Toyota 5FBCU15
Toyota 5FBCU15
Toyota 5FBCU15
This manual deals with the above models as of October 1999. Please under-
stand that disagreement can take place between the descriptions in the manual
and actual vehicles due to change in design and specifications. Any change
or modifications thereafter will be informed by Toyota Industrial Equipment
Parts & Service News.
GENERAL
DRIVE UNIT (2.3 TON SERIES)
-
FRONT AXLE (2.3 TON S E R I E S )
REAR AXLE (2.3 TON SERIES)
MAST (2.3TON SERIES)
CYLINDER (2.3 TON SERIES)
OIL CONTROL VALVE
APPENDIX
GENERAL
*: These high capacity (battery compartment) models are not established in EEC specification.
Note: Way and the position of the model and frame No. indications have been unchanged.
LUBRICATION CHART (2.3TON SERIES)
I*
2*
3*
4*
5
6
7
8
9
lo*
11*
12*
13*
Note: This manual covers only the portions different from conventional models. Refer to the
Repair Manual (No.CU305) for the maintenance of other portions.
TRAVELING EQUIPMENT
GENERAL 0 0
BAlTERY 0
CONTROLCIRCUIT 0
MULTIDISPLAYFUNCTIONS 0
ELECTRICAL SYSTEM TROUBLESHOOTING 0
MOTOR 0 Refer to Parts & Service
News GE-8031 of Dec.
1998.
1 ton series 0
DRIVE UNIT
2.3 ton series 0
1 ton series 0
FRONT AXLE
2.3 ton series 0
1 ton series 0
REAR AXLE
2.3 ton series 0
STEERING 0
BRAKE 0
BODY & FRAME 0
MATERIAL HANDLING SYSTEM 0
1 ton series 0
MAST
2.3 ton series 0
Lift 1 ton series 0
CYLINDER 2.3 ton series 0
Tilt cylinder 0
OIL PUMP 0 Refer to Parts & Service
News GE-8024 of Oct.
1998
OIL CONTROLVALVE 0
APPENDIX 0 0
MEANING OF LATEST MODIFICATION ON 5FBCU
2 TON AND 3 TON SERIES
Accompanied by the model change - Development to 7FGCU 2 ton & 3 ton series from GFGCU 2 ton & 3
ton series -, several new design features of 7FGC 2 ton & 3 ton series have also been adapted for 5FBCU
2 ton & 3 ton series. As the effect that, several components have been standardized for the developments
as well as for service efficiencies and conveniences.
The major components involved are tabulated as follows:
Standardization between model series
Meaning of Marks Used for List item
0 Standardized between 5FBCU series and 7FGCU series, or interchangeable.
Partly standardized between 5FBCU series and 7FGCU series, or Partly Interchangeable.
x Exclusively for 5FBCU series
1
Components 2 ton series 3 ton series
Axle housing 0 0
Axle bracket 0 0
Axle shaft 0 0
Wheel bearing 0 0
Wheel & hub drum 0 0
Differentialcase 0
Rear axle Rear axle beam 0 0
Rear axle cylinder 0
Tie rod 0
Steering knuckle 0
Wheel bearing 0
Mount rubber or bushing 0 0
Tire size Front tire x
Rear tire 0
Forks 0 0
Seat belt 0
DRIVE UNIT
(2.3TON SERIES)
Number of gears 4 +-
Pinion gear
Teeth 10 C
Number of gears 2 +
Side gear
Teeth 14 +
12 Support the front axle & drive motor ASSY with a hoist and garage jack. [Point 21
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the brake system after installation.
Point Operations
[Point 11
Installation:
After reassembly, fill hypoid gear oil to the specified level.
A = 15 mm (0.59 in) or less
[Point 21
Removal.lnstallation:
Install hub nuts on hub bolts on the left and right side, and
sling wire at the tapered portion.
[Point 31
Removal:
Remove the reamer bolts. (2 pcs. each at top and bottom
on one side)
SST 09310-23320-71
[Point 41
Removal.Installation:
Operate carefully so as not to bring the axle shaft into con-
tact with the oil seal lip to damage it.
N.m (kgf-cm) [ft-lbfl
Disassembly Procedure
1 Remove the differential cover. [Point 11
4 Remove the differential case ASSY. (See page 1-1 4 for the disassembly, inspection and reassembly
procedure.)
7 Remove the drive pinion, bearing, spacer and shim from the retainer. [Point 61
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 11
Reassembly:
Apply sealing agent (Three Bond's No.1217C or the equiva-
lent) on the mating surfaces of the differential cover and
housing before reassembly.
[Point 21
Inspection:
Measure the ring gear backlash.
- -
Standard: 0.2 0.3 mm (0.008 0.012 in)
[Point 31
Disassembly:
Put match marks on the bearing cap and differential hous-
ing.
Reassembly:
Install the adjusting nuts and bearing cap.
1, Install the adjusting nuts.
