This document provides an overview and instructions for using a service manual for Toyota battery forklifts. It begins with a foreword stating the manual covers service procedures for various forklift models from July 1995. It then provides a section index and general information sections covering topics like exterior views, vehicle models, frame numbers, how to read the manual, terminology, abbreviations, operational tips, and maintenance schedules. It includes diagrams, part numbers, torque specifications and other technical details.

1. FOREWORD
Thjs manual covers the service procedures of the TOYOTA BATTERY
FORKLIFT 5FBCU15 -- 30 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of July 1995. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due to change in disign and specifica-
tions. Any change or modifications thereafter will be informed by
Toyota Industrial Vehicles' Parts & Service News.
TOYOTA MOTOR CORPORATION

2. SECTION INDEX
NAME 1 SECT1
e
x m
CC
MULTIDISPLAY FUNCTIONS
ELECTRICAL SYSTEM TRouBLEsHooTlNG mA
MOTOR
DRIVE UNIT
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY & FRAME
y
MAST
CYLINDER
OIL PUMP
pa
APPENDIX

3. GENERAL
Page
EXTERIOR VIEWS ........................................ 0-2
VEHICLE MODEL ................................................ 0-3
FRAME NUMBER ............................................... 0-4
HOW TO READ THIS MANUAL ......................... 0-5
.....................................EXPLANATION METHOD 0-5
TERMINOLOGY ..................................................0-6
................................................ABBREVIATIONS 0-6
.............LIST OF ABBREVIATIONS AND SYMBOLS 0-7
OPERATIONAL TIPS ..........................................0-8
CIRCUIT TESTER ............................................... 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE .......................................................... 0-11
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ........................................................ 0-11
TIGHTENING TORQUE TABLE ...............................0-12
PRECOAT BOLTS ............................................... 0-13
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE .................................... 0-13
WIRE ROPE SUSPENSION ANGLE LIST ............. 0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ......................................0-14
COMPONENTS WEIGHT .................................... 0-15
RECOMMENDED LUBRICANTS
AND CAPACITIES ...................................... 0-16
GREASE ON MICRO SWITCH FOR
INSTALLATION ......................................... 0-17
INSTRUCTION OF OIL CHECK LEVEL
...........................IN HYDRAULIC OIL TANK 0-17
LUBRICATION CHART .................................. 0-18
PERIODIC MAINTENANCE ............................. 0-19
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ..................................... 0-24

4. EXTERIOR VIEWS
I I
Front View
I
Rear View

5. VEHICLE MODELS
Types on Spec.
1-ton
series
STD spec.
models
STD capacity
battery
compartment
High capacity
%
Dust proof
models
STD capacity
battery
compartment
High capacity
2-ton
series
3-ton
series
2-ton
series
I -ton
series
2-ton
series
%ton
series
2-ton
series
% These high capacity (battery compartment) models are not established in EEC specification.
Load Capacity Model

6. FRAME NUMBER
Above side frame of LH
7
1-ton series
2-ton series
3-ton series
1-ton series
2-ton series
3-ton series
Models
5FBCU15
5FBCU18
5FBCU20
5FBCU25
5FBCHU20
5FBCHU25
5FBCU30
30-5FBCU15
30-5FBCU18
30-5FBCU20
30-5FBCU25
30-5FBCHU20
30-5FBCHU25
30-5FBCU30
Stamping Form
[( ) showing EEC specifications for ECI
5FBCU15-10011
(5FBCU15 @ 10011)
5FBCU25-10011
(5FBCU25 @ 10011)
5FBCHU25-10011
(5FBCHU25 @ 1001 1)
5FBCU30-10011
(5FBCU30 @ 10011)
305FBCU15-10011
(305FBCU15 @I10011)
305FBCU25-10011
(305FBCU25 @ 1001 1)
305FBCHU25-10011
(305FBCHU25 @ 100111
305FBCU30-10011
(305FBCU30 @ 1001 1)
Remark

7. HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Ex~lanationof each ooeration step with a photo or illustration.
Pattern B: ~xplanationof operatiin procedure by indicating step numbers in one illustration, fol-
lowed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T = N-m (kgf-cm) [ft-lbfl
If a place or part cannot be indi-
cated directly, the part name is
described on the either side of
the illustration.
Example: 1 Piping
I I
Oil Pump Disassembly Procedure
Disassembly Procedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 2loOperation explained on a laterpage
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 1I 4
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit:19.12 mm (0.7528 in)

8. 2. How to read components figures (Example)
(1) The components figure use the illustra-
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of each FIG number in parts catalog
components figure indicates the Fig.
number in the parts catalog.
3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
Cleaning and washing of removed parts as required
@ visual inspection (Partially described)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to observe them.
Note:
Important items of which negligence may cause accidents or matters in operation procedure re-
quiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code)
ASSY
LH
OPT
01s
PS
RH
SAE
- - -
Meaning
Assembly
Left hand
Option
Oversize
Power steering
Right hand
Society of Automotive
Engineers (USA)
---- --
Abbreviation (code)
SST
STD
T =
0O T
UIS
W/
-- - -
Meaning
Special service Tool
Standard
Tightening torque
Number of teeth (00 )
Undersize
With
- - - --

