Toyota Electric Forklift Truck 5FBE10, 5FBE13, 5FBE15, 5FBE18, 5FBE20 Workshop Service Manual

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) 
    REMOVAL.INSTALLATION (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 REMOVAL.INSTALLATI0N 
    CONTACTOR PANEL REMOVAL-INSTALLATION 
    DISPLAY INSPECTION 
    ACCELERATION POTENTIOMETER ADJUSTMENT 
    BRAKE SWITCH.STOP 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 
    REMOVAL.INSTALLATION 
    DlSASSEMBLY.INSPECTI0N.REASSEMBLY 
    PUMP MOTOR 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    REMOVAL.INSTALLATION 
    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 
    REMOVAL.INSTALLATI0N 
    DISASSEMBLY .INSPECTION.REASSEMBLY  
    FRONT AXLE 
    DlSASSEMBLY.INSPECTl0N.REASSEMBLY .
FRONT AXLE & DRIVE UNlT (1998.2 -)
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    FRONT AXLE & DRIVE UNIT 
    REMOVAL.INSTALLATION 
    DISASSEMBLY.REASSEMBLY .
REAR AXLE (1993.1 -  1998.1) 
    REAR AXLE ASSY 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    REMOVAL.INSTALLATION 
    DISASSEMBLY .INSPECT10  NmREASSEMBLY 
    REAR AXLE HUB 
REAR AXLE (1998.2-)
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    REAR AXLE HUB 
    REMOVAL-INSTALLATION 
    REAR AXLE ASSY 
    REMOVAL.INSTALLATION .
STEERING 
    GENERAL 
    COMPONENTS 
    SPECIFICATIONS 
    HYDROSTATICS STEERING VALVE ASSY 
    REMOVAL.INSTALLATION 
    DlSASSEMBLY.INSPECTI0N.REASSEMBLY 
    STEERING WHEEL 
    REMOVAL.INSTALLATION 
    MAST JACKET ASSY 
    REMOVAL.INSTALLATION 
    DISASSEMBLY *INSPECTION.REASSEMBLY 
    STEERING CYLINDER ASSY 
    REMOVAL.INSTALLATION 
    DISASSEMBLY mlNSPECTlON.REASSEMBLY .
BRAKE (1993.1 -  1998.1)
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    DISC BRAKE 
    REMOVAL.INSTALLATION 
    DISASSEMBLY.INSPECTION.REASSEMBLY 
    DISC BRAKE ADJUSTMENT 
    BRAKE PEDAL 
    REMOVAL-INSTALLATION  
    BRAKE PEDAL ADJUSTMENT  
    MASTER CYLINDER 
    REMOVAL.INSTALLATION 
    DISASSEMBLY.INSPECTI0N.REASSEMBLY 
    PARKING BRAKE 
    REMOVAL.INSTALLATION 
    AIR BLEEDING FROM BRAKE SYSTEM 
BRAKE (1998.2 -) 
    GENERAL 
    SPECIFICATIONS 
    COMPONENTS 
    DISC BRAKE 
    REMOVAL-INSTALLATION 
    DISASSEMBLY.INSPECTI0N . 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  
    REMOVAL.INSTALLATION 
    DISASSEMBLY INSPECTION .REASSEMBLY 
    PARKING BRAKE 
    REMOVAL-INSTALLATION 
    BRAKE PEDAL 
    REMOVAL.INSTALLATI0N 
    ADJUSTMENT .
BODY & FRAME 
    BODY FRAME 
    COMPONENTS 
    BATTERY HOOD 
    BALANCE WEIGHT 
    COMBINATION METER 
     DISASSEMBLY *INSPECTION.REASSEMBLY 
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 
    REMOVAL.INSTALLATION 
    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 
    REMOVAL.INSTALLATION 
    DISASSEMBLY.INSPECTION.REASSEMBLY 
    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.] .
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