2. Install the bearing cap by aligning the match marks and
temporarily tighten the set bolt.
T = 19.6 N-m(200 kgf-cm) [I4.5 ft-lbf]
3. Set the dial gauge in the thrust direction of the differential
case.
4. Use the SST and tighten until the thrust clearance is elimi-
nated.
SST 09630-10110-71
5. Tighten adjusting nuts on both sides by one notch each.
6. Set the dial gauge vertical to the ring gear tooth surface,
and measure the backlash.
[Point 41
Reassembiy:
Adjust the drive pinion protrusion by means of the drive pin-
ion bearing retainer shims. Select the shim by teeth con-
tact inspection. (See Point 3.)
Shim thickness:
0.10.0.15.0.35 and 0.45 mm
(0.0039~0.0059~0.0138 and 0.0177 in)
[Point 51
Reassembly:
After the drive pinion bearing starting torque adjustment,
caulk the output gear lock nut.
0 Good examples 0
Point contact
[Point 61
Reassembly:
SST 09370-20270-71
Reassembly:
Adjust the drive pinion bearing starting torque.
1. Install the output gear and tighten the lock nut to the speci-
fied torque.
2. Set a torque wrench on the lock nut, and measure the start-
ing torque.
Starting torque:
-
10.79 13.24 N-m
-
(110 135 kg-cm)
-
[7.96 9.77 ft-lb]
Shim thickness:
0.03.0.1 0.0.15.0.35 and 0.45 mm
(0.0012~0.0039~0.0059~0.0138 and 0.0177 in)
[Point 71
Disassembly:
SST 09950-40011
SST
Reassembly:
Use the SST and install the pilot bearing.
SST 09608-04031
Check the installed direction.
[Point 81
Disassembly:
SST 09420-23000-71
Reassembly:
SST 09316-60011
DIFFERENTIAL CASE ASSY
DISASSEMBLYINSPECTION-REASSEMBLY T = N-m (kgf-cm) [ft-lbfl
Disassembly Procedure
1 Remove the differential case bearings. [Point I ]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
SST a [Point I]
Disassembly:
SST 09950-40011 --- @
09950-60010 --- @
Reassembly:
, SST @
Install the side bearing.
1. Use the SST and drive in the side bearing to the end
surface.
SST 09950-60020 --- O
09950-70010 --- @
2. Use a striking driver and fully drive in the bearing.
[Point 21
Disassembly-Reassembly:
Check the match marks.
Reassembly:
Apply locking agent (08833-00070) on the set bolt threaded
Match marks portion before reassembly.
[Point 31
Inspection:
Measure the inside diameter of the differential pinion.
Standard: 22.12 mm(0.8709 in)
Limit: 22.22 mm(0.8748 in)
Inspection:
Measure the spider outside diameter
Standard: 22.00 mm(0.8661 in)
Limit: 21.75 mm(0.8563 in)
Inspection:
Measure the side gear thrust washer thickness.
Inspection:
Measure the pinion gear thrust washer thickness.
Reassembly:
Install the side gear thrust washer with its oil groove facing
the gear.
Reassembly:
Apply chassis grease (molybdenum disulfide grease) on
both sides of the spider pinion thrust washer before reas-
sembly.
[Point 41
Reassembly:
Apply locking agent (08833-00070) on the set bolt threaded
portion before reassembly. Tighten the set bolts gradually
in the diagonal order, and finally tighten in the circular order
to the specified torque.
FRONT AXLE
(2.3TON SERIES)
Page
GENERAL ........................................................................ 2-2
SPECIFICATIONS .......................................................... 2 9
COMPONENTS .............................................................. 2 4
FRONT AXLE SHAFTmAXLE HUB ............................. 2-5
REMOVAL*INSTALLATION...............................................2-5
FRONT AXLE BRACKETmAXLE HOUSING ............ 2-9
REMOVAL*INSTALLATION............................................... 2-9
2-2
GENERAL
2 ton series
3 ton series
SPECIFICATIONS
Vehicle model
2 ton series 3 ton series
Item
3 ton series
FRONT AXLE SHAFTeAXLE HUB
REMOVAL- INSTALLATION T = N.m (kgf-cm) [I?-lbfl
Removal Procedure
1 Drain differential oil. [Point I]
6 Remove the outer bearing roller and front axle hub. [Point 51
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply thread tightener (08833-00070)on the hub bolt set nut before tightening.
Point Operations
[Point I ]
Installation:
Fill Hypoid gear oil to the specified level after installation.
A = 15 mm (0.59 in) or less
[Point 21
Removal.lnstallation:
Carefully operate so as not to damage the oil seal by con-
tact with the axle shaft.
[Point 31
Removal:
SST 09320-23000-71
Installation:
SST 09950-60010 --- O
09950-70010 --- @
[Point 41
Removal.Installation:
SST 09509-55020
Installation:
Adjust the front axle hub starting force.
