rear wheel. [Point 41

6 Remove the inner bearing roller and oil seal. [Point 51

7 Disconnect the tie rod (on the knuckle side).

8 Remove the king pin cover.

9 Remove the king pin lock bolt and king pin. [Point 61

10 Remove the thrust bearing, spacer and steering knuckle.

11 Remove the king pin oil seal and needle roller bearing. [Point 71



Note: After installation, add MP grease through grease fittings.

Point Operations


Fill MP grease in the hub cap, and install by tapping the flange portion.


Adjust the rear wheel starting force. 1. Install the claw washer in the correct direction. 2. Install the castle nut and temporarily tighten it to a torque

of 15 to 32 N-rn (1 50 to 330 kgf-cm) [I 0.9 to 23.9 ft-lbfl. 3. Rotate the hub by 3 to 5 turns to run in the bearing.

4. Set a spring scale at the outer periphery of the wheel, and measure the starting force.

Standards: 9.8 - 29 N (1.0 - 3.0 kg9 [2.2 - 6.6 Ibf]

5. If the standard is not satisfied, adjust the degree of castle nut tightening for adjustment.

6. Install a new cotter pin.


Fill MP grease in the hub and knuckle spindle.

Installation: Install the rear wheel and outer bearing.

SST 09370-20270-71

SST

[Point 41 Removal:

Use a brass bar and remove the bearing outer race

Installation: SST 09950-60020 --- @

09950-7001 0 --- @

[Point 51 Removal:

SST 09950-4001 1

Installation: Install the oil seal and inner bearing roller. 1. Use the SST and install the oil seal.

SST 09370-1 041 0-71

2. Use the SST and install the inner bearing roller. SST 09370-20270-71


Measure the king pin outside diameter

Limit: 27.8 mm (1.094 in)

0 rnrn (0 in)

4 rnrn (0.1 6 in)

M

Press-fitting direction

Installation: Measure the steering knuckle starting force. 1. Temporarily install the king pin and king pin lock bolt.

Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing.

2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 Ibf] or less

3. If the standard is exceeded, check the king pin for bend, the needle bearing for damage and axle beam for deformation.

Spacer thickness:3.0,3.5,4.0 and 4.5 mm (0.118,0.138,0.157 and 0.177 in)

4. Tighten the lock nut for the king pin lock bolt.

[Point 71 Removal:

Remove the king pin oil seal and needle roller bearing. 1. Use a straight-edge screwdriver to remove the dust seal

and oil seal. 2. Use the SST and remove the needle roller bearing.

SST 09950-6001 0 --- @ 09950-7001 0 --- @

Installation: Install the needle roller bearing and king pin oil seal. 1. Use the SST and install the needle bearing.

Check the needle roller bearing press-fitting surface, pressing direction and installation depth. SST 09950-6001 0 --- @

09950-7001 0 --- @ 2. Install the dust seal. 3. Use the SST and install the oil seal.

SST 09950-6001 0 --- O 09950-7001 0 --- @

3-1 1

REAR AXLE CYLINDER REMOVAL0lNSTALLATlON T = N-m (kgf-cm) [ft-Ibfl

Removal Procedure

1 Jack up the vehicle.

2 Disconnect the tie rod (on the piston rod side). [Point 11

3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 21

4 Remove the rear axle cylinder.



Point Operations

[Point 11 Removal:

Mark the punch mark position on each of cylinder end pins LH and RH.

Installation: Install each cylinder end pin by aligning the punch mark with the mark.


Install the fitting in the illustrated direction.

DISASSEMBLY*lNSPECTIONgREASSEMBLY T = N-m (kgf-cm) [ft-Ibfl


1 Remove the through bolt.

2 Remove the piston rod guide.

3 Remove the piston rod. [Point I ]

4 Inspect the cylinder. [Point 21



Note: Coat hydraulic oil before reassembly.

Point Operations

[Point I ] Inspection:

Measure the piston rod outside diameter. Limit: 49.92 mm (1.9654 in)

Inspection: Measure the bend of the piston rod. Limit: 0.5 mm (0.020 in)

Reassembly: Warm the seal or water before

ring to a little below 80°C (1 76°F) in hot oil installation.

Do not stretch it excessively.

Caution: Operate carefully to avoid scalding.


Measure the rear axle cylinder bore.

Limit: 76.35 mm (3.0059 in)

REAR WHEEL ALIGNMENT Toe-in Inspection

1. Check to see that dimensions Ar and A! of the rear axle cylinder are equal.

2. Measure the toe-in (Bf - Br). Standard: 0 + 4 mm (0 + 0.16 in)

Toe-in Adjustment

Punch mark on plate side

Punch mark on cylinder end pin side

1. Check to see that Ar and A! of the rear axle cylinder are equal.

2. Align the punch mark on the cylinder end pin (eccentric pin) with the punch mark on the plate on the front side for both the LH and RH sides.

3. Measure and adjust the toe-in (Bf - Br). Standard: 0 + 4 mm (0 + 0.16 in) If the standard is not satisfied, make adjustment by the cylinder end pin in the range where the difference between Rt and Rr is within 0 t 3 mm (0.1 2 in). ( I ) When measued value > 4 mm (0.1 6 in):

Measure Rt and Rr, and adjust the cylinder end pin on the smaller side toward IN.

(2) When measured value < 4 mm (0.1 6 in): Measure Rt and Rr, and adjust the cylinder end pin on the greater side toward OUT.

Note: If Rt equals to Rr, adjust the same amount on the LH and RH sides. If the standard is not attained by adjustment on one side, make adjustment also on the other side.