9. 0-7
LIST OF ABBREVIATIONS AND SYMBOLS
Symbol
BATT
Bz
CADIP
CH
CHI,
CHI,
CSDIP
CS,,
DcH
DC-SDD
DC-SDP
DF112
DF314
DG
DlSP
DMD,,
DMps
DSBu
DSF
DSFo
DSR
F1
F2
F3
F4
F5
F c ~
Name
Flasher Relay
Horn
Back-up Lamp, LH
Back-up Lamp, RH
Clearance Lamp, LH
Clearance Lamp, RH
Flasher Lamp, LH
Flasher Lamp, LH (Rear)
Flasher Lamp, RH
Flasher Lamp, RH (Rear)
Head Lamp, LH
Head Lamp, RH
Rotaly Forward Lamp
Rotaly Reverse Lamp
Attachment Limit Switch
No. 112
Brake Limit Switch
Dead Man Limit Switch
Lift Limit Switch No.112
Parking Brake Limit
Switch
Stop lamp limit Switch
Stop Lamp, LH
Stop Lamp, RH
Tilt Limit Switch
Tail Lamp, LH
Tail Lamp, RH
Working Lamp
Forward Contactor
Regenerative Contactor
Pump Contactor
Power Steering Contactor
Reverse Contactor
Short Contactor
Name
Battery
Buzzer
DriveIPump Absorber
Capacitor
Charger
Forward Chime
Reverse Chime
DriveIPump Current
Sensor
Power Steering Current
Sensor
Charger Diode
DC-DC Converter &
Source Drive (Drive)
DC-DC Converter &
Source Drive (Pump)
FLY-WHEELDiode,
No. 112
FLY-WHEEL Diode No.314
Regenerative Diode
Display
DriveIPump Motor
Power Steering Motor
Back-up Direction Switch
Forward Direction Switch
Forward Optional
Direction Switch
Reverse Direction Switch
Drive Fuse
Pump Fuse
Power Steering Fuse
Lamp Fuse
Control Circuit Fuse
Charger Fuse
Symbol
MScH
M W
PBcpu
PBsps
PL,
RF
RFW
RG
RADIP
SA
SDD
SDP
SLL
SN1
SSP
SP
STH
SWAc
SW,
SW,
SW,,
SW,
SW,,
TF
TG
THR
T M
TMP
TMps
TU
VRAD
Symbol
FRY
H
L,,,
L,,.,
LC-L
LF-L
LF-,,
LF-R
L,-,,
LH-L
LH-R
LR-F
LR-R
LSATT,,,
LSB
LSD
LSL1/2
LS,,
LS,,
LST-,
LsT-,
LS,
LT-L
LT-R
L,
MF
MG
MP
MPS
MR
MS
Name
Charger Magnet Switch
Field Weakning Contactor
Computer Print Board
SPS Print Board
Working Pilot Lamp
Fan Resistor
Field Weakning Resistor
Regenerative Resistor
Drivelpump Absorber
Resistor
Surge Absorber
Drive SIT Driver
Pump SIT Driver
Lequid Level Sensor
Snubber No. 1
Speed Sensor
Steering Pressure Sensor
Thermo Sensor
Accel Switch
Flasher Switch
Horn Switch
Key Switch
Light Switch
Speed Control Switch
Transformer
Regenerative Transistor
Thermal Relay
Main Transistor
Main Pump Transistor
Main Power Steering
Transistor
Timer Unit
Accel Drive Vari-Ohm

10. OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s)with a sufficient reserve in
load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1 Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the
parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassembly.
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Grasping the troule state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for remedying.

11. CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. The should be used selectively accord-
ing 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 judgement.
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 t o its operation manual. Cautions when the polarities are dif-
ferent between the analog type and digital type are described below.
Circuit tester range: Analog type + kohm range Digital type + 2 Mohm range
Forward direction Reverse direction
Black
probe
Red
probe
Measurement result example
As seen from the example above, the measurement results with the analog and digital types are re-
verse. In measurement with a digital type circuit tester, therefore, use the tester probes as shown be-
iow.
Forward direction Reverse direction
Digital type
No continuity
1
Continuity
shall exist
2 MSZ
Forward
Reverse
Analog type
Continuity
shall exist
11 Kn
No continuity
00

12. 2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5V, 3.OV or 6.OV is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply
voltage.
The diode characteristics are shown in the figure below.
Current
in
forward
direction
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Voltage in forward direction (')
The resistance values of the same semiconductor mea-
sured
with two types of circuit testers having different
power supply voltages are different.
This manual describes the results of measurement
with a circuit tester whose power supply voltage is
3.0 V.
3. Difference in measurement result by measurement range (analog type)
In the analog type circuit tester, changing the measurement
range switches over the internal circuit to vary the circuit
resistance. Even when the same diode is measured, the
measurement result varies with the measurement range.
Always use the range described in the repair manual
for measurement.
Variable resistor
Resistor
Range: x 10
Red Black

13. 0-11
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the
table.
2. The nut tightening torque can judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1. Identification by bolt shape 2. Identification by part No.
Hexagon head bolt
Parts No.
91611-40625
Length (mm)
Diameter (mm)
iameter
Stud bolt
Parts No.
92132-40614
Length (mm)
Diameter (mml
iameter
Class
4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
4T
4T
5T
6T
7T
8T
4T
4T
6T
Hexagon
head bolt
Hexagon
flange bolt
Hexagon
head bolt
Hexagon
flange bolt
Hexagon
head bolt
Hexagon
head bolt
Welded bolt
Stud bolt
Shape and class
GD- Bolt head No.
No mark
No mark
Two protruding
0 lines
Two protruding
ines
Three protruding
0 lines
@ Four protruding
lines
kNo mark
I
Grooved

14. 0-12
TIGHTENING TORQUE TABLE
13 ) 130 1 9
5T
6T
7T
8T
16
6
8
10
12
14
16
6
8
10
12
14
6
8
10
12
14
16
8
10
12
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.25
1.25
1.25
113 f 1150 1 83
6.4 1 65 1 56 in-lbf
I I
16 f 160 1 12
I I
32 j 330 f 24
I I
59 1 600 f 43
I I
91 1 930 1 67
I I
137 1 1400 1 101
7.8 1 80 1 69 in-lbf
19 1 195 1 14
39 400 29
72 1 730 j 53
II
- I - I -II
11 / 110 / 8
I I
25 260 f 19
I I
52 j 530 j 38
I
95 1 970 j 70
I I
147 1 1500 f 108
I I
226 1 2300 ) 166
29 f 300 1 22
61 1 620 1 45
110 1 1100 1 80
I I- - -I I
I I
I I
I I
I I
I I
I I
I I- - -I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
8.8 1 90 1 78 in-lbf
I
21 1 215 1 16
43 440 1 32
79 1 810 j 59
123 / 1250 / 90
12 / 120 j 9
I
28 290 21
I I
58 1 590 f 43
I I
103 1 1050 1 76
I I
167 1 1700 1 123
I I
I I- - -I I
33 1 330 1 24
68 1 690 1 50
120 1250 1 90

15. PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the fol-
lowing cases.
(a) After is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable tight-
ening torque range. If the bolt moves, retighten it according
to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Parfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth 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.
Hose inside
diameter
mm (in).
6 (0.24)
9 (0.35)
12 (0.47)
12 (0.47)
15 (0.59)
19 (0.75)
25 (0.98)
6 (0.24)
9 (0.35)
12 (0.47)
19 (0.75)
25 (0.98)
Nominal diameter
of screw
7116 - 20UNF
9116 - 18UNF
314 - 16UNF
718 - 14UNF
718 - 14UNF
1-1116-12UNF
1.511 6 - 12UNF
PF114
PF318
PFII2
PF314
PF1
Standard tightening torque N-m (kgf-cm) [ft-lbfl
Standard
25 ( 250) [ 18.11
49 ( 500) [ 36.21
59 ( 600) [ 43.41
59 ( 600) [ 43.41
78 ( 800) [ 57.91
118 (1200)[ 86.81
137 (1400) [101.3]
25 ( 250) [ 18.1I
49 ( 500) [ 36.21
59 ( 600) [ 43.41
118 (1200) [ 86.81
137 (1400) [101.31
Tightening range
24 -- 26 ( 240 -- 270) [ I7.4 -- 19.51
47 -- 52 ( 480 - 530) [34.7 - 38.31
56 -- 62 ( 570 -- 630) [41.2 -- 45.61
56 -- 62 ( 570 - 630) 141.2 -- 45.61
74 - 82 1 760 -- 840) 155.0 -- 60.81
112-123(1140--12501[82.5- 90.41
130 -144 (1330 -1470) 196.2 -106.41
24 -- 26 1 240 - 270) I17.4 -- 19.51
47 - 52 ( 480 -- 530) [34.7 - 38.31
56 -- 62 ( 570 - 630) 141.2 -- 45.61
112 -- 123 (1140 -1250) 182.5 - 90.41
130 -144 (1330 -- 1470) 196.2 -- 106.41

16. 0-14
WlRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (ton) [Ibl
Suspension
method
by5
2' A
2%k0
Compres-
sion
1.OO time
1.73 time
Tension
1.41 time
2.00 time
Lifting
angle
90°
120°
Lifting
angle
0 O
30O
60O
Rope
diameter
6 mm
(0.24in)
8 mm
(0.32in)
10 mm
(0.4in)
12.5 mm
(0.5in)
14 mm
(0.56in)
Four-rope suspensionTwo-rope suspension
Tension
1.OO time
1.04 time
1.16 time
Cutting
load
21380
(2.18)
[48071
31480
(3.21)
[70781
49230
(5.02)
[I1.691
76880
(7.84)
1173871
96400
(9.83)
[21675]
90O
8630
(0.88)
[I9401
12550
(1.28)
[23221
19610
(2.0)
144101 -
29420
(3.0)
166151
37270
(3.8)
183791
Single-rope
suspension
0 O
3040
(0.31)
[683.6]
4410
(0.45)
[992.3]
6960
(0.71)
[I565.61
10980
(1.12)
[2469.5]
13730
(1.4)
[3087]
60O
10400
(1.06)
123371
15300
(1.56)
[3440]
23540
(2.4)
152921
37270
(3.8)
[83791
47070
(4.8)
[ I05841
90O
4310
(0.44)
[970]
6280
(0.64)
[I41 11
9810
(1.0)
[2205]
14710
(1.51
133081
18630
(1.9)
[4190]
0O
12160
(1.24)
[27341
17650
(1.8)
[3969]
27460
(2.8)
[6174]
43150
(4.4)
[9702]
54920
(5.6)
[I 23481
0O
6080
(0.62)
[I 3671
8830
(0.9)
[I 9851
14020
(1.43)
[3153]
21570
(2.2)
148511
27460
(2.8)
[6174]
Compres-
sion
0 time
0.27 time
0.58 time
30O
11770
(1.2)
[2646]
17060
(1.74)
[39371
26480
(2.7)
[5954]
41190
(4.2)
192611
52960
(5.4)
[I 19071
Suspension
method
-
L1
h0%
30O
5880
(0.6)
[I 3231
8530
(0.87)
[I9181
13440
(1.37)
[3021]
21280
(2.1)
[4631]
26480
(2.7)
[5954]
60O
5200
(0.53)
[I1691
7650
(0.78)
[I7201
11770
(1.2)
[2646]
18630
(1.9)
[4190]
23540
(2.4)
[5292]

17. COMPONENTS WEIGHT
Counter Weight
Note: Refer to Page 1 - 2 for the battery weight.
Model
1 ton series
2 ton series
3 ton series
1 ton series
2 ton series
3 ton series
5FBCU15
5FBCU18
5FBCU20
5FBCU25
5FBCU30
5FBCHU20
5FBCHU25
1 ton series
2 ton series
3 ton series
Motor
Approx Weight
STD
Dust proof type
STD
Dust proof type
STD
Dust proof type
STD
Dust proof type
STD
Dust proof type
STD
Dust proof type
440
Item
Drive Motor
Pump Motor
kg (Ibs)
66 (145)
75 (165)
104 (229)
120 (264)
104 (229)
120 (264)
38 (84)
42 (92)
75 (165)
75 (165)
75 (165)
75 (165)
(970)
Mast WILift bracket (with Lift cylinder,
less Back rest and forks).
[Max. Fork height = 3000mm (118 in)]
410 (904)
480 (1058)
825 (1819)
825 (1819)
410 (904)
480 (1058)
390 (860)
460 (1014)
600 (1323)