1. Install the plate.
2. Fully tighten the bearing lock nut, and rotate the hub by 4
to 5 turns to run in the bearing.
3. Return the bearing lock nut by 1/12 to 116 turn (30 to
60°), and rotate the hub by 4 to 5 turns again.
4. Set a spring scale on a hub bolt, and measure the start-
ing force.
Standard:
25.5 - 72.6 N (2.6 - 7.4 kg9 [5.7 - 16.3 Ibf]
5. If the standard is not satisfied, adjust the degree of bear-
ing lock nut tightening for adjustment.
6. Install the nut lock bolt.
Coat thread tightener (08833-00070) on the nut lock bolt
before tightening.
[Point 51
Installation:
Fill MP grease in the hub before installing the front axle hub.
Installation:
SST 09370-10410-7 1
[Point 61
Removal:
Use a screwdriver or the like to remove the oil seal.
Installation:
SST 09950-60020 --- @I
09950-70010 --- @
[Point 71
Removal:
Use a brass bar to remove the bearing outer race.
Installation:
SST 09950-60020 --- @I
09950-70010 --- @
FRONT AXLE BRACKET*AXLEHOUSING
REMOVAL.INSTALLATION T = N.m (kgf-cm) [ft-lbfl
- -
T = 107.9 137.3 (1100 1400) 179.59 - 101.3]
Removal Procedure
1 Remove the front axle & drive motor ASSY. (See page 1-5)
2 Remove the front axle shaft and axle hub. (See page 2-5)
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease on the O-ring before installation.
Point Operations
[Point I ]
Installation:
Apply sealing agent (08826-00080) on the mating surfaces
of the brake backing plate and front axle bracket before in-
stallation.
Installation:
Apply locking agent (08833-00070) on the set bolts before
tightening.
REAR AXLE
(2.3TON SERIES)
Page
GENERAL ........................................................................3-2
SPECIFICATIONS .........................................................3-3
COMPONENTS ..............................................................3 9
REAR AXLE ASSY ....................................................... 3-5
...............................................3-5
REMOVAL*INSTALLATION
STEERING KNUCKLE .................................................. 3-7
REMOVALINSTALLATION............................................... 3-7
REAR AXLE CYLINDER ...............................................3-11
REMOVAL*INSTALLATION............................................... 3-11
DISASSEMBLVINSPECTION~REASSEMBLY .................. 3-13
REAR WHEEL ALIGNMENT ....................................... 3-15
GENERAL
Rear Axle Cylinder
SPECIFICATIONS
Rear axle type Elliot type
4302
L... a
.
4302-024
REAR AXLE ASSY
REMOVAL- INSTALLATION T = N-m (kgf-cm) [ft-lbfl
Removal Procedure
1 Remove the counter weight.
2 Apply the parking brake and chock the front wheels.
3 Jack up the frame and support it with the wooden block.
4 Remove the rear wheels (See removal procedure steps 2 to 4 in steering knuckle removal section on
page 3-7).
5 Disconnect the rear axle cylinder hose.
6 Support the rear axle ASSY with a garage jack.
7 Remove the rear axle ASSY. [Point I]
8 Remove the center pin bushing. [Point 21
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add grease through each grease fitting. Add genuine molybdenum disulfide grease
at the rear axle beam center pins (two places). Use MP grease to other grease fittings.
Point Operations
[Point I ]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the front
to rear clearance on the rear side.
Spacer thickness:
L I 1.2.2.3.3.0.3.5.4.0.4.5 and 5.0 mm
j First and 0.1 97 in)
(0.047~0.091~0.118~0.138~0.157~0.177
I
I : I Second
3, Install the spacer at the rear side center pin.
The first spacer shall be installed with its chamfered at
the inside diameter in contact with the center pin boss.
t ;
I
[Point 21
Inspection:
Inspect the inside diameter of the rear axle center pin bush-
ing.
Installation:
Apply molybdenum disulfide grease on the bushing and in-
stall the bushing by aligning the grease groove in the bush-
ing with the grease fitting position.
-rI I I
Grease fitting
STEERING KNUCKLE
REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl
Removal Procedure
1 Jack up the vehicle.
2 Remove the hub cap. [Point 11
3 Remove the castle nut and claw washer. [Point 21
4 Remove the outer bearing and rear wheel. [Point 31
5 Remove the bearing outer race from the rear wheel. [Point 41
6 Remove the inner bearing roller and oil seal. [Point 51
7 Disconnect the tie rod (on the knuckle side).
8 Remove the king pin cover.
9 Remove the king pin lock bolt and king pin. [Point 61
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seal and needle roller bearing. [Point 71
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add MP grease through grease fittings.
Point Operations
[Point 11
Installation:
Fill MP grease in the hub cap, and install by tapping the
flange portion.
[Point 21
Installation:
Adjust the rear wheel starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a torque
of 15 to 32 N-rn(150 to 330 kgf-cm) [I 0.9 to 23.9 ft-lbfl.
