This manual provides service procedures for the Toyota Battery Forklift 5FBE10-20 series, effective as of September 1998. It includes operational tips, maintenance guidance, wiring schematics, and parts identification for efficient servicing. Users are advised of possible discrepancies due to design or specification changes and are instructed to refer to official Toyota updates for modifications.

1. FOREWORD
This manual covers the service procedures of the TOYOTA BATTERY
FORKLIFT 5FBE10-20 Series. Please use this manual for providing
quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of September 1998. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due to change in design and specifi-
cations. Any change or modifications thereafter will be informed by
Toyota Industrial Vehicles' Parts & Service News.
TOYOTA MaterialHandling Company
A Division of TOYOTA INWSRIES CORPORATION

2. SECTION INDEX
[FOR OTHER THAN U.S.A.] (1993.1 -1998.8)
ELECTRICAL SYSTEM TROUBLESHOOTING [FoRu.s.A.1 (1993.1 -1
ELECTRICAL SYSTEM TROUBLESHOOTING [FOR OTHERTHANU.s.Ad(199889-I A A
NAME
MOTOR
SECTION
/ FRONT AXLE &TRANSMISSION (lgg3.1 - lgg8-l)
GENERAL
BATTERY
[FOR OTHER THAN U.S.A.] (1993.1- 1998.8)
CONTROL ClRCUIT IFOR u.s.A.1 (1993.1 -1999.1 -)
CONTROL CIRCUIT [FOR OTHER THAN U.S.A.] (1998.9 -) A
[FOR UL. U.S.A.. CANADA] (1999.2- )
[FOR OTHER THAN U.S.A.] (1993.1 - 1998.8)
MULTI-DISPLAY FUNCTIONS [Fouu.s.A.j (1993.1 -)
FRONT AXLE & DRIVE UNIT (1998-2-1
REAR AXLE (1993.1- 1998.1)
A
STEERING
--
BRAKE (1998.2-I
BODY & FRAME
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL
APPENDIX

3. GENERAL
Page
EXTERIOR VIEWS ........................... 0-2
VEHICLE MODEL ........................... 0-3
FRAME NUMBER ........................... 0-3
HOW TO USE THIS MANUAL ................ 0-4
EXPLANATION METHOD .......................... 0-4
TERMINOLOGY .................................. 0-5
ABBREVIATIONS ................................. 0-5
LIST OF ABBREVIATIONS AND SYMBOLS .......... 0-6
OPERATIONAL TIPS ......................... 0-7
JACK-UP POINTS ........................... 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 ......................... 0-15
LUBRICATION CHART ....................... 0-16
PERIODIC MAINTENANCE ................... 0-17
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................ 0-22

4. 0-2
EXTERIOR VIEWS

5. VEHICLE MODEL
*: 36 V is provided for UL specification.
FRAME NUMBER
Load capacity
1.0 ton
1.25 ton
1.5 ton
1.75 ton
1.815 ton
Model
5FBE10
5FBE13
5FBE15
5FBE18
5FBE20
Punching
position
1 ton
series
1.5 ton
series
2.0 ton
series
Battery capacity
AH/5HR
280
t
390
t
375
Upper face of side member
of frame RH
Vehicle model
5FBE10
5FBE13
5FBE15
5FBE18
5FBE20
Voltage
V
*36 or 48
t
t
t
t
Punching format
5FBE13-10011
5FBE13E10011(EEC spec.)
(1993.1 -1993.9)
5FBE13010011 (EEC spec.)
(1993.10 - )
5FBE18-10011
5FBE18E10011(EEC spec.)
(1993.1 -1993.9)
5FBE18010011 (EEC spec.)
(1993.10 - )
5FBE20-10011
Control circuit
MCS-IIIA
t
t
t
t

6. HOW TO USE THIS MANUAL
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 illustra-
tion, followed 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
T =46.09 -48.05
(470-490)
134.00- 35.451
8
DisassemblyProcedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 21 Operation explained later
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 11 JDisassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528in)

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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 components figure indicates the
Fig. number in the parts catalog.
FIG number in parts catalog
fl3. 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 (Partiallydescribed)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents.Be sure to observe them.
Note:
lmportant items of which negligence may cause accidents or matters in operation procedure
requiring 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
EHPS
FR
I-/
LH
0PT
01s
PS
RH
Meaning
Assembly
Electrical hydraulic power
steering
Front
Less
Left hand
Option
Oversize
Power steering
Right hand
Abbreviation (code)
RR
SAE
SST
STD
T =
OOT
U/S
w/
Meaning
Rear
Society of Automotive
Engineers (USA)
Special service Tool
Standard
Tightening torque
Number of teeth (00)
Undersize
With