4. Install the plate. The plate can be installed with either face UP.

5. After adjustment, fully steer the tires and check to see that they do not come into contact with the vehicle body.

MAST (2.3 TON SERIES)

Page

................................................................. V MAST ASSY 4-2

COMPONENTS ............................................................... 4-2

REMOVAL* INSTALLATION ............................................... 4-5

REMOVAL-INSTALLATION (WJLIFT BRACKET) .............. 4-7

MAST DISASSEMBLY*INSPECTION*REASSEMBLY ........ 4-9

LlFT BRACKET DISASSEMBLY-INSPECTION- REASSEMBLY ............................................................. 4-11

....................................... MAST ADJUSTMENT (V MAST) 4-13

MAST ROLLER REMOVAL-INSTALLATION ..................... 4-18

CHAIN ............................................................................. 4-19

.................................................................... INSPECTION 4-19

REASSEMBLY O/.FV*FSV) ............................................... 4-19

....................................................... REASSEMBLY (Q FV) 4-20

ADJUSTMENT ................................................................ 4-21

................................................................................. FORK 4-21

REMOVAL ........................................................................ 4-21

................................................................. INSTALLATION 4-21

.................................................................... INSPECTION 4-21

.................................................... FV* FSV MAST ASSY 4-22

................................................................ COMPONENTS 4-22

....................................... MAST ADJUSTMENT (FV- FSV) 4-25

.......................................................... QFV MAST ASSY 4-29

................................................................ COMPONENTS 4-29

............................................. MAST ADJUSTMENT (an/) 4-31

LlFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) ................. 4-33

V MAST ASSY COMPONENTS

2 ton series 6301 V FV -

40

FSV QFV

02

40 6301-467A

3 ton series 6301

V FV

02

6301-465

3 ton series 6302

6302-298

- - - - -

REMOVAL* INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 11

3 Remove the chain wheel. [Point 21

4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift bracket, and slowly run the vehicle backward to depart from the lift bracket.)

5 Remove the toe board.

6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)

7 Slightly hoist the mast.

8 Remove the mast support cap.

9 Remove the tilt cylinder front pin. [Point 31

10 Remove the mast ASSY.



Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease to the tilt cylinder front pin. Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 4-34.) Adjust the chain tension after installation.

Point Operations

[Point I ] Removal-Installation:

SST 09630-23600-71

[Point 21 Removal:

If the fitting is hard, use the SST for removal. SST 09950-4001 1

[Point 31 Removal:

SST 0981 0-201 72-71

REMOVAL. INSTALLATION (WILI FT BRACKET) T = N-m (kgf-cm) [ft-lbfj

Removal Procedure

1 Set the mast vertical.

2 Remove the forks.


4 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast and operate the lift lever several times to release the residual pressure from the lift cylinder.)

5 Slightly hoist the mast.

6 Remove the mast support cap.

7 Remove the tilt cylinder front pin. [Point I]

8 Remove the mast ASSY W/lift bracket.



Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease to the tilt cylinder front pin. Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 4-33.)

Point Operation

[Point I ] Removal:

SST 0981 0-201 72-71

MAST DISASSEMBLY-INSPECTION-REASSEMBLY


1 Remove the hose cover.

2 Disconnect the high pressure hose.

3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 11

4 Remove each cylinder support. [Point 21

5 Remove each cylinder bottom set bolt, and remove each lift cylinder.

6 Slide the inner mast in the lowering direction, and remove the lift rollers.

7 Remove the mast strip. [Point 31

8 Remove the outer mast.



Shim Point Operations

[Point I ] Disassembly:

Shim adjustment is made at the lift cylinder rod end for pre- venting uneven lifting by lift cylinders LH and RH. Take a note on the cylinder where the adjustment is made and the number of shims in use.

[Point 21 Disassmbly:

Take a note on the number of cylinder support shims in use.

Reassembly : Make cylinder support shim adjustment if the mast or either cylinder is replaced. With the cylinder rod end inserted to the inner mast, insert shim(s) between the cylinder support and outer mast to eliminate the clearance. The shim thickness should be slightly greater than the clearance.


Measure the mast strip thickness.

Thickness limit: A = 2.7 mm (0.106 in) B = 1.3 mm (0.051 in)

LIFT BRACKET DISASSEMBLY*INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-lbfl


1 Remove lift rollers. [Point 11

2 Remove side rollers. [Point 21

3 Remove the back rest.



Point Operations

[Point I ] Disassembly: SST 09950-400 1 1


Install the side roller in the correct direction. The side chamfered with a greater radius of the roller shall be on the front side of the vehicle.

MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast

1. Clearance between inner mast roller and outer mast

into

I Shim

Inner mast ;::rJ These ;oilers

Adjust the mast overlap to approx. 450 mm (1 7.72 in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

2. Clearance between outer mast roller and inner mast

These rollers

Outer mast inner

mast

Adjust the mast overlap to approx. 450 mm (1 7.72 in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: B = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.


(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

4-1 5

Roller Adjustment at Lift Bracket

1. Middle/lower lift roller and side roller clearance adjustment

100 rnrn (3.94 in)

:ti$ifi 11 lnner mast

bracket

100 rnrn (3.94 in)

lnner mast bracket

(1) Bring the center of the side roller in the upper part of the lift bracket to approx. 100 mm (3.94 in) from the top of the inner mast.