3. Rotate the hub by 3 to 5 turns to run in the bearing.
[Point 31
Installation:
Fill MP grease in the hub and knuckle spindle.
Installation:
Install the rear wheel and outer bearing.
SST 09370-20270-71
[Point 41
Removal:
Use a brass bar and remove the bearing outer race
Installation:
SST 09950-60020 --- @
09950-7001 0 --- @
SST
[Point 51
Removal:
SST 09950-40011
Installation:
Install the oil seal and inner bearing roller.
1. Use the SST and install the oil seal.
SST 09370-10410-71
[Point 61
Inspection:
Measure the king pin outside diameter
4. Tighten the lock nut for the king pin lock bolt.
[Point 71
Removal:
Remove the king pin oil seal and needle roller bearing.
1. Use a straight-edge screwdriver to remove the dust seal
and oil seal.
2. Use the SST and remove the needle roller bearing.
SST 09950-60010 --- @
09950-70010 --- @
Installation:
Install the needle roller bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
Check the needle roller bearing press-fitting surface,
pressing direction and installation depth.
SST 09950-60010 --- @
0 rnrn
09950-70010 --- @
(0 in) 2. Install the dust seal.
3. Use the SST and install the oil seal.
SST 09950-60010 --- O
09950-70010 --- @
4 rnrn
(0.16 in)
Press-fitting direction
3-11
Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 11
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 21
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 11
Removal:
Mark the punch mark position on each of cylinder end pins
LH and RH.
Installation:
Install each cylinder end pin by aligning the punch mark
with the mark.
[Point 21
Installation:
Install the fitting in the illustrated direction.
DISASSEMBLY*lNSPECTIONgREASSEMBLY T = N-m (kgf-cm) [ft-Ibfl
Disassembly Procedure
1 Remove the through bolt.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat hydraulic oil before reassembly.
Point Operations
[Point I ]
Inspection:
Measure the piston rod outside diameter.
Limit: 49.92 mm (1.9654 in)
Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)
Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil
or water before installation.
Do not stretch it excessively.
Caution:
Operate carefully to avoid scalding.
[Point 21
Inspection:
Measure the rear axle cylinder bore.
Toe-in Adjustment
1. Check to see that Ar and A! of the rear axle cylinder are
equal.
Punch mark on plate side 2. Align the punch mark on the cylinder end pin (eccentric pin)
with the punch mark on the plate on the front side for both
the LH and RH sides.
3. Measure and adjust the toe-in (Bf - Br).
Standard: 0 + 4 mm (0 + 0.16 in)
If the standard is not satisfied, make adjustment by the cyl-
inder end pin in the range where the difference between Rt
and Rr is within 0 t 3 mm (0.12 in).
Punch mark on cylinder end pin side ( I ) When measued value > 4 mm (0.16 in):
Measure Rt and Rr, and adjust the cylinder end pin on
the smaller side toward IN.
(2) When measured value < 4 mm (0.16 in):
Measure Rt and Rr, and adjust the cylinder end pin on
the greater side toward OUT.
Note:
If Rt equals to Rr, adjust the same amount on the LH
and RH sides.
If the standard is not attained by adjustment on one
side, make adjustment also on the other side.
4. Install the plate. The plate can be installed with either face
UP.
5. After adjustment, fully steer the tires and check to see that
they do not come into contact with the vehicle body.
MAST
(2.3TON SERIES)
Page
V MAST ASSY................................................................. 4-2
COMPONENTS ............................................................... 4-2
REMOVAL*INSTALLATION ............................................... 4-5
REMOVAL-INSTALLATION (WJLIFTBRACKET) .............. 4-7
MAST DISASSEMBLY*INSPECTION*REASSEMBLY........ 4-9
LlFTBRACKET DISASSEMBLY-INSPECTION-
REASSEMBLY ............................................................. 4-11
MAST ADJUSTMENT (V MAST) ....................................... 4-13
MAST ROLLER REMOVAL-INSTALLATION ..................... 4-18
CHAIN .............................................................................4-19
INSPECTION .................................................................... 4-19
REASSEMBLY O/.FV*FSV)............................................... 4-19
REASSEMBLY (Q FV) ....................................................... 4-20
ADJUSTMENT ................................................................ 4-21
FORK................................................................................. 4-21
REMOVAL ........................................................................4-21
INSTALLATION ................................................................. 4-21
INSPECTION .................................................................... 4-21
FV*FSV MAST ASSY .................................................... 4-22
COMPONENTS ................................................................ 4-22
FSV) ....................................... 4-25
MAST ADJUSTMENT (FV-
QFV MAST ASSY .......................................................... 4-29
COMPONENTS ................................................................ 4-29
MAST ADJUSTMENT (an/)............................................. 4-31
LlFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) ................. 4-33
V MAST ASSY
COMPONENTS
40
FSV QFV
02
40
6301-467A
3 ton series 6301
V FV
02
6301-465
3 ton series 6302
6302-298
- - - - -
Removal Procedure
1 Set the mast vertical and fully lower the fork.
4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift
bracket, and slowly run the vehicle backward to depart from the lift bracket.)