18. RECOMMENDED LUBRICANTS AND CAPACITIES
*For 3000 mrn (118 in) maximum fork height.
**For 6000 mm (236 in) maximum fork height.
***Use where unspeicified.
HYDRAULIC OIL CAPACITY DEPENDING ON FORK HEIGHT
APPLICATION
Differential & transmission
Hydraulic oil
Brake oil
Grease ***
TYPE
STD: Hypoid gear oil SAE85W-90
(VALVOLINE80W90)
20s: Hypoid gear oil W
(VALVOLINE80W90)
STD: Hydraulic oil IS0 VG32 (Daph-
ne Fluid AW32)
20s: Auto Fluid
STD: SAE J-1703 DOT-3
(INTAC AUTOMOTIVE PRODUCTS
INC. GC325)
20s: GC325
STD: MP Grease No.2
(VALVOLINE BRB GRESE)
20s: Esso Beacon 325
CAPACITY (TOTAL)
P.S. There are no capacity differences depending on the type of mast, such as V, FV, and FSV.
1.5 ton
1.8 -- 3ton
1.5 ton
1.8- 3ton
7.0 Q
(1.85 US gal.)
7.5 Q
(1.98 US gal.)
*16 Q (4.2 US gal.)
*21 Q (5.5 US gal.)
*20 Q (5.3 US gal.)
**26 Q (6.9 US gal.)
Proper quantity
Proper quantity
4300
- 5000
19
16
2 4
20.5
3300
-4000
17.5
14.5
22
18.5
Model
5FBCU15
30-5FBCU15
5FBCU18,20,25
5FBCUH20, H25
5FBCU30
30-5FBCU18, 20, 25
30-5FBCUH20,25
30-5FBCU30
5500
- 6000
21
18
26
22.5
Height [
Capacity
Total
( Q 1
Oil tank
( 0 )
Total
( Q )
Oil tank
( Q 1
Remarks
Same as 5FB15
&
5FB20 series
Same as 5FB30
series
3000
or less
16
13
20
16.5

19. -Fork Height 5500- 6500
-Fork Height 4300- 5000
-Fork Height 3300- 4000
-Fork Height 3000 or less
INSTRUCTION OF OIL CHECK LEVEL IN
HYDRAULIC OIL TANK
1. To check the oil level, touch the lower threaded end
portion of the cap to retainer without screwed in.
2. Adjust oil amount within 0 -- +10 mm (0.39 in) dif-
ference from each of the height indication.
GREASE ON MICRO SWITCH FOR
INSTALLATION
Put grease on roller.

20. LUBRICATION CHART
I 1. Chain I Inspect every 8 hours (daily)
2. Mast support bushing
3. Tilt cylinder front pin
4. Front wheel bearing
5. Differential & transmission
6. Brake fluid reservoir tank
7. Tilt steering locking mechanism
8. Tilt steering universal joint
9. Oil tank
10. Rear wheel bealing
11. Steering knuckle king pin
12. Rear axle beam front
13. Rear axle cylicder rod joint (1 ton series)
14. Rear axle beam rear
Located on right and left sides
I1 lnspect every 40 hours (weekly)
111 lnspect every 170 hours (monthly)
IV lnspect every 1000 hours (6monthly)
V lnspect every 2000 hours (annually)
0 lnspect and service
Replace
1. MP grease
2. Engine oil
3. Hypoid gear oil
4. Hydraulic oil
5. Brake fluid
1
Lubrication Chart

21. PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T : Retightening C: Cleaning L: Lubrication
1 *: Flaw detector
Inspection Period
Item
3
500
Months
Hours
1
170
6
1000
12
2000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
ELECTRICAL
Motor
Battery
Charger
Magnet
contactor
Microswitch
I
T
M
I
I
M
I
I
M
I
I
M
M
I
I
M
I
I
I
I
I
I
I
I
I
SYSTEM
Abnormal sound during revolution
Loose terminal
Insulation resistance
Brush wear and sliding contact status
Commutator fouling and damage
Brush spring fatigue
Charge
Battery fluid level
Battery fluid specific gravity
Loose terminal
Abnormality at top of battery and
battery case
Insulation resistance
Cell voltage measurement after
charging
Timer operation
Terminal loosening
Operating voltage measurement
Magnet switch function, contact
fouling and roughening
Loose contact, damage and wear
Auxiliary contact function, fouling and
wear
Arc chute installation status
Timing and functioning
Loose coil installation
Loose main circuit lead installation
Timing and operating function
Damage and loose installation
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
' 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

22. 1
170
0
0
0
0
0
0
0
0
Months
Hours
I
I
C
M
I
I
I
I
I
I-
Inspection Period
Item -
Direction lever
Controller
Fuse
Wiring
(including
charging cord)
Accelerator
POWER TRAIN
3
500
0
0
0
0
0
0
0
0
Operating conditions and damage
Operation
Inside fouling and damage
Overcurrent limit valve
Loosening
Damage of wiring harness and loose
clamp
Loose connection and taping status
Battery connector damage and
connection status
Operating and damage
0
0
0
6
1000
0
0
0
0
0
0
0
0
12
2000
0
0
0
0
0
0
0
0
0
0
0
I
I
T
Differential,
Transmission
TRAVELING EQUIPMENT
Oil leak
Oil level
Loosening of nuts and bolts
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
I
T
M
I
I
I
I
I
I
Wheels
Front axle
Rear axle
Tire cuts, damage and uneven wearing
Loose rim and hub nuts
Tire groove depth
Metal chips, pebbles and other foreign
matter trapped in tire grooves
Rim and disc wheel damage
Abnormal sound and looseness of
front wheel bearing
Abnormal sound and looseness of rear
wheel bearing
Cracks, damage and deformation of
housing
Cracks, damage and deformation of
beam

23. Inspection Period
Item
Months
Hours
STEERING SYSTEM
1
170
Steering wheel
Steering valve
Power steering
Knuckle
3
500
Play and looseness
Function
Oil leak
Looseness of mounting
Oil leak
Damage of power steering hose
King pin looseness
Cracks and deformation
I
I
I
T
I
I
I
I
BRAKING SYSTEM
Brake pedal
Parking brake
Brake pipe and
hose
Brake fluid
Master cylinder
or brake valve
and wheel cyl-
inder
Brake drum
and brake shoe
Backing plate
6
1000
0
0
0
0
0
0
12
2000
Play and reserve
Braking effect
Pull margin
Braking effect
Rod and cable looseness and damage
Ratchet wear and damage
Leakage, damage and mounting status
Fluid level
Function, wear, damage, leak and
mounting looseness
Clearance between drum and lining
Wear of shoe sliding portion and lining
Drum wear and damage
Shoe operation condition
Anchor pin rusting
Return spring fatigue
Automatic adjuster function
Deformation, cracks and damage
Loose mounting
0
0
0
0
0
0
M
I
I
I
I
I
I
I
I
M
I
I
I
I
M
I
I
T
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

