Original Illustrated Factory Workshop Service Manual for Toyota Electric Forklift Truck 5FB-Series.

Original factory manuals for Toyota (BT) Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks

Covered models:
5FBE10
5FBE13
5FBE15
5FBE18
5FBE20

Format: PDF,734 Pages
Language: English

Contents:
GENERAL
EXTERIOR VIEWS
VEHICLE MODEL
FRAME NUMBER
HOW TO USE THIS MANUAL
EXPLANATION METHOD
TERMINOLOGY
ABBREVIATIONS
LIST OF ABBREVIATIONS AND SYMBOLS
OPERATIONAL TIPS
JACK-UP POINTS
CIRCUIT TESTER
STANDARD BOLT & NUT TIGHTENING TORQUE
BOLT STRENGTH TYPE IDENTIFICATION METHOD
TIGHTENING TORQUE TABLE
PRECOAT BOLTS
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE
COMPONENTS WEIGHT
RECOMMENDED LUBRICANTS AND CAPACITIES
LUBRICATION CHART
PERIODIC MAINTENANCE
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
BATTERY
SERVICE STANDARDS
DISPLAY INDICATION
OVERDISCHARGE ALARM FUNCTION
BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
TROUBLESHOOTING
BATTERY ASSY
INSPECTION
ELECTRICAL SYSTEM TROUBLESHOOTING [For USA 1993.1 -1999.1; For non USA 1993.1-1998.8]
MCS-IIIA CONTROLLER
GENERAL
SPECIFICATIONS
COMPONENTS
CONTROL PANEL REMOVAL . INSTALLATION
CONTACTOR PANEL REMOVAL . INSTALLATION
INSPECTION
DISASSEMBLY
REASSEMBLY
PANEL PARTS TIGHTENING TORQUE
CONTINUITY CHECK WITH CIRCUIT TESTER
OCL (OVERCURRENT LIMIT) VALUES
ACCELERATION POTENTIOMETER
ADJUSTMENT
BRAKE SWITCH-STOP LAMP SWITCH
ADJUSTMENT
PARKING BRAKE SWITCH ADJUSTMENT
MATERIAL HANDLING SWITCH
ADJUSTMENT
DIRECTION SWITCH
DISASSEMBLY-INSPECTION-REASSEMBLY
PS CONTROLLER
COMPONENTS
INSPECTION (STD)
(EHPS)
EHPS CONTROLLER VOLTAGE MEASUREMENT
INSPECTION (EHPS)
REASSEMBLY (EHPS)
STEERING POTENT10 INSTALLATION
ADJUSTMENT
ELECTRICAL SYSTEM TROUBLESHOOTING [FOR For USA: 1999.2 -; FOR OTHER THAN USA 1998.9 -]
OPERATION
GENERAL
SYSTEM CONFIGURATION
DESCRIPTION
MAJOR FUNCTIONS
MAIN CIRCUIT COMPONENTS
DRIVE CIRCUIT OPERATION
MATERIAL HANDLING CIRCUIT OPERATION
REPAIR
SPECIFICATIONS
COMPONENTS
INSPECTION
DISASSEMBLY
REASSEMBLY
PANEL PARTS TIGHTENING TORQUE
CONTINUITY CHECK WITH CIRCUIT TESTER
OCL (OVERCURRENT LIMIT) VALUES
For the follwing matters, see chapter 2 (CONTROL CIRCUIT)
CONTROL PANEL
CONTACTOR PANEL REMOVAL-INSTALLATION
DISPLAY INSPECTION
ACCELERATION POTENTIOMETER ADJUSTMENT
BRAKE LAMP SWITCH ADJUSTMEN
PARKING BRAKE SWITCH ADJUSTMENT
MATERIAL HANDLING SWITCH ADJUSTMENT
DIRECTION SWITCH
PS CONTROLLER
STEERING POTENT10 INSTALLATION ADJUSTMEN
MULTI-DISPLAY FUNCTIONS [FOR OTHER THAN USA: 1993.1 - 1998.8; FOR USA 1993.1 - ]
DIAGNOSIS
GENERAL
ANALYZER
GENERAL
USING THE ANALYZER MODE
METHOD FOR SELECTING EACH ITEM
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM
MASK FUNCTIONS
PASSWORD INPUT METHOD
MULTI-DISPLAY FUNCTIONS [FOR OTHER THAN USA: 1998.9 - ]
DIAGNOSIS
GENERAL
ANALYZER
GENERAL
USING THE ANALYZER MODE
METHOD FOR SELECTING EACH ITEM
FUNCTIONAL EXPLANATION OF EACH
TEST ITEM
MASK FUNCTIONS
PASSWORD INPUT METHOD
ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHER THAN USA 1993.1 - 1998.8; FOR USA 1993.1 -]
GENERAL
TROUBLESHOOTING EXPLANATION
DRIVE SYSTEM-MATERIAL HANDLING
SYSTEM TROUBLES
WHEN DIAGNOSTIC ERROR CODE IS
DISPLAYED
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (DRIVE SYSTEM)
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (MATERIAL HANDLING SYSTEM)
TROUBLESHOOTING-OTHERS
TROUBLESHOOTING RELATED TO MULTI-DISPLAY
AND MCS COMMUNICATION SYSTEM
STEERING SYSTEM TROUBLES
DIAGNOSIS ERRORS
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (STD)
WHEN DIAGNOSTIC ERROR CODE IS NOT
DISPLAYED (WIEHPS)
ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHER THAN USA 1998.9 - ]
GENERAL
TROUBLESHOOTING EXPLANATION
LOCATIONS OF TERMINALS AND CONNECTORS
BEFORE TROUBLESHOOTING
DRIVE SYSTEM-MATERIAL HANDLING SYSTEM TROUBLES
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (DRIVE SYSTEM)
WHEN DIAGNOSTIC ERROR CODE IS NOT DISPLAYED (MATERIAL HANDLING SYSTEM)
TROUBLESHOOTING RELATED TO STEERING SYSTEM
WHEN DIAGNOSTIC ERROR CODE IS DISPLAYED
MOTOR
DRIVE MOTOR
GENERAL
SPECIFICATIONS
COMPONENTS