6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)
Note:
Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift
cylinder is replaced. (See page 4-34.)
Adjust the chain tension after installation.
Point Operations
[Point I ]
Removal-Installation:
SST 09630-23600-71
[Point 21
Removal:
If the fitting is hard, use the SST for removal.
SST 09950-40011
[Point 31
Removal:
SST 09810-20172-71
REMOVAL. INSTALLATION (WILI FT BRACKET) T = N-m (kgf-cm) [ft-lbfj
Removal Procedure
1 Set the mast vertical.
4 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift cylin-
der.)
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either
lift cylinder is replaced. (See page 4-33.)
Point Operation
[Point I ]
Removal:
SST 09810-20172-71
MAST DISASSEMBLY-INSPECTION-REASSEMBLY
Disassembly Procedure
1 Remove the hose cover.
3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 11
5 Remove each cylinder bottom set bolt, and remove each lift cylinder.
6 Slide the inner mast in the lowering direction, and remove the lift rollers.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
Shim
[Point I ]
Disassembly:
Shim adjustment is made at the lift cylinder rod end for pre-
venting uneven lifting by lift cylinders LH and RH.
Take a note on the cylinder where the adjustment is made
and the number of shims in use.
[Point 21
Disassmbly:
Take a note on the number of cylinder support shims in use.
Reassembly:
Make cylinder support shim adjustment if the mast or either
cylinder is replaced.
With the cylinder rod end inserted to the inner mast, insert
shim(s) between the cylinder support and outer mast to elimi-
nate the clearance. The shim thickness should be slightly
greater than the clearance.
[Point 31
Inspection:
Measure the mast strip thickness.
Disassembly Procedure
1 Remove lift rollers. [Point 11
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point I ]
Disassembly:
SST 09950-4001 1
[Point 21
Reassembly:
Install the side roller in the correct direction.
The side chamfered with a greater radius of the roller shall
be on the front side of the vehicle.
MAST ADJUSTMENT (V MAST)
Lift Roller Adjustment at Mast
;::rJ
Inner mast
into
These ;oilers
These rollers
Outer
mast inner
mast
(3) Distribute shims equally to the rollers on the left and right
side.
(4) After the adjustment, see that the inner mast moves
smoothly in the outer mast.
4-15
:$tif
lnner
mast
bracket
11
100 rnrn (3.94 in)
lnner
mast bracket
(1) Bring the center of the side roller in the upper part of the
lift bracket to approx. 100 mm (3.94 in) from the top of
the inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect on the opposite
side the clearance between the roller side face and the
mast where they are the closest. (No adjustment is nec-
essary for the upper lift rollers since they are fastened
by snap rings.)
Standard
- -
C = 0 0.5 mm (0 0.020 in)
(6) After adjusting the middle and lower lift rollers, bring the
side roller on one side into contact with the outer mast
and measure on the opposite side the clearance between
the side roller and inner mast surface.
Standard
- -
D = 0 0.5 mm (0 0.020 in)
- Roller
Outward
(3) After the adjustment, check the mast for smooth move-
ment.
MAST ROLLER REMOVAL-INSTALLATION
1. Remove the lift bracket. (See steps 1 to 4 of the mast
ASSY removal procedure on page 4-5.)
2. Jack up the vehicle, and support tires with wooden blocks.
Also lock the front and rear tires from rotation.
3. Remove the lift cylinders. (See page 5-11.)
Note:
Perform measurement without removing the chain
from the vehicle.
lnspect elongation over the entire chain length since
it may be localized.
REASSEMBLY O/.FV0FSV)
1. Installing direction
-
Install with the split pin on the Install with the split pin on the Install with the split pin on the
vehicle center side. vehicle outside. vehicle rear side.
Clamp
Sketch
0 0 0
0 0 0
REASSEMBLY (QFV)
1. Installing direction
As shown in the table below.
2. Chain adjusting nut tightening order
(I) Tighten nuts @ and 0. T = 49.0- 78.0N.m (500 - 800 kgf-cm) [36.2- 57.9fi-lbfl
(2) Tighten nut @.
$
Outer chain Middle chain Inner chain
y7
T = 98.0-
[72.35
147.0 N m (1000
- 108.5 ft-lbfl
- 1500 kgf-cm)
Upper middle
&
Split pin
lnner mast
T = 98.0 - 147.0 N.m (1000 - 1500 kgf-cm) Installation side of split pin is at center Installation side of split pin is outward of
[72.35 - 108.5 ft-lbfl side of the truck. the truck center.
Chain connection
ADJUSTMENT
1. Park the vehicle on a flat ground and set the mast vertical.
2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting
nut.