24. I Abnormality of fork and stopper pin / I 1 0
Inspection Period
Item
Misalignment between left and right
fork fingers
I 0
Cracks at fork root and welded part I*
/ Forks
MATERIAL HANDLING SYSTEM
Months
Hours
Deformation and damage of each part
and crack at welded part
Mast and lift bracket looseness
Wear and damage of mast support
bush
1
170
Mast and fork
bracket
Wear, damage and rotating condition
of rollers
Wear and damage of roller pins
Wear and damage of mast strip
3
500
Tension, deformation and damage of
chain
Chain and
chain wheel
6
1000
Chain lubrication
12
2000
Abnormality of chain anchor bolt
Wear, damage and rotating condition
of chain wheel
HYDRAULIC SYSTEM
Loosening and damage of cylinder
mounting
Deformation and damage of rod, rod
screw and rod end
Cylinder operation
Natural drop and natural forward tilt
(hydraulic drift)
Various
attachments
Cylinder
I
Abnormality and mounting condition
of each part
I Oil leak and damage I I I o ~ o I o I o
Wear and damage of pin and cylinder
bearing
0
Cylinder
/ Lifting speed / I " I o o I o
0
Oil level and contamination
Tank and oil strainer
0
Oil pump
Hydraulic oil
tank
0
Uneven movement
Oil leak and abnormal sound
I Oil leak
I
I
I
0
0
0
0
0
0
0
0
0 1 0
0
0

25. -
- Inspection Period
Item --++
Months
Hours
I
I
I
M
I
I
I
T
I
Control lever
Oil control
valve
Hydraulic
piping
Loose linkage
Operation
Oil leak
Relief pressure measurement
Relief valve and tilt lock valve
functions
Oil leak
Deformation and damage
Loose joint
Hoise tension and twisting
SAFETY DEVICES,
Head guard
Back-rest
Lighting
system
Horn
Direction
indicator
Instruments
Back up buzzer
Rear-view
mirror
Seat
Body
Other
1
170
0
0
0
0
0
0
0
0
ETC.
Cracks at welded portion
Deformation and damage
Loosening of mounting
Deformation, crack and damage
Function and mounting condition
Function and mounting condition
Function and mounting condition
Functions
Function and mounting condition
Dirt, damage
Rear reflection status
Loosening and damage of mounting
Damage and cracks of frame, cross
members, etc.
Bolt looseness
Grease up
3
500
0
0
0
0
0
0
0
0
6
1000
0
0
0
0
0
0
0
0
12
2000
0
0
0
0
0
0
0
0
0
I
I
T
I
I
I
I
I
I
I
I
I
I
T
L
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
0
C

26. 0-24
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
12
2000
•
•
a
•
•
•
•
a
(Every 2 years)
a
(Every 2 years)
a
(Every 2 years)
a
(Every 2 years)
a
(Every 3 years)
3
500
1
170
a
(New veh~cle)
Inspection (operating hours or
months, whichever is earlier)
6
1000
•
•
a
Months
Hours
Brake fluid
Hydraulic oil
Hydraulic oil return filter
Differential and transmission oil
Wheel bearing grease
Master cylinder rubber parts
Wheel cylinder rubber parts
Reserve tank hose
Power steering hose
Internal rubber parts of power steering system
Material handling hose
Chain
-

27. BATTERY
Page
............................................................GENERAL 1-2
CAPACITY ON SPEC..........................................1-2
WEIGHT OF BATTERY WICASE .............................1-2
RECOMMENDED BATTERIES ................................. 1-2
BATTERY COMPARTMENT &
MINIMUM WEIGHT REQUIRED ....................... 1-5
BATTERY COMPARTMENT SIZE
ADJUSTMENT .................................................1-6
BATTERIES SUITABLE TO BATTERY
ROLL OUT SPEC. COMPARTMENT ................ 1-8
BATTERY WEIGHT SUPPLEMENT
ADJUSTMENT BY SUB-WEIGHT .....................1-9
.........................................TROUBLE SHOOTING 1-12
SERVICE STANDARDS ....................................... 1 3-I
BATTERY ASSY ..................................................1 4-I
REMOVAL.INSTALLATION ................................... 1.14
INSPECTION .......................................................1-15

28. 1-2
GENERAL
CAPACITY ON SPECIFICATIONS
Capacity
AH16HR
WEIGHT OF BATTERY WICASE
Model
5FBCU15
30-5FBCU15
5FBCU18
30-5FBCU18
5FBCU20
30-5FBCU20
5FBCU25
5FBCU25
(Compact model)
5FBCU30
30-5FBCU30 '
5FBCHU20
30-5FBCHU20
. 5FBCHU25
30-5FBCHU25
5FBCHU25
(Compact model)
High capacity
RECOMMENDED BATTERIES
STD
36 V
595
680
. 680
680
680
935
935
36 V
680
935
935
935
935
1020
1020
Model
5FBCU15
30-5FBCU15
5FBCU20
30-5FBCU20
5FBCU25
30-5FBCU25
5FBCU30
30-5FBCU30
The recommended Batteries are shown in the next table. Those batteries satisfy the minimum weight
required for counter balance. For that reason, the sub-weight are unnecessary. (The maximum capacity
batteries are also given for reference.)
battery
48 V
425
510
510
557
-
-
48 V
510
680
610
680
-
-
Approx. weight battery
ASSY Wlcase
kg (Ibs)
830 (1840)
1090 (2400)
1090 (2400)
1360 (3000)
Model
5FBCHU20
30-5FBCHU20
5FBCHU25
30-5FBCHU25
Approx. weight battery
ASSY Wlcase
kg (Ibs)
1360 (3000)
1360 (3000)