(2) Remove side rollers. (3) Shift the lift bracket to one side to bring the roller into

contact with the inner mast, and inspect on the opposite side the clearance between the roller side face and the mast where they are the closest. (No adjustment is necessary for the upper lift rollers since they are fastened by snap rings.)

Standard C = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the lift roller shim thickness.


(4) Distribute shims equally to the left and right side. (5) Install side rollers.

(6) After adjusting the middle and lower lift rollers, bring the side roller on one side into contact with the outer mast and measure on the opposite side the clearance between the side roller and inner mast surface.

Standard D = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the side roller shim thickness.


7) Distribute shims equally to the left and right side. (See Lift Bracket Disassembly-Inspection-Reassembly section for the side roller installation method. Shim replacement is possible on the vehicle.)

(8) After the adjustment, see that the lift bracket moves smoothly over the entire length of the mast.

Mast Strip Adjustment

1. Mast strip clearance adjustment -

- Roller

Bring into contact

Outward

Note: The strip is of tapered shape, thicker side of the width must be placed outward.

(1) Lower the inner mast fully. (2) With the inner mast in contact with the outer mast roller,

measure the clearance between the mast strip and inner mast.

Standard: E = 0.5 - 1.0 mm (0.020 - 0.039 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.


(3) After the adjustment, check the mast for smooth movement.

I Shim

MAST ROLLER REMOVAL-INSTALLATION

1. Remove the lift bracket. (See steps 1 to 4 of the mast ASSY removal procedure on page 4-5.)

2. Jack up the vehicle, and support tires with wooden blocks. Also lock the front and rear tires from rotation.

3. Remove the lift cylinders. (See page 5-1 1 .)

4. Remove mast rollers. (1) Remove wooden blocks under the inner mast, and

lower the hoisted inner mast slowly until mast rollers appear.

(2) Support the bottom of the inner mast with wooden blocks.

(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims. 5. The installation procedure is the reverse of the removal

procedure.

CHAIN

INSPECTION 1. lnspect the chain elongation according to the following

procedure: SST 09631 -22000-71

(1) Since the SST measurement line varies with the chain type, set the corresponding line on the chain as illustrated.

(2) Check the number of the chain to be inspected, and check the pin center position. If the pin center is at the arrow mark on the chain gauge, it is the limit.

Chain Link Pitch Standard (V.FV.FSV.QFV)

Note: Perform measurement without removing the chain from the vehicle. lnspect elongation over the entire chain length since it may be localized.

REASSEMBLY O/.FV0FSV)

1. Installing direction

Vehicle model

2 ton series QFV inner and middle chain

3 ton series

QFV outer chain

Type

BL634

BL823

BL834

Pitch mm (in)

1 9.05 (0.7500)

25.4 (1 .O)

25.4 (1 .O)

2. Chain adjusting nut tightening order (1) Tighten nuts @I and 0. T = 49.0 - 78.0 N-m (500 - 800 kgf-cm) [36.2 - 57.9 ft-lbfl (2) Tighten nut 0.

Chain No.

60

80

80

mast and portion

Sketch

V: Lift bracket

Install with the split pin on the vehicle center side.

Applicable mast and portion

Sketch

FV: Lift bracket FSV: Lift bracket

Outside of 0 ' vehicle

Split pin

Install with the split pin on the vehicle outside.

FV: Front cylinder (3 ton series) FSV: Front cylinder (3 ton series)

0

0

V: Outer mast FV: Front cylinder (2 ton series) FSV: ~~~~t cylinder (2 ton series)

0

0

-

FSV: Inner mast

Rear of 0 vehicle

Split pin

Install with the split pin on the vehicle rear side.

FSV: Outer mast

Clamp

0

0

REASSEMBLY (QFV)

1. Installing direction As shown in the table below.

2. Chain adjusting nut tightening order (I) Tighten nuts @ and 0. T = 49.0 - 78.0 N.m (500 - 800 kgf-cm) [36.2 - 57.9 fi-lbfl (2) Tighten nut @.

Outer chain

Clamp $ ZZ y7

T = 98.0 - 147.0 N m (1 000 - 1500 kgf-cm) [72.35 - 108.5 ft-lbfl

Upper middle

& 0

T = 98.0 - 147.0 N.m (1000 - 1500 kgf-cm) [72.35 - 108.5 ft-lbfl

Chain connection

Middle chain

clamp 5s

Split pin

lnner mast

Installation side of split pin is at center side of the truck.

Inner chain

@ yw5 $:&r

Installation side of split pin is outward of the truck center.

ADJUSTMENT

1. Park the vehicle on a flat ground and set the mast vertical.

2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting nut.

3. Check to see that the chain tension is equal on the left and right side.

4. Check to see no chain twist.

5. See that the fork height is the standard.

6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast is not in contact with the lift bracket.

FORK

REMOVAL

1. Set the fork at approx. 20 cm (7.9 in) above the ground. 2. Place a wooden block under the knotched portion of the

fork rail. 3. Unlock the fork by lifting the fork stopper pin, and shift

the fork blades, one at a time, to the center. 4. Slowly lower the fork for removal.

INSTALLATION

The installation procedure is the reverse of the removal procedure.

INSPECTION

1. Inspect misalignment of the fork tip ends.

Limit: 10 mm (0.39 in)

If the limit is exceeded, inspect individual fork bend, looseness of fork installation and lift bracket finger bar distor- tion.