3. Check to see that the chain tension is equal on the left and right side.
4. Check to see no chain twist.
6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast
is not in contact with the lift bracket.
FORK
REMOVAL
1. Set the fork at approx. 20 cm (7.9 in) above the ground.
2. Place a wooden block under the knotched portion of the
fork rail.
3. Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.
INSTALLATION
The installation procedure is the reverse of the removal pro-
cedure.
INSPECTION
1. Inspect misalignment of the fork tip ends.
FSV 31
61O I
43A
6101-491A
FV 2 ton series 6302
21K
FV 3 ton series
6302-297
FSV 6302
2 ton series
FSV
3 ton series
6302-296
MAST ADJUSTMENT (FV-FSV)
Lift Roller Adjustment at Mast
1. Clearance between:
lnner mast roller and outer mast (FV).
lnner mast lower roller and middle mast (FSV).
Middle mast lower roller and outer mast (FSV).
FSV mast
FV mast
lnner mast
Outer mast
@These rollers
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the
clearance between the roller side face and mast where they are the closest.
(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast movement is smooth.
2. Clearance between:
Outer mast roller and inner mast (FV).
Middle mast upper roller and inner mast (FSV).
Outer mast upper roller and middle mast (FSV)
Outer mast
Outer mast
Middle mast
Inner
mast
(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast movement is smooth.
LiftISide Roller Adjustment at Lift Bracket
FV-FSV mast
Lift bracket
(1) Raise the lift bracket to the uppermost position for the FSV mast, and bring the center of the upper
lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for FV mast.
(2) Shift the lift bracket to one side to bring the lower lift roller, and measure on the opposite side the
clearance between the roller side face and the mast where they are the closest.
(3) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers.
Bring the side roller on one side into contact with mast side surface, measure on the opposite side
the clearance between the side roller and the inner mast side surface where they are the closest.
Standard: D = 0 - 0.5 mm (0 - 0.020 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims
equally to the rollers on the left and right sides.)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) After the adjustment, check to see that the lift bracket moves smoothly over the entire length of the
mast.
Mast Strip Adjustment
FV mast
FSV mast
w
-
(1) Lower the inner (or middle) mast fully.
(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.
(3) After the adjustment, check the mast for smooth movement.
4-29
Channel seen from the top Channel seen from the bottom
--
0 0.5 mm
(0 0.02 in)
-
0 0.5 mm
<
-
(0 0.02 in)
-
0 0.8 mm
-
(0 0.03 in) 450 mm
(17.7 in)
450 mm
(17.7 in)
450 mm
(17.7 in)
Note:
The mast strip & shim adjustment between the mast channels can also be performed in the same
sequence with those of V.FV.FSV.
Lift Roller Position on Each Upright:
Inner
Upper Middle
Lower Middle
B f
Outer
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required t o prevent uneven lifting on
the left and right sides due to tolerances of parts, etc.
The inspection and adjustment must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY, and inner mast SUB-ASSY
1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
2. Adjustment method
(1) Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches the
SST.
SST 09610-22000-71
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.
Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)
CYLINDER
(2.3TON SERIES)
Page
LlFT CYLINDER (V)
REAR LIFT CYLINDER (FV-FSV*QFV)................. 5-2
GENERAL ........................................................................5-2
SPECIFICATIONS ............................................................ 5-5
COMPONENTS ................................................................ 5-7
SPECIFICATIONS
Lift Cylinder O/)
Vehicle model
2 ton series 3 ton series
Itern
Cylinder type Single-acting Single-acting
Cylinder bore mrn (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter rnm (in) 42.0 (1.65) 45.0 (1.77)
Piston seal type U packing U packing
Rod seal type U packing U packing
Others Built-in safety down valve (RH, LH)
Rear Lift Cylinder (FV)
Vehicle model
2 ton series 3 ton series
ltem
Cylinder type Single acting Single acting
Cylinder bore mm (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter mm (in) 34.9 (1.37) 40.0 (1 57)
Rod seal type U packing U packing
Others Built-in safety down valve (LH)
Vehicle model
2 ton series 3 ton series
ltem
Cylinder type Single acting Single acting
Cylinder bore mm (in) 50.2 (1.98) 55.0 (2.17)
Piston rod outside diameter mm (in) 42.0 (1.65) 45.0 (1.77)
Piston seal type U packing U packing
Rod seal type U packing U packing
Others Built-in safety down valve (RH)
Vehicle model
2 ton series
ltem
Cylinder type Single acting type
Cylinder bore mm (in) 63.5 (2.50)
Piston rod outside diameter mm (in) 50.8 (2.00)
Rod seal type U packing
Others Built-in safety down valve (LH)
5-7
COMPONENTS
Lift Cylinder for V Mast (2 Ton Series)
AN
AM
OP[LH] 01[RH]
...,
22
21 1 , 20
I
-1.J
L... -
6503-113A
6503
94125-4120-
&AI
a
BE+
AM
01[RH]
.