29. Note:
In UL-EE specifications, a battery side cover and an insulated cover on the rear of the battery hood
are installed; thereby it is unnecessary to use a battery (with cover) for EE use.
Installed battery Battery case
Type
5FBCU15
[MAXI
t t 24c85-17 1 680 1 (6.54) / (6.30) /166 160
1
Voltage
V
36
t
t
t
t
t
48
t
t
t
T
t
36
Manufacturer
EXlDE
t
GNB
t
C&D
t
EXlDE
t
GNB
t
C&D
t
EXlDE
Model
18E85-17
18E100-17
18-75C-17
18-85C-17
18C75-17
18C85-17
24E75-13
24E100-13
24-75C-13
24-85C-13
24C75-13
24C85-13
8E1 low-'
Capacity
AH16HR
680
800
600
680
600
680
450
600
450
510
450
510
880
Single cell dimensions Inside dimensions
Height
575
(22.64)
578
(22.76)
554
(21.81
t
575
(22.64)
t
574
(22.60)
578
(22.76)
554
(22.60)
t
575
(22.64)
t
578
(22.76)
Length
660
(25.98)
.
Length
159
(6.26)
t
t
t
160
(6.30)
t
157
(6.18)
t
t
t
158
(6.18)
t
159
(6.26)
mm (in)
Width
165
(6.50)
T
166
(6.54)
t
127
(5.00)
t
t
128
(5.04)
t
165
(6.50)
mm (in)
Width
862
(33.94)
1
Height
575
(22.64)

30. Type
5FBCU20
25
Battery case
Inside dimensions
mm (in)
Voltage
V
36
t
t
t
t
t
48
T
t
Installed battery
Length
C&D 24C85-19 765 (7 28, (6 30) (22 64)
A *
24C85-21 850
[MAXI
~ F B C H U ~ ~36 EXlDE 8E 540
Single cell dimensions
. mm (in)
Length Width Height
222 159 575
(8 74) (6 26) (22 64)
t t t
T 554
(21 81)
t t t
204 160 575
(8 03) (6 30) (22 64)
(8 78) t
223
165 159 575
(6 50) (6 26) (22 64)
t t t
t 554
(21 81)
Width
Capacity
AHI6HR
825
935
825
935
850
935
600
600
600
Manufacturer
EXlDE
t
GNB
t
C&D
t
EXlDE
t
GNB
Height
(iz)
Mode'
18E75-23
18E85-23
18-75C-23
18-85C-23
18C85-21
18C85-23
24E75-17
24E85-17
24-75C-17
5FBCU30 48
A 203 159
24E 11OW-21 1100 (7 99, (6 26,
t t
1
279 159
( 10 98) , (6 26)
T
578
(22 76)
7

31. BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED
When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by refer-
ring to the table below.
Compartment dimensions mm (in)
I I
Front to rear
length X
I Width Y / Height Z
Minimum required
battery weight
(with case)
kg (Ib)
830
(1840)
Maximum battery
weight (with case)
kg (Ib)
Battery Compartment Shape

32. 1-6
BATTERY COMPARTMENT SIZE ADJUSTMENT
The battery compartment is made adjustable in both the length and width direction.
1. Length (To front and back)
Since TI6 plate
is mounted with
a bolt, the compart-
ment length is
adjustable in two
stages by removing
this plate.
With TI6 Plate mounted:
Compartment length = 691 mm (27.20")
Without T I6 Plate:
Compartment length = 698 mm (27.48")
Note:
Adjust so the space between the battery compartment and the battery is under 12.7 mm (112")
2. Width (To right and left)
W (Battery compartment width)
+
a r
C
-
Battery Stopper RH
Battery stopper LH
(Bolted to frame)

33. Battery compartment width: W is adjustable in 6 stages with different combinations of battery stopper
LH.
Note: Adjust so the space between the battery and battery compartmentis under 12.7 mm (112")

34. BATTEROES SUITABLE TO BATTERY ROLL OUT SPEC. COMPARTMENT
The batteries mountable on battery-rollout specification are limited since the battery compartment length
and width differ from standard models. A recommended list of mountable batteries are shown in the
table below.
Voltage
36 V
48 V
Note: The following matters must be observed when mounting batteries other than the above.
1. Battery weight: Over 1090 kg (2403.45 Ib)
2. Space between battery and battery compartment
(UL Standards) to be under 12.7 mm (112")
A
X
Manufacturer
EXlDE
C&D
GNB
EXlDE
C&C
GNB
36
V
48
V
TYpe
18E75-23
18E85-23
18C85-23
18-75C-23
18-85C-23
24E75-17
24E85-17
24C75-17
24C85-17
24-75C-17
24-85C-17
EXIDE
EXlDE
Capacity
(AHI6HR)
825
935
935
825
935
600
680
600
680
600
680
Length
mm (in)
690.6
(27.19)
690.6
(27.19)
684.3
(26.94)
685.8
(27.00)
685.8
(27.00)
685.8
(27.00)
685.8
(27.00)
684.3
(26.94)
684.3
(26.94)
679.5
(26.75)
679.5
(26.75)
18E11OW-23
24E110W-17
Width
mm (in)
982.7
(38.69)
982.7
(38.69)
979.4
(38.56)
973.1
(38.31
973.1
(38.31
982.7
(38.69)
982.7
(38.69)
979.4
(38.56)
979.4
(38.56)
973.1
(38.31)
973.1
(38.311
Height
mm (in)
574.8-
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
574.8
(22.63)
1210
880
690.6
(27.19)
690.6
(27.19)
982.7
(38.69)
982.7
(38.69)
577.9
(22.75)
577.9
(22.75)

35. BATTERY WEIGHT SUPPLEMENT ADJUSTMENT BY SUBWEIGHT
It will be possible to mount a battery that does not satisfy
minimum battery weight by adding a subweight in the bat-
tery compartment.
The subweight must be procured locally and will not be op-
tionally set.
Taps are provided at two places on the forklift body for at-
taching the subweight. Subweight reference diagrams,
mounting methods, principal battery subweights and required
weights are shown:
1. Sub-weight reference diagram Unit: mm
(in)
Thickness Weight
T19mm 72 kg
(0.748 in) (158.76
T 50 mm 192 kg
(1.969 in) (423.36
Nozzle way for
400
welding flame dl/o (15.748)
cutting. m
20
I
f-'
L
- 7 I
(0.7W& b
-
6 +* @F
i
.J 0,
*+ 3 be.
i
OO?.@~~
3s
i
i
i
i
i
i
i
i
i
I
500 (19 685)
870 (34.252)
d
P
P
fu
N-0
r
m -0
CO
b
2-0
m
m