FV* FSV MAST ASSY COMPONENTS

FSV 31 61 O I

43A 6101-491A

FV 2 ton series 6302

21K

FV 3 ton series

6302-297

FSV 6302 2 ton series

FSV 3 ton series

6302-296

MAST ADJUSTMENT (FV-FSV)

Lift Roller Adjustment at Mast

1. Clearance between: lnner mast roller and outer mast (FV). lnner mast lower roller and middle mast (FSV). Middle mast lower roller and outer mast (FSV).

Position where the roller is the closest

FSV mast FV mast

lnner mast

@ Outer mast

These rollers These rollers

(1) Adjust the mast overlap to approx. 450 mm (1 7.72 in). (2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the

clearance between the roller side face and mast where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.


(3) Distribute shims equally to the rollers on the left and right sides. (4) After the adjustment, see that mutual mast movement is smooth.

2. Clearance between: Outer mast roller and inner mast (FV). Middle mast upper roller and inner mast (FSV). Outer mast upper roller and middle mast (FSV)

N mast FSV mast These rollers These rollers

Outer mast Outer mast

Middle mast

Inner mast

(1) Adjust the mast overlap to approx. 450 mm (1 7.72 in). (2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on

the opposite side the clearance between the roller side face and mast where they are the closest.

Standard: B = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.


(3) Distribute shims equally to the rollers on the left and right sides. (4) After the adjustment, see that mutual mast movement is smooth.

LiftISide Roller Adjustment at Lift Bracket

FV-FSV mast

Lower lift roller

100 mm (3.94 in)

Lift bracket

FSV Mast N Mast

(1) Raise the lift bracket to the uppermost position for the FSV mast, and bring the center of the upper lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for FV mast.

(2) Shift the lift bracket to one side to bring the lower lift roller, and measure on the opposite side the clearance between the roller side face and the mast where they are the closest.

Standard: C = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims equally to the rollers on the left and right sides.)


(3) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers. Bring the side roller on one side into contact with mast side surface, measure on the opposite side the clearance between the side roller and the inner mast side surface where they are the closest.

Standard: D = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims equally to the rollers on the left and right sides.)


(4) After the adjustment, check to see that the lift bracket moves smoothly over the entire length of the mast.

Mast Strip Adjustment

Mast strip clearance adjustment

FV mast

Bring into contact

FSV mast

Bring into contact

w -

(1) Lower the inner (or middle) mast fully. (2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),

measure the clearance between the mast strip and mast.

Standard: E = 0.5 - 1.0 mm (0.020 - 0.039 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.


(3) After the adjustment, check the mast for smooth movement.

4-29

QFV MAST ASSY

COMPONENTS

MAST ADJUSTMENT (QFV)

Lift Roller Adjustment The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown:

Channel seen from the top Channel seen from the bottom

0 - 0.5 mm (0 - 0.02 in)

< 0 - 0.5 mm (0 - 0.02 in)

0 - 0.8 mm (0 - 0.03 in) 450 mm

(17.7 in)

450 mm (17.7 in)

450 mm (17.7 in)

Note: The mast strip & shim adjustment between the mast channels can also be performed in the same sequence with those of V.FV.FSV.

Lift Roller Position on Each Upright:

Inner

Upper Middle

C

d

Lower Middle

B e

f

Outer

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)

Note: For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left and right sides due to tolerances of parts, etc. The inspection and adjustment must be made whenever any of the following parts is replaced: Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner mast SUB-ASSY

1. Inspection method Slowly raise the inner mast, and observe the stopping states of the left and right cylinder rods at the moment when the inner mast reaches the maximum height.

(1) Normal case Both the left and right rods stop almost simultaneously with almost no shaking of the inner mast.

(2) Abnormal case The rods stop with slight difference and the top of the inner mast shakes at the time of stopping. To correct this, add shims to the cylinder that stops first.

2. Adjustment method (1) Raise the inner mast, set the SST to the outer mast

tie beam, and lower the inner mast until it reaches the S ST. SST 0961 0-22000-71

(2) Remove the set bolt of the cylinder rod end on the side requiring shim adjustment.

(3) Slowly lower the lift cylinder rod and disconnect the cylinder rod end.

(4) Place shims on the cylinder rod end. Slowly raise the cylinder rod end into the inner mast.

(5) Fix the set bolt of the cylinder rod end. (6) Raise the inner mast for reinspection. (7) Repeat the inspection and adjustment until the num-

ber of shims is determined.


CYLINDER (2.3 TON SERIES)

Page

LlFT CYLINDER (V) REAR LIFT CYLINDER (FV-FSV*QFV) ................. 5-2

GENERAL ........................................................................ 5-2

SPECIFICATIONS ............................................................ 5-5

................................................................ COMPONENTS 5-7

FLOW REGULATOR VALVE (V*FV*FSV-QFV) ..... 5-22

GENERAL .................................................................... 5-22

SPECIFICATIONS ............................................................. 5-22

SAFETY DOWN VALVE (V-FV-FSVoQFV) .............. 5-23

GENERAL ..................................................................... 5-23

FRONT LIFT CYLINDER (W-FSV-QFV) ................. 5-24

G EN ERA1 ........................................................................ 5-24

SPECIFICATIONS ............................................................. 5-25

COMPONENTS ............................................................... 5-26

REMOVAL~INSTALLATION .............................................. 5-27

.................. DISASSEMBLY.INSPECTI0N.REASSEMBLY 5-28

TILT CYLINDER ............................................................. *

* The tilt cylinder has been unchanged . Please refer to the Repair Manual 5FBCU15. 18.20.25. 30 Pub . No . CU305 .