...
I
02K
AA
6503
AW
02 [LH] 01 [RH]
rm==
I
I
I ==mi I
I
r=l=
I
I
I
I
I I I I
W A D
W A F
W A C
-02K - 01K
23 22
I I
I
, I
I I I I
Llll 11111 Llll 11111
6503-0938
REMOVAL-INSTALLATION
Removal Procedure
1 Set the mast vertical and lower the fork fully.
3 Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point I ]
4 Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space.
5 Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer
mast.
Note:
After installing the lift cylinder, follow the steps below.
1. Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal function-
ing.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect lift cylinders for uneven lifting, and make necessary adjustment.
Point Operations
[Point I ]
Removal:
Shim adjustment is made at the lift cylinder rod end to pre-
vent uneven lifting by lift cylinders LH and RH. Take notes
on the cylinder where adjustment is made and the number
of shims used.
[Point 21
Installation:
Temporarily fasten the cylinder support here, and eliminate
any clearance between the cylinder support and outer mast
by shim insertion after connecting the rod end. (Use shim(s)
slightly thicker than the clearance.)
DISASSEMBLY-INSPECTION-REASSEMBLY
Lift Cylinder for V Mast T = N-m (kgf-cm) [ft-lbfl
2 2
4 4
* Cylinder cover
2 ton series: 3 ton series:
- -
T = 230 265 (2345 2703) [I 70 - 1951 - -
T = 264 305 (2695 31 10) [I 75 - 2251
Disassembly Procedure
1 Remove the safety down valve.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Point Operations
[Point I]
Disassem bly-Reassembly:
SST 09620-10100-71
[Point 21
Inspection:
Measure the piston rod outside diameter.
2 ton series
Standard: 42.0 mm(1.654 in)
Limit: 41.92 mm(1.6504 in)
3 ton series
Standard: 45.0 mm(1.772 in)
Limit: 44.92 mm(1.7685 in)
Inspection:
Measure the piston rod bend.
[Point 31
Reassembly:
Install the check valve arrow pointing to the lower side of
the cylinder.
Inspection:
Measure the cylinder bore.
2 ton series
Standard: 50.0 mm(1.969 in)
Limit: 50.20 mm(1.9764 in)
3 ton series
Standard: 55.0 mm(2.165 in)
Limit: 55.35 mm(2.1791 in)
- - - - - - --
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080)on the threaded portion of the cylinder cover before tightening.
Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following
sequence:
(1) Extend the N rear lift cylinder.
(2) Stop the engine.
(3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.
Point Operations
[Point 1]
Disassembly.Reassernbly:
SST 09620-10100-71
[Point 21
Inspection:
Measure the piston rod outside diameter.
2 ton series
Standard: 34.9 mm (1.374 in)
Limit: 34.82 mm (1.3709 in)
3 ton series
Standard: 40.0 mm (1.575 in)
Limit: 39.92 mm (1.5717 in)
Inspection:
Measure the piston rod bend.
[Point 31
Disassembly~Reaseembly:
Follow the procedure view.
1. Fix the boss portion at the tip end of the piston rod in a
vise.
[Point 41
Inspection:
Measure the lift cylinder bore.
2 ton series
Standard: 50.0 mm (1.969 in)
Limit: 50.20 mm (1.9764 in)
3 ton series
Standard: 55.0 mm (2.165 in)
Limit: 55.35 mm (2.1791 in)
Rear Lift Cylinder for FSV Mast
LH RH
*Cylinder cover:
2 ton series - - -
T = 230 265 (2345 2702) [I70 1951
3 ton series - - -
T = 237 305 (2419 31 10) [I75 2251
Disassembly Procedure
1 Remove the safety down valve.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Point Operations
[Point 1]
Disassembly-Reassembly:
SST 09620-10100-71
[Point 21
Inspection:
Measure the piston rod outside diameter.
2 ton series
Standard: 42.0 mm(1.654 in)
Limit: 41.92 mm(1.6504 in)
3 ton series
Standard: 45.0 mm(1.772in)
Limit: 44.92 mm(1.7685 in)
Inspection:
Measure the piston rod bend.
[Point 31
Reassembly:
Install the check valve so that the arrow directs to down-
ward of the lift cylinder.
[Point 41
Inspection:
Measure the lift cylinder bore.
2 ton series
Standard: 50.2 mm(1.976 in)
Limit: 50.40 mm(1.9843 in)
3 ton series
Standard: 55.0 mm(2.165 in)
Limit: 55.20 mm(2.1732 in)
Rear Lift Cylinder for QFV Mast
Disassembly Procedure
1 Remove the safety down valve.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Point Operations
[Point I ]
Inspection:
Measure the piston rod outside diameter.
Inspection:
Measure the piston rod bend.
[Point 21
Inspection:
Measure the lift cylinder bore.