36. 2. Mounting method Unit: mm
(in)
h x 1 i (Frame)
(Sub-weight)
A-A section for T 19 mm (0.748) sub-weight
(Sub-weight)
A-A section for T 50 mm (1.969 in) sub-weight
* Tapped holes were already bored in frame.
3. Principal Battery Sub-weight and Required Weight.
A: T I 9 mm (0.748 in) 72 kg (158.76 Ib)
B: T50 mm (1.969 in) 192 kg (423.361b)
Vehicle
tYPe
30-5FBCU15
5FBCU
30-5FBCU18
5FBCU20
30-5FBCu20
5FBCU25
30-5FBCU25
Minimum
battery
weight
kg (~bs)
830 (18401
(2000)
OgO (2400)
Battery
Size
W x L xHmm
(Wx LxH in1
i $ ~ ~ , " ~ ~ ~ ~ ' ~ 0 3 )
9 9 2 x 7 1 0 ~ 5 8 5
(39.06 x 27.95 x 23.03)
992X710x585
(39.06x 27.95 x 23.03)
Weight
lacking
kg (Ibs)
105 (231)
40 (88)
105 (231
52 (114)
11 (24)
191 (420)
152 (334)
67 (147)
152 (334)
49 (108)
49 (108)
132 (2901
46 (101
32 (290)
Manufacturer
GNB
GNB
GNB
Mounted-Battery
Voltage
(V)
36
48
36
36
48
Battery type
18-75C-15
18-85C-15
8-75B-1
24-85C-11
18-85C-17
8-85C-1
18-75C-19
18-85C-19
18-75B-1
8-75c-21
8-75B-21
24-75C-15
24-85C-15
24-75B-1
Loadable
subweight
width
mm
(in1
83
13.27)
83
13.27)
83
r3,27,
3 2
100
13,941
li.gl
76
12.99)
76
(2,991
76
(2,99,
45.5
~-
45.5
61.5
12,42)
61.5
(2.42)
61.5
12.42)
B
A
B
A
A
B
B
A
B
A
A
A
(Subweight required)
Battery Case
Size
W X Lx H mm
IWxLXHin)
811 X597x575
131,93x 23,50x 22,641
8 1 1 x 5 9 7 ~ 5 7 5
i31,g3x23,50x22,64)
811 x 597x 575
131.93X23.50~22.64)
685 x 848 x 575
126.18x25.51 x22,64)
970X 508x 575
~38,19x20,00x22,64,
970X 508 x 575
(38.19X 2 0 . 0 0 ~22.641
973X 568x 575
138,31,22,36x 22,641
973 x 568 x 575
,38,31 22,36x 22.64)
973 x 568 x 575
138.31 X22.36x22.64)
973 x 629x 575
138.31x --24.76%22.64)
973x629x575
138.31 X 24.76X 22.64)
970x 597x 575
138,19x23,50x22,64~
970 x 597 x 575
138,1gx 23,50, 22,641
970x 597 x 575
( 3 8 . 1 9 ~23.50~22.64)
weight
kg (~bs)
725 (1598)
790 (1741)
725 (1598)
778 (1716)
899 (1981)
899 (1981)
938 (2069)
1023 (2256)
938 (2069)
1041 (2294)
1041 (2294)
958 (2111)
1044 (2302)
958 (21 )

38. TROUBLESHOOTING
Pole plate corrosion
lnsufflc~entcharge
-No operation for Repetillon of
overdischarge
Shorting between
and overcharge
cells
Excessive
charg~ng
current
temperature
Incomplete
terminal
Improper water
connection
supply
Overcharge
Deposition of fallen
-acting substance In Duty terminal or plug-
Short circuit Loosened or corroded
and decrease connections

39. 1-13
SERVICE STANDARDS
DISPLAY INDICATION
1. The display indicates the remaining battery charge
level in 1 0 stages. When the remaining charge drops
below 20 %, the indication flashes the warn the timing
for charging.
1.280 (20)
1.150 (20)
32.0
42.5
Sulfuric acid diluted with distilled water
Distilled (deionized) Water
I or more
Specific gravity in fully charged state (OC)
Specific gravity in fully discharged state (OC)
2. When the battery is discharged fully (100 %), the
overdischarge alarm function operates as follows:
Discharge end voltage
V
OVERDISCHARGE ALARM FUNCTION
36 V specification
48 V specification
1. Material handling with traveling becomes impossible.
If simultaneous operation is attempted, priority is
given to traveling and material handling is not ef-
fected. (For prevention of battery from damage by
large current flow)
Electrolyte
Fluid to be spplied
Insulation resistance MO
2. When material handling is attempted, all indicators on
the display flash and the buzzer sounds to alarm over-
discharge.
Note:
Material handling operation becomes impossible on the ve-
hicle with chopperless material handling circuit.
For thirty seconds after the key switch is turned on how-
ever, material handling operation can be performed.

40. BATTERY ASSY
REMOVAL.INSTALLATION
Removal Procedure
1 Place the mast in vertical position.
2 Disconnect the battery plug.
3 Pull the-steering unlocking lever to tilt the steering forward
4 Place the seat to the foremost position.
(When the deadman seat is used, remove the seat together with the seat stand.)
5 Release the battery hood catch.
(For the battery roll-out spec. model, release the battery stoppeer. For the dust-proof spec. model,
remove the battery side cover, too.)
6 Open the battery hood as holding the handle on RHS and hook the hood stay.
7 Hoist the battery Assy W/Case to relocate. (Caseof the battery roll out spec., removable sidewise.)
Installation Procedure
Follow the reverse sequences of the removal.