LlFT CYLINDER (V) REAR LlFT CYLINDER (FV*FSV*QFV)

GENERAL

Lift Cylinder 0//2 Ton Series)

Lift Cylinder (V13 Ton Series)

Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSV12 Ton Series)

Rear Lift Cylinder (FSVl3 Ton Series)

Rear Lift Cylinder (QFV)

SPECIFICATIONS

Lift Cylinder O/)

3 ton series

Single-acting

55.0 (2.1 7)

45.0 (1.77)

U packing

U packing


Itern

Cylinder type

Cylinder bore mrn (in)

Piston rod outside diameter rnm (in)

Piston seal type

Rod seal type

Single-acting

50.0 (1.97)

42.0 (1.65)

U packing

U packing

Others Built-in safety down valve (RH, LH)

Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSV)

3 ton series

Single acting

55.0 (2.1 7)

40.0 (1 57)

U packing


ltem

Rear Lift Cylinder (QFV)

Cylinder type



Rod seal type

Single acting

50.0 (1.97)

34.9 (1.37)

U packing

Others

3 ton series

Single acting

55.0 (2.1 7)

45.0 (1.77)

U packing

U packing


ltem

Built-in safety down valve (LH)

Cylinder type



Piston seal type

Rod seal type


ltem

Single acting

50.2 (1.98)

42.0 (1.65)

U packing

U packing

Others

Cylinder type



Rod seal type

Others

Built-in safety down valve (RH)

Single acting type

63.5 (2.50)

50.8 (2.00)

U packing

Built-in safety down valve (LH)

5-7

COMPONENTS

Lift Cylinder for V Mast (2 Ton Series)

Lift Cylinder for V Mast (3 Ton Series)

Rear Lift Cylinder for N Mast on 2 Ton & 3 Ton Series

6503

AN

AM

OP[LH] 01 [RH] ...,

22

21 1 , 20

I -1.J

L... - 6503-113A

Rear Lift Cylinder for FSV Mast on 2 Ton Series

Rear Lift Cylinder for FSV Mast on 3 Ton Series

6503 94125-4120-

BE+ & AI

a AM

01 [RH] ....I

02K

A A

9 1 6 1 1 - 4 1 0 1 4 d 6503-1 12A

Rear Lift Cylinder for QFV Mast

6503

02 [LH] AW

01 [RH]

rm== I I ==mi I r=l= I I

I I , I I I I I L l l l 11111 L l l l 11111

6503-0938

I I I I I I I

W A D W A F W A C

-02K -01 K 23 22

I

I

REMOVAL-INSTALLATION

Removal Procedure

1 Set the mast vertical and lower the fork fully.

2 Remove the lift cylinder rod end set bolt.

3 Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point I ]

4 Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space.

5 Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.

6 Remove the hose cover.

7 Disconnect the hose.

8 Remove the lift cylinder bottom end set bolt.

9 Remove the lift cylinder support. [Point 21

10 Remove the lift cylinder ASSY.


. The installation procedure is the reverse of the removal procedure.

Note: After installing the lift cylinder, follow the steps below. 1. Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal function-

ing. 2. Check the hydraulic oil level and add if insufficient. 3. Inspect lift cylinders for uneven lifting, and make necessary adjustment.

Point Operations

[Point I ] Removal:

Shim adjustment is made at the lift cylinder rod end to prevent uneven lifting by lift cylinders LH and RH. Take notes on the cylinder where adjustment is made and the number of shims used.


Temporarily fasten the cylinder support here, and eliminate any clearance between the cylinder support and outer mast by shim insertion after connecting the rod end. (Use shim(s) slightly thicker than the clearance.)

DISASSEMBLY-INSPECTION-REASSEMBLY

Lift Cylinder for V Mast T = N-m (kgf-cm) [ft-lbfl

2 2

4 4

* Cylinder cover 2 ton series: 3 ton series:

T = 230 - 265 (2345 - 2703) [I 70 - 1951 T = 264 - 305 (2695 - 31 10) [I 75 - 2251


1 Remove the safety down valve.

2 Remove the cylinder cover. [Point 11

3 Remove the seals from the cylinder cover

4 Remove the piston rod. [Point 21

5 Remove the seals on the piston rod

6 Remove the check valve from the piston rod. [Point 31

7 Remove the cylinder. [Point 41



Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Point Operations

[Point I]

Disassem bly-Reassembly: SST 09620-1 01 00-71

[Point 21

Inspection: Measure the piston rod outside diameter.

2 ton series Standard: 42.0 mm (1.654 in) Limit: 41.92 mm (1.6504 in)


Inspection: Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

[Point 31

Reassembly: Install the check valve arrow pointing to the lower side of the cylinder.

Inspection: Measure the cylinder bore.



Rear Lift Cylinder for FV Mast

- - - - - - --


*-I Cylinder cover 2 ton series:

T = 203 - 271 (2073 - 2764) [ I 50 - 2001 3 ton series:

T=237 -305 (2419 -3110) [I75 -2251

*-2 Air bleed screw: T = 4.5 - 5.0 (46 - 51) [3.33 - 3.691

Disassembly Procedure (1) LH Rear Lift Cylinder.


2 Remove the cylinder cover. [Point 11

3 Remove the seals from the cylinder cover.


5 Remove the wear ring.

6 Remove the bleed screw.


(2) RH Lift Cylinder.

1 Loosen the cylinder cover. [Point 11


3 Remove the piston. [Point 31

4 Remove the piston seals.

5 Remove the cover and the seals.

6 Remove the bleed screw.




Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening. Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following sequence: (1) Extend the N rear lift cylinder. (2) Stop the engine. (3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.

