Professional Documents
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GENERAL
CONTROL CIRCUIT
MULTIDISPLAY FUNCTIONS
ELECTRICAL SYSTEM TROUBLESHOOTING
MATERIAL HANDLING SYSTEM
MAST
CYLINDERS
APPENDIX
FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
5FB10 ~ 30 series.
Since this manual describes alterations made in the vehicles being pro-
Section Index
EXTERIOR VIEWS
0-3
VEHICLE MODELS
FRAME NUMBER
0-4
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.
Example: 1 Piping
Disassembly Procedure
[Point 1]
Disassembly: Put a match mark when removing the pump cover.
[Point 2]
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
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0-5
TERMINOLOGY
Caution:
Important 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.
ABBREVIATIONS
0-6
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively ac-
cording to 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 judgment.
Digital type: Fairly accurate reading is possible, but it is difficult to 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 to 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
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-
low.
Forward direction Reverse direction
0-7
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 repe(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 they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts 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.
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.
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.
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth to 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.
0-13
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (ton) [lb]
0-14
COMPONENTS WEIGHT
0-15
LUBRICATION CHART
PERIODIC MAINTENANCE
INSPECTION METHOD
GENERAL
The 5FB series has the diagnosis (self-diagnostic) function to sound the buzzer (beep, beep) and
indicate the abnormal part by the corresponding “error code” on the multidisplay by automatically
detecting any trouble in the main drive and material handling circuits, operating system such as
the accelerator, and sensors.
When this display is switched to the analyzer (failure analysis) mode, defective part detection and
functional check of the main circuits for traveling and material handling, each operating system
and sensors are carried out.
In the minor change, the MP contactor in the control panel is abolished and the MB contactor is
installed in the control panel.
SPECIFICATIONS
2-4
COMPONENTS
2401
2-5
2403
2-6
CONTROL PANEL ASSY
Removal·Installation
Removal Procedure
Installation Procedure
<Note>
Before setting the battery plug to ON, check cable connection status for any omission or insuffi-
l
cient tightening. If loose, elements in the controller panel may be damaged.
Check for no incorrect wiring in the installation job. (See page 2-26.)
l
2-7
Inspection
Some components can be inspected without removal from the vehicle while other components
require removal before inspection.
The CPU board and DC-CD board are inspected on the vehicle because battery voltage application
is necessary. (Use SST 09240-13200-71 or SST 09240-23400-71.)
The description here is mainly for inspection after removing control panel from the vehicle.
1. Insulation resistance measurement (always inspect the insulation resistance before starting
control panel inspection.)
(1) Set the battery plug to off and measure the insulation resistance between the battery plug
wire harness and body.
2-8
2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor)
(1) Inspection method
Disconnect the CAD and CAP wirings after discharging CAD and CAP through a resistance
of about 100 Ω .
Standard
The multimeter pointer deflects when multimeter probes are brought into contact with the termi-
nals of CAD or CAP, gradually returns toward then, and finally indicates .( Ω results be
cause the capacitor is charged by the multimeter current.)
Standard
The circuit tester pointer deflects once to 0 Ω side when circuit tester probes are brought into
contact with the terminals of CO. Gradually returns toward Ω then, and finally indicates Ω.
Ω results because the capacitor is charged by the circuit tester current.
2-9
If any abnormality is found in inspection for each of TM and TMP, replace them as a set.
5. TG (regenerative transistor)
(1) Inspection method
Disconnect the TG wiring.
2-10
8. DG (regeneration diode)
(1) Inspection method
Disconnect the DG wiring.
Caution:
Always disconnect the battery plug before removing or installing the CPU board or DC-CD board.
Caution:
l Always carry out measurement before replacing the CPU or DC-CD board according to the
judgment of a defect of the CPU or DC-CD board by troubleshooting.
l Use SST 09240-13200-71 for measurement.
Caution
If the SST is set without disconnecting the battery plug, the SST (IC clip) may short-circuit
between connector pins.
2-16
Table
CN101 Connector: Basic conditions (battery plug ON and key switch OFF)
2-17
CN101 Connector: Basic conditions (battery plug ON and key switch OFF)
CN102 Connector: Basic conditions (battery plug ON and key switch OFF)
2-18
CN104 Connector: Basic conditions (battery plug ON and key switch ON)
2-19
CN105 Connector: Basic conditions (battery plug ON and key switch ON)
2-20
CN106 Connector: Basic conditions (battery plug ON and key switch ON)
2-21
CN106 Connector: Basic conditions (battery plug on and key switch on)
CN107 Connector: Basic conditions (battery plug on and key switch on)
2-22
15. Display
When the cause of a trouble is judged to exist in the display, apply the battery voltage and
measure the voltages applied to each connector.
Disassembly
The controller requires little overhaul operation. Most of service jobs are defective parts replace-
ment after grasping the cause by inspection.
l Tighten the bar and harness mounting nuts and screws to the specified torques, and always coat
Locktite (thread tightener).
l Loosening or insufficient tightening (tightening failure) will cause new troubles.
Before disconnecting a bar or harness, always record the mounting position or put a tag show-
ing the position. Check the memo or tag at the time of connection to prevent incorrect installa-
tion or wiring.
In correct installation or wiring will cause new troubles.
l Always coat silicone grease for parts applied with silicone grease. Omission of coating may
cause overheating.
l After completion of installation, check no contact of the bar and wiring at unnecessary places.
Use a multimeter to check continuity at check points before installation on the vehicle.
(See page (2-26) for the check points with the multimeter.)
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