41. INSPECTION
1 Electrolyte inspection
(1) The battery electrolyte should be colorless and
transparent in normal state. Check turbidity, etc. at
the time of specific gravity inspection.
If clear confirmation is impossible, put in a beaker
for inspection.
Hydrometer
Duter tube -
2 Inspection of electrolyte specific gravity
(1) Use a hydrometer and measure the specific gravity
of the electrolyte
1
Specific gravity in fully charged state:
1.280 (at 2 0 O C)
Specific gravity in fully discharged state:
1.150 (at 2 0 OC)
The specific gravity of the electrolyte is expressed
by the value at 2 0 O C as the standard.
Specific gravity conversion equation
S,, = St + 0.0007'(t-20)
S,,: Specific gravity at 2 0 O C
St : Specific gravity at t O C
t : Temperature at the time of measurement
How to use the hydrometer
@ Insert the nozzle of the hydrometer into the wa-
ter supply port and suck the electrolyte into the
outer cylinder.
@ Let the hydrometer in the outer cylinder float
correctly without contact with the top, bottom
and side wall of the outer cylinder, and read the
graduation at the using electrolyte surface as
shown at left after disappearance of bubbles in
the sucked electrolyte.
@ After the measurement wash outside and in-
side of the hydrometer with clear water and
wipe thoroughly with clean cloth for storage.
3 Insulation resistance inspection
Use an insulation resistance meter (megger) and mea-
sure the resistance between the battery and battery
case.
Insulation resistance: 1 MQor more
Note:
If the insulation resistance is less than 1 MQ,remove
the battery from the vehicle and wash it with water.
Dry the battery case the roughly, and measure the
insulation resistance again. Install the battery on the
vehicle after checking that the insulation resistance
is 1 MQor more.

42. * Battery control table
Prepare the control table for each battery t o record and retain the inspection result.

43. CONTROL CIRCUIT
Page
.......................................MCS I11 CONTROLLER 2-2
GENERAL ........................................................... 2-2
.................................................SPECIFICATIONS 2-3
COMPONENTS ...................................................2-4
......................................CONTROL PANEL ASSY 2-9
OCL VALUE (OVER CURRENT LIMIT VALUE) .......... 2-39
ACCELERATOR POTENTIOMETER
ADJUSTMENT ................................................2-41
BRAKE SWITCH & STOP LAMP SWITCH
ADJUSTMENT ................................................2-41
.......PARKING BRAKE SWITCH ADJUSTMENT 2-42
SEAT SWITCH ADJUSTMENT FOR
BATTERY ROLL OUT (OPT)......................... 2-43
MATERIAL HANDLING SWITCH
ADJUSTMENT ................................................ 2-43
MATERIAL HANDLING CHOPPER SWITCH (OPT)
ADJUSTMENT ............................................... 2-44
..........................................DIRECTION SWITCH 2-45
...................................REMOVAL-INSTALLATION 2-45
DISASSEMBLY-ASSEMBLY .................................. 2-46
INSPECTION ...................................................... 2-47
.....................POWER STEERING CONTROLLER 2-48
COMPONENTS ................................................... 2-48
REMOVAL.INSPECTION.INSTALLATlON (STD) ....... 2-49
REMOVAL-INSPECTION-
INSTALLATION (WIEHPS) ................................. 2-51

44. MCS-I11CONTROLLER
GENERAL
The 5FBCU series is provided with the diagnostic (self-diagnosis) function for automatically detecting
any abnormality in the main travelinglmaterial handling circuit, operating system such as the ac-
celerator and sensors to sound the buzzer (peep, peep) and to display the abnormal portion by the cor-
responding error code on the multidisplay.
At the same time, such an action as traveling stop, material handling stop or traveling speed restriction
is taken to ensure safety.
When the display is set to the analyzer (fault analysis) mode, defect detection and functional check of
the main drivelmaterial handling circuit, operating systems, and sensors are performed.
See the Multidisplay section (page 3-3) for the diagnosis. See the Multidisplay section (page 3-71 for
the analyzer.
Drive Control Panel ASSY
Material Handling Control Panel ASSY Material Handling Control Panel ASSY (with Chopper)

45. SPECIFICATIONS
Fuses
F2 (Material handling circuit) 1 225 A I 325 A I c 1
Portion
F1 (Drive circuit)
F3 (PS circuit) I 75 A I t I + 1
F 4 (For lamps) I 1 0 A I C
I t
I
1 ton series
275 A
F5 (Control circuit) I 1 0 A 1 t I t 1
T M (For traveling)
2 ton series
325 A
3 ton series
t
Transistors
IDG (For regeneration)
DAD (For traveling)
DAP (For material handling: OPT)
TMP (For material handling: OPT)
TG (For regeneration preexcitation)
TM ,,(For PS : OPT)
I D F ~(PM flywheel) 1 20M30 I t I 4- 1
30MF40
30MF40
Diodes
/ D F ~(PM flvwheel: OPT) I 70M30 1 +- I +- I
TSM 0 0 3 (3 pcs.)
ETI8 8
# IM1100H-025
I D F ~(PS flywheel) I # IM1100H-025 I + I t I
t
t
DFI (DM flywheel)
DF2 (DM flywheel)
c
c
t
t
t
SR250L-6s
SR250L-6s
Current
sensors
c
t
c
CAD (Absorber for traveling) I 60pF ( 2 pcs.) 1 +-
+
+-
CSD (For traveling)
CSP (For material handling: OPT)
CS,, (For PS: OPT)
+-
Capacitors CAP
I I(Absorber for material handling: OPT)
C
C
I
60pF ( 2 pcs.)
Resistors
MF.MR
1 ME250
(For forwardireverse traveling) 1
HS800RT
HS800RT
MBP20A-1OMJN
RAP
(Absorber for material handling: OPT)
RAD (Absorber for traveling)
RG (For regeneration)
MP (For material handling) 1 ME251 I
c
t
C
1.5Q 220W
MG (For regeneration)
MS (Bypass)
M W (For field weakening)
c
c
+-
1 .5Q 220W
0.6Q 120W
# : The PS transistor and diode are integrated.
c
ME251
ME251
ME251
MPS (For PS)
t
t
c
c
t
c
+-
+-
ME252
t
t
+
+- t

46. COMPONENTS
Drive Control Panel Components
2401

47. Resistor Panel Components
2401

48. Material Handling Contactor Components

49. z
%
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E
I
al
3
Q
--.3
(C1
0
0
3
B
2
z
z
0
z
0
'El
u
e
0
0
3
'El
0
3
tD
2V)

50. MF-MRContactor Components
MG-MS.MPsMWContactor Components

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for your reading.
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