Point Operations

[Point 1]

Disassem bly.Reassernbly: SST 09620-1 01 00-71

[Point 21





Limit: 2.0 mm (0.079 in)

[Point 31

Disassembly~Reaseembly: Follow the procedure view. 1. Fix the boss portion at the tip end of the piston rod in a

vise.

2. Use a screwdriver and rotate the piston to remove the wire.

3. The installation is the reverse.

[Point 41

Inspection: Measure the lift cylinder bore.


3 ton series Standard: 55.0 mm (2.1 65 in) Limit: 55.35 mm (2.1791 in)

Rear Lift Cylinder for FSV Mast


LH RH

2 ton series and 3 ton series

*Cylinder cover: 2 ton series T = 230 - 265 (2345 - 2702) [I70 - 1951 3 ton series T = 237 - 305 (241 9 - 31 10) [I 75 - 2251



2 Remove the cylinder cover. [Point I]



5 Remove the piston seals, and the check valve. [Point 31


Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.


Point Operations

[Point 1]

Disassembly- Reassembly: SST 09620-1 01 00-71

[Point 21





Limit: 2.0 mm (0.079 in)

[Point 31

Reassembly: Install the check valve so that the arrow directs to down- ward of the lift cylinder.

[Point 41




Rear Lift Cylinder for QFV Mast



2 Remove the plug.

3 Remove the cylinder cover.








Point Operations

[Point I ]




Limit: 2.0 mm (0.079 in)

[Point 21



FLOW REGULATOR VALVE (V-FV-FSV-QFV) G E N E R A L T = N-m (kgf-cm) [ft-lbfl

Piston

T = 58.8 - 68.6 (600 - 700) [43.4 - 50.61

SPECIFICATIONS

Fork Lowering Speed Unit: mmtsec (fpm)

Note: The flow regulator valve is installed in the hydraulic piping system, respectively for each model.

V FV

420 (83)

480 (94)

390 (77)

460 (91 )

500 (98)

500 (98)

500 (98)

500 (98)

2 ton series

3 ton series

FSV

450 (89)

480 (94)

420 (83)

460 (91 )

No-load

Loaded

No-load

Loaded

QFV

400 (79)

510 (100)

SAFETY DOWN VALVE (V*FV*FSV-QFV) GENERAL

I I

I' I I

Cartridge type L---. Ex. FSV Rear Cyl.

on 2.3 ton series Internal type

FRONT LIFT CYLINDER (FV-FSVQFV) GENERAL

FV: 2 ton series FSV: 2 ton series QFV: 2 ton series O

0

FV: 3 ton series r FSV: 3 ton series 0

w

4 I

m

0

5-25

SPECIFICATIONS

Front Lift Cylinder (FV)

Front Lift Cylinder (FSV-QFV)

3 ton series

Single acting

85.0 (3.35)

50.8 (2.00)

U packing

U packing


ltem

Cylinder type



Rod seal type

Piston seal type

Vehicle model

ltem

Cylinder type



Piston seal type

Rod seal type

Others

Single acting

75.0 (2.95)

50.8 (2.00)

U packing

U packing

Others Built in safety down valve

2 ton series

Single acting

75.0 (2.95)

50.8 (2.00)

U packing

U packing

Built-in safety down valve

3 ton series

Single acting

85.0 (3.35)

50.8 (2.00)

U packing

U packing

2 ton series QFV

Single acting

75.0 (2.95)

50.8 (2.00)

U packing

U packing

COMPONENTS

Front Lift Cylinder for N Mast

Front Lift Cylinder for FSV and QFV Mast


Removal Procedure

1 Remove the lift bracket Wlfork.

2 Disconnect the piping.

3 Remove the front lift cylinder



Note: After installing the lift cylinder, follow the steps below. (1) Repeat full-stroke raising and lowering without load to bleed air and check normal function-

ing. (2) Check the hydraulic oil level, and add if insufficient. (3) Adjust the lift chain tension equally on the left and right sides.

Front Lift Cylinder for FV-FSV-QFV


FV FSVQFV

4 4

* Cylinder cover FVIFSVIQFV on 2 ton series T = 339 - 407 (3455 - 41 47) [250 - 3001 FVIFSV on 3 ton series T = 420 - 454 (4283 - 4630) [310 - 3351



2 Remove the cylinder cover. [Point I ]

3 Remove the cover seals.



6 Remove the check valve. [Point 31




Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening. Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the cylinder cover.

Filling amount cm3 (in3): FVIFSV 2 ton series 100 (6.1 0) FVIFSV 3 ton series 75 - 80 (4.57 - 4.88)

Point Operations

[Point I]

Disassem bly.Reassembly: SST 09620-1 01 00-71

[Point 21


2 ton series and 3 ton series: Standard: 50.8 mm (2.0 in) Limit: 50.72 mm (1.9969 in)


Limit: 2.0 mm (0.079 in)

[Point 31

Assembly: Install the check valve so that the arrow will direct down- ward of the front lift cylinder.

[Point 41




OIL CONTROL VALVE Page

GENERAL ..................................................................... 6-2 SPECIFICATIONS ..................................................... 6-4

COMPONENTS ......................................................... 6-4

OIL CONTROL VALVE ASSY .................................. 6-5

REMOVAL.INSTALLATION ........................................... 6-5

DISASSEMBLY.INSPECTI0N.REASSEMBLY ................ 6-6

RELIEF PRESSURE ADJUSTMENT ...................... 6-8

GENERAL Oil Control Valve

Relief Valve

Lift relief valve Tilt relief valve

Tilt Lock Valve

Hydraulic Circuit

TI T2 P

. . . . . . . . . . - . . . . -. . . - --- . . . . . . . . - - -. . . . . . . . -. . .