9. LISTOF ABBREVIATIONS AND SYMBOLS
Symbol
BATT
BZ
CA
CADIP
CH
CHIF
CHIR
CSDIP
CSps
DADIP
DCH
DC-SDD
DC-SDP
DF112
DF314
DlSP
DMDlP
DMps
DSBu
DSF
DSFo
DSR
F1
F2
F3
F4
F5
FCH
Symbol
FRY
H
IWP
LBU-~
L B U - ~
LC-L
LC-R
LF-L
L F - ~ ~
LF-R
LF-RR
LH-L
L H - ~
LR-F
L R - ~
LSAnIl2
LSB
LSD
LSL1/2
LSsT
LST-~
LsT-~
LST
LT-~
LT-~
Lw
MFL
MFR
MP
MPS
MRL
MRR
MScH
PBcpu
PBEHPs
Name
Battery
Buzzer
Absorber Capacitor
Drivelpump Absorber
Capacitor
Charger
Forward Chime
Reverse Chime
DriveIPumpCurrent
Sensor
Power Steering Current
Sensor
Drivelpump Absorber
Diode
Charger Diode
DC-DC Converter &
Source Drive (Drive)
DC-DC Converter &
Source Drive (Pump)
FLY-WHEEL Diode,
No.112
FLY-WHEEL Diode No.314
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
Name
Flasher Relay
Horn
Wheel Position Indicator
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
Stop lamp limit Switch
Stop Lamp, LH
Stop Lamp, RH
Tilt Limit Switch
Tail Lamp, LH
Tail Lamp, RH
Working Lamp
Forward Contactor, LH
Forward Contactor, RH
Pump Contactor
Power Steering Contactor
Reverse Contactor, LH
Reverse Contactor, RH
Charger Magnet Switch
Computer Print Board
EHPS Print Board
Symbol
PBsN
PLw
RA
RADIP
PCKII 2
SA
SLL
SN1
SNCI12
SNR112
SSP
SSL
SSR
STH
SWAC
SWF
SWH
SWKy
SWL
SWPB
SWsc
TF
THR
TM
TMD
TMP
TMps
TU
VRAD
VRSP
Name
Snubber Print Board
Working Pilot Lamp
Absorber Resistor
Drivelpump Absorber
Resistor
Check Resistor No.112
Surge Absorber
Lequid Level Sensor
Sunbber No.1
Snubber Capacitor 112
Snubber Resistor 112
Steering Pressure Sensor
Speed Sensor, LH
Speed Sensor, RH
Thermo Sensor
Accel Switch
Flasher Switch
Horn Switch
Key Switch
Light Switch
Parking Brake Limit
Switch
Speed Control Switch
Transformer
Thermal Relay
Main Transistor
Main Drive Transistor
Main Pump Transistor
Main Power Steering
Transistor
Timer Unit
Accel Drive Variable
resistor
Steering Position Variable
resistor (Steering
potentiometer)

10. OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks on 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
pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnectingwiring, 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, inspectionand 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 reassem-
bly. 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, du not attempt immediate disassembly or replacement but first check
if the trouble requires disassembly or replacement for remedying.
4. How to treat liquid waste
When draining liquid waste from a vehicle, use a pan or other suitable container to collect the
liquid.
Do not throw away oil, fuel, cooling water, oil filters, batteries, or other injurious materialssince
these materialsmay adverselyaffect human health and the environment. Sort liquid waste into
different types and seek the service of experts for proper disposal.
Hoisting the vehicle
Loop wire ropes on the mast hook hole and the rear of the
head guard to hoist the vehicle.

11. JACK-UP POINTS
The vehicle often needs to be jacked up during assembly and reassembly.
Be sure to jack up the vehicle at the right positions. Placing a jack in the wrong position or jacking up
the vehicle in the wrong manner may cause an unexpected accident.
Front jack-up Rear jack-up
Front jack-up
If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with
a bearing plate at least 80 m m long.
Rear jack-up
When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the
weight on the opposite side.
The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle
maintains its balance during jack-up.

12. CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively
according to the purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the mea-
sured 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
movement.
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.
Always use a circuit tester according to its operation manual. Cautions when the polarities are
different between the analog type and digital type are described below.
(1) Analog circuit tester
I Measurement result example
Forward direction Reverse direction
(2) Digital circuit tester
Forward direction Reverse direction
Tester range: KR range
Analog type
Continuity
I Forward I shall exist I
Reverse
No continuity
Measurement result example
Tester range: 2 M Q range
Digital type
I
I NO continuity II Forward
1
Continuity
Reverse shall exist
2 MR

13. 2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V 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.
( m ~ ) The resistance values of the same semiconductor
5 measured with two types of circuit testers having
different power supply voltages are different.
Current 4
in This manual describes the results of measurement
forward
direction
with a circuit tester whose power supply voltage is
2
3.0 V.
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Voltage in forward direction lV)
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 measure-
ment result varies with the measurement range.
Always use the range described in the repair manual
for measurement.
Current
flow
I
4
TEwersource: 1.5 V
"0Red 6@Black
Variable resistor
,- ,Resistor
Range: x 10
(SW1)
Resistor
1 4
(SW2)
Range: x 1
,,
,

14. STANDARD BOLT AND NUT TIGHTENINGTORQUE
How to judge tightening torque of a standard bolt or nut.
1. How to judge tightening torque of a standard bolt.
Find out the type of the bolt from the list below.
Then, find the bolt tightening torque from the table.
2. How to judge tightening torque of a standard nut.
The nut tightening torque can be judged from the bolt type. (Seethe item above.)
BOLT STRENGTH TYPE IDENTIFICATIONMETHOD
1. Identification by bolt shape 2. Identification by part No.
Hexagon head bolt I
Part No.
91611-40625
T L e n g t h (mml
Diameter (mm)
iameter
Stud bolt
Part No.
92132-40614
Length (mm)
Diameter (mm)
Class
4=4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
4T
4T
5T
Shape and class
Two protruding
Four protruding
Hexagon
head bolt
Hexagon
flange bolt
Hexagon
head bolt
@-Bolt head No.
0 No mark
No mark
Two protruding
lines