PUMP MOTOR
GENERAL
SPECIFICATIONS
COMPONENTS

DISASSEMBLY INSPECTION REASSEMBLY
POWER STEERING MOTOR
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL-INSTALLATION
DISASSEMBLY .INSPECT10 NmREASSEMBLY
FRONT AXLE & TRANSMISSION (1993.1 - 1998.1)
GENERAL
SPECIFICATIONS
COMPONENTS
TRANSMISSION

DISASSEMBLY .
FRONT AXLE
.
FRONT AXLE & DRIVE UNlT (1998.2 -)
GENERAL
SPECIFICATIONS
COMPONENTS
FRONT AXLE & DRIVE UNIT

.
REAR AXLE (1993.1 - 1998.1)
REAR AXLE ASSY
GENERAL
SPECIFICATIONS
COMPONENTS

DISASSEMBLY .INSPECT10 NmREASSEMBLY
REAR AXLE HUB
REAR AXLE (1998.2-)
GENERAL
SPECIFICATIONS
COMPONENTS
REAR AXLE HUB
REMOVAL-INSTALLATION
REAR AXLE ASSY
.
STEERING
GENERAL
COMPONENTS
SPECIFICATIONS
HYDROSTATICS STEERING VALVE ASSY


STEERING WHEEL

MAST JACKET ASSY

DISASSEMBLY *
STEERING CYLINDER ASSY

DISASSEMBLY .
BRAKE (1993.1 - 1998.1)
GENERAL
SPECIFICATIONS
COMPONENTS
DISC BRAKE


DISC BRAKE ADJUSTMENT
BRAKE PEDAL
REMOVAL-INSTALLATION
BRAKE PEDAL ADJUSTMENT
MASTER CYLINDER


PARKING BRAKE

AIR BLEEDING FROM BRAKE SYSTEM
BRAKE (1998.2 -)
GENERAL
SPECIFICATIONS
COMPONENTS
DISC BRAKE
REMOVAL-INSTALLATION
. REASSEMBLY
DISC BRAKE WHEEL INSPECTION
BRAKE ADJUSTMENT
AIR BLEEDING FROM BRAKE SYSTEM
BRAKING FORCE INSPECTION
MASTER CYLINDER (1998.2 - 2000.3)
REMOVAL-INSTALLATION
DISASSEMBLY-INSPECTION-REASSEMBLY
MASTER CYLINDER (2000.4 -1

DISASSEMBLY INSPECTION .REASSEMBLY
PARKING BRAKE
REMOVAL-INSTALLATION
BRAKE PEDAL

ADJUSTMENT .
BODY & FRAME
BODY FRAME
COMPONENTS
BATTERY HOOD
BALANCE WEIGHT
COMBINATION METER
DISASSEMBLY *
MATERIAL HANDLING SYSTEM
NATURAL DROP TEST
NATURAL FORWARD TILT TEST
OIL LEAK TEST
MAST
V MAST ASSY
COMPONENTS .
REMOVAL INSTALLATION
DISASSEMBLY . INSPECTION . REASSEMBLY
LIFT BRACKET
REMOVAL INSTALLATION
DISASSEMBLY . INSPECTION . REASSEMBLY
CHAIN
REMOVAL INSTALLATION
CHAIN INSPECTION .
CHAIN ADJUSTMENT .
FORK
REMOVAL
INSTALLATION .
INSPECTION
MAST ADJUSTMENT .
V-SV MAST
FV MAST
FSV MAST
LlFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)
CYLINDER
LIFT CYLINDER ASSY (1993.1 . 1994.1)
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL . INSTALLATION
DISASSEMBLY . INSPECTION . REASSEMBLY
TILT CYLINDER
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL . INSTALLATION
DISASSEMBLY . INSPECTION . REASSEMBLY
LIFT CYLINDER ASSY (1 994.1 . )
GENERAL
SPECIFICATIONS
COMPONENTS

DISASSEMBLY INSPECTION-REASSEMBLY
OIL PUMP
OIL PUMP ASSY
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL . INSTALLATION
DISASSEMBLY . INSPECTION . REASSEMBLY
TEST PROCEDURE
POWER STEERING PUMP ASSY
GENERAL
SPECIFICATIONS
COMPONENTS
REMOVAL . INSTALLATION .
OIL CONTROL VALVE
GENERAL
SPECIFICATIONS
HYDRAULIC CIRCUIT
COMPONENTS
OIL CONTROL VALVE ASSY


RELIEF PRESSURE ADJUSTMENT
OIL CONTROL VALVE LINK
COMPONENTS .
APPENDIX
SST LIST
SERVICE STANDARDS LIST
CONNECTOR DRAWING [FOR OTHER THAN U.S.A.]
CONNECTOR DRAWING [FOR U.S.A.]
CPU BOARD & DC/SD BOARD
CONNECTOR DRAWING (Harness side)
CONNECTING DIAGRAM [FOR OTHER THAN U.S.A.]
CONNECTING DIAGRAM [FOR U.S.A.]
WIRING DIAGRAM [FOR OTHER THAN U.S.A.]
WIRING DIAGRAM [FOR U.S.A.]