P: Pump port T: Tank port TI: To tank T2: From power steering

SPECIFICATIONS

COMPONENTS

Spec. item

Oil control valve type

Lift relief valve set pressure kPa (kgf/cm2) [psi]

Tilt relief valve set pressure kPa (kgf/cm2) [psi]

Type & values

Add on type of 3 spools (Monoblock for each spool section)

171 60 (1 75) [2490]

15690 (1 60) [2280]

OIL CONTROL VALVE ASSY


Note: Before disconnecting the control lever link, release the residual pressure in the material handling system piping by operating the control lever, set the mast in the neutral state and lowering the fork to the bottom position.

Removal Procedure


2 Disconnect the control valve lever link

3 Disconnect the piping.

4 Remove the oil control valve set bolt.

5 Remove the oil control valve ASSY.



Note: Apply grease to the oil control valve lever link parts. Check the hydraulic oil level, and add if insufficient.

DISASSEMBLY-INSPECTION-REASSEMBLY

Note: Operate in a clean place. As each part is finished with high precision, carefully disassemble them to prevent any damage.


1 Remove the through bolt.

2 Separate each housing.

3 Remove the O-ring, spring and check valve.

4 Remove the seal holder.

5 Remove the spring holder.

6 Remove the spool Wlspring.

7 Remove the spring. [Point I ]

8 Remove the tilt lock valve.

9 Remove the relief valve. [Point 21

Point Operations

[Point 11 Disassembly.Reassembly:

SST 0961 0-1 01 61 -71


When the relief valve is disassembled, always loosen the adjust screw fully.

RELIEF PRESSURE ADJUSTMENT Note: Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices.

1. Install an oil pressure gage. (1) Remove the oil pressure detection plug (911 6-1 8UNF-

2B) installed on top of the oil control valve, and install the oil pressure gage.

2. Check loosening of the adjust screw. (1) Remove the cap nuts and packings on top of the relief

valves. Loosen the adjust screw to a degree not to come off from the body.

3. Turn the key switch on.

4. Adjust the lift side relief pressure. (1) Set the control lever to the lift position and gradually

tighten the adjust screw on the lift relief valve until the fork starts to rise.

(2) Lift the forks to the maximum height, and read the pressure gage. Adjust the oil pressure then to the specified level by turning the adjust screw.

5. Adjust the tilt side relief pressure. (1) Set the control lever at the backward tilt position, and

gradually tighten the adjust screw on the tilt relief valve until the mast starts to be tilted backward.

Relief Set Pressure (2) Tilt the mast fully backward, and read the oil pressure Unit: kPa (kgf/cm2) [psi] gage. Adjust the oil pressure then to the specified level

All models I by turning the adjust screw.

7. Remove the oil pressure gage, and tighten the plug.

Lift

Tilt

171 60:~(175::)[2490:~]

15690::,9: (1 601~)[2280:~~]

6. After the adjustment, insert the packing and tighten the cap nut. Inspect the relief pressure again.

APPENDIX Page

SST LlST ...................................................................... 7-2

SERVICE STANDARDS LlST ...................................... 7 4

SST LIST

lllustrat~on

0 0 0 ~

Front axle bearlng

Part No

0931 6-6001 1

09509-55020

09608-04031

09950-4001 1

09950-6001 0

09950-60020

Part Name

Transmlsson & transfer bearlng replacer

Rear wheel bearlng nut wrench

Front hub inner bearlng cone replacer

Puller B set

Replacer set

Replacer set No 2

0

0

0

0

0

O

0

0

0

0

Sectlon

1 2 3 4 5 6

0

Drlve pinlon bearing

011 control valve sprlng

@ 4 0

g- c-

e

0961 0-22000-71

09620-1 01 00-71

09630-1

09630-23600-71

09631-22000-71

0981 0-201 72-71

Inner mast stopper

Cylinder cap remover and replacer

Tilt cylinder cap remover and replacer

Deep socket A

Wear scale chain

Jolnt pln remover

0

0

0

0

0

0

O

SERVICE STANDARDS LIST

DRIVE UNIT

Differential

Ring gear backlash mm (in)

Differential pinion bore mm (in)

Spider outside diameter mm (in)

Side gear thrust washer thickness mm (in)

Pinion gear thrust washer thickness mm (in)

Drive pinion bearing starting torque N.m (kgf-cm) [ft-lbfl

Standard

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

0.2 - 0.3 (0.008 - 0.012)

22.12 (0.8709)

22.22 (0.8748)

22.00 (0.8661)

21.75 (0.8563)

1.6 (0.063)

1.3 (0.051)

1.6 (0.063)

1 .O (0.039)

10.79 - 13.24 (1 10 - 135) [7.96 - 9.771

Tightening torque Unit: N-m (kgf-cm) [ft-lbf]

Drive pinion lock nut

Drive pinion bearing retainer set bolt

Ring gear set bolt

Differential upper case set bolt

Differential case bearing cap set bolt

Differential cover set bolt

Standard

Standard

Standard

Standard

Standard

Standard

343 - 392 (3500 - 4000) [253.2 - 289.31

88.3 - 11 7.7 (900 - 1200) [65.1 - 86.821

127.4 - 176.5 (1 300 - 1800) [94.0 - 130.21

43.1 - 53.9 (440 - 550) [31.8 - 39.81

11 7.7 - 137.3 (1 200 - 1400) [86.82 - 101.31

29.4 - 44.1 (300 - 450) [21.7 - 32.61

FRONT AXLE

REAR AXLE

- Front axle shaft hub

Front axle bearing starting force N (kgf) [Ibfl

Rear axle ASSY

Standard

Rear axle ASSY front to rear clearance mm (in)

Rear axle center pin bushing inside diameter mm (in)

25.5 - 72.6 (2.6 - 7.4) [5.7 - 16.31

Tightening torque Unit: N.m (kgf-cm) [ft-lbf]

Hub bolt set nut

Bearing lock nut stopper bolt

Axle shaft set bolt

Front wheel hub nut

Front axle housing set bolts

Standard

Limit

0.7 (0.028) or less

52.0 (2.047)

Rear axle hub and steering knuckle

Standard

Standard

Standard

Standard

Standard

166.7 - 205.9 (1 700 - 21 00) [ I 23.0 - 151.91

14.7 - 21.6 (1 50 - 220) [ I 0.9 - 15.91

98.07 - 127.5 (1 000 - 1300) [72.35 - 94.061

294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

107.9 - 137.3 (1 100 - 1400) [79.59 - 101.31

9.8 - 29 (1 .O - 3.0) [2.2 - 6.61

27.8 (1.094)

19.3 (2.0) [4.4] or less

Rear axle wheel starting force N (kgf) [Ibfl (at outer periphery of the wheel)

King pin outside diameter mm (in)

Steering knuckle starting force N (kgf) [Ibfl (at front end of knuckle)

Standard

Limit

Standard

Rear axle cylinder

Rear axle cylinder piston rod outside diameter mm (in)

Rear axle cylinder piston rod bend mm (in)

Rear axle cylinder inside diameter mm (in)

Limit

Limit

Limit

49.92 (1.9654)

0.5 (0.01 7)

76.35 (3.0059)

Rear wheel alignment

0 k 4 (0 k0.16) Toe-in mm (in) Standard


11 7.7 - 166.7 (1 200 - 1700) [86.82 - 123.01

44.1 - 53.9 (450 - 550) [32.6 - 39.81

88 - 118 (900 - 1200) [65.1 - 86.81

166.7-215.8(1700-2200)[123.0-159.11

Axle bracket cap set bolt

King pin lock bolt and lock nut

Rear axle cylinder rod guide set nut

Rear axle cylinder set bolt

Standard

Standard

Standard

Standard

Mast adjustment (V mast)

Mast 'Oilers

Lift bracket 'Oilers

0 - 0.8 (0 - 0.031)

0 - 0.5 (0 - 0.020)

0 - 0.5 (0 - 0.020)

0 - 0.5 (0 - 0.020)

Inner mast roller clearance mm (in)

Outer mast roller clearance mm (in)

Middle and lower lift roller clearance mm (in)

Side roller clearance mm (in)

0.5 - 1 .O (0.020 - 0.039)

Standard

Standard

Standard

Standard

Mast strip to inner mast clearance mm (in) Limit

Fork

Fork front end misalignment mm (in)

Tightening torque Unit: N.m (kgf-cm) [ft-lb]

Mast support cap set bolt

Back rest set bolt

Chain adjusting nut

Standard

Standard

Standard

68.6 - 107.9 (700 - 11 00) [50.6 - 79.571

99.54 - 184.9 (1 01 5 - 1885) [73.42 - 136.31

49.0 - 78.0 (500 - 800) [36.2 - 57.91

CYLINDER

Lift cylinder 01)



2 ton series

3 ton series

2 ton series

3 ton series

Piston rod bend mm (in)

Limit

Limit

Limit

Limit

41.92 (1.6504)

44.92 (1.7685)

50.20 (1.9764)

55.35 (2.1 791)

Limit 2.0 (0.079)

Rear lift cylinder (FV-FSV-QFV)

34.82 (1.3709)

41.92 (1.6504)

39.92 (1.571 7)

44.92 (1.7685)

50.72 (1.9969)

50.20 (1.9764)

50.40 (1.9843)

55.35 (2.1 791)

55.20 (2.1 732)

63.85 (2.51 38)

2.0 (0.079)

Piston rod outside diameter mm On)


2 ton series

3 ton series

2 ton series

2 ton series

3 ton series

2 ton series

Piston rod bend mm (in) Limit

FV

FSV

FV

FSV

QFV

FV

FSV

FV

FSV

QFV

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

OIL CONTROL VALVE

Front lift cylinder (FV.FSV.QFV)

Piston rod outside diameter mm On)


Oil control valve

2 ton series

3 ton series

2 ton series

2 ton series

3 ton series

2 ton series

Relief set pressure kPa (kgf/cm2) [psi]

Piston rod bend mm (in)

FV

FSV

FV

FSV

QFV

FV

FSV

FV

FSV

QFV

Lift

Tilt

Limit 2.0 (0.079)

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit


Standard

Standard

50.72 (1.9969)

t

t

7

?

75.35 (2.9665)

t

85.40 (3.3622)

t

75.35 (2.9665)

171 60 'igO(l 75 'i) [2490'?]

15690 ~ ~ ~ ~ ( 1 6 0 '3,) [2280'j:]

58.8 - 68.7 (600 - 700) [43.4 - 50.61 Flow regulator valve Standard

TOYOTA BATTERY FORKLIFT 5FBCU15 1999. Please...

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Transcript of TOYOTA BATTERY FORKLIFT 5FBCU15 1999. Please...