Piston
-
T = 58.8 68.6
-
(600 700)
-
[43.4 50.61
SPECIFICATIONS
Fork Lowering Speed Unit: mmtsec (fpm)
V FV FSV QFV
Note:
The flow regulator valve is installed in the hydraulic piping system, respectively for each model.
SAFETY DOWN VALVE (V*FV*FSV-QFV)
GENERAL
I
I
I'
I I
4 I
0
5-25
SPECIFICATIONS
Front Lift Cylinder (FV)
Vehicle model
2 ton series 3 ton series
ltem
Cylinder type Single acting Single acting
Cylinder bore mm (in) 75.0 (2.95) 85.0 (3.35)
Piston rod outside diameter mm (in) 50.8 (2.00) 50.8 (2.00)
Rod seal type U packing U packing
Piston seal type U packing U packing
Others Built in safety down valve
Vehicle model
2 ton series 3 ton series 2 ton series QFV
ltem
Cylinder type Single acting Single acting Single acting
Cylinder bore mm (in) 75.0 (2.95) 85.0 (3.35) 75.0 (2.95)
Piston rod outside diameter mm (in) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00)
Piston seal type U packing U packing U packing
Rod seal type U packing U packing U packing
Others Built-in safety down valve
COMPONENTS
Front Lift Cylinder for N Mast
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the lift cylinder, follow the steps below.
(1) Repeat full-stroke raising and lowering without load to bleed air and check normal function-
ing.
(2) Check the hydraulic oil level, and add if insufficient.
(3) Adjust the lift chain tension equally on the left and right sides.
Front Lift Cylinder for FV-FSV-QFV
4 4
* Cylinder cover
FVIFSVIQFV on 2 ton series - - -
T = 339 407 (3455 4147) [250 3001
FVIFSV on 3 ton series - - -
T = 420 454 (4283 4630) [310 3351
Disassembly Procedure
1 Remove the safety down valve.
ReassemblyProcedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the
cylinder cover.
Disassembly.Reassembly:
SST 09620-10100-71
[Point 21
Inspection:
Measure the piston rod outside diameter.
Inspection:
Measure the piston rod bend.
[Point 31
Assembly:
Install the check valve so that the arrow will direct down-
ward of the front lift cylinder.
[Point 41
Inspection:
Measure the lift cylinder bore.
2 ton series
Standard: 75.0 mm (2.953 in)
Limit: 75.35 mm (2.9665 in)
3 ton series
Standard: 85.0 mm (3.346 in)
Limit: 85.40 mm (3.3622 in)
OIL CONTROL VALVE
Page
GENERAL .....................................................................6-2
SPECIFICATIONS .....................................................6-4
COMPONENTS .........................................................6-4
OIL CONTROL VALVE ASSY ..................................6-5
REMOVAL.INSTALLATION........................................... 6-5
DISASSEMBLY.INSPECTI0N.REASSEMBLY ................ 6-6
RELIEF PRESSURE ADJUSTMENT ......................6-8
GENERAL
Oil Control Valve
Relief Valve
Hydraulic Circuit
TI T2 P
..- ---........-- -.
..........-....-. .......-.
..
P: Pump port
T: Tank port
TI: To tank
T2: From power steering
SPECIFICATIONS
Spec. item Type & values
Oil control valve type Add on type of 3 spools (Monoblock for each spool section)
COMPONENTS
OIL CONTROL VALVE ASSY
REMOVAL-INSTALLATION
Note:
Before disconnecting the control lever link, release the residual pressure in the material han-
dling system piping by operating the control lever, set the mast in the neutral state and lowering
the fork to the bottom position.
Removal Procedure
1 Remove the toe board.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease to the oil control valve lever link parts.
Check the hydraulic oil level, and add if insufficient.
DISASSEMBLY-INSPECTION-REASSEMBLY
Note:
Operate in a clean place.
As each part is finished with high precision, carefully disassemble them to prevent any damage.
Disassembly Procedure
1 Remove the through bolt.
[Point 21
Reassembly:
When the relief valve is disassembled, always loosen the
adjust screw fully.
RELIEF PRESSURE ADJUSTMENT
Note:
Always make adjustment according to the procedure described below. Careless adjustment may
generate a high pressure to cause damage to the oil pump or other hydraulic devices.
Transmlsson &
09316-60011 transfer bearlng 0
replacer
000~
09950-60020 Replacer set No 2 0 0 0
011
control valve sprlng
@ 09620-10100-71
Cylinder cap remover
and replacer
O
4 09630-1
Tilt cylinder cap
remover and replacer
0
-g
-c 09631-22000-71 Wear scale chain 0
Drive pinion lock nut Standard 343 - 392 (3500 - 4000) [253.2 - 289.31
Drive pinion bearing retainer set bolt Standard 88.3 - 117.7 (900 - 1200) [65.1 - 86.821
Ring gear set bolt Standard 127.4 - 176.5 (1300 - 1800) [94.0 - 130.21
Differential upper case set bolt Standard 43.1 - 53.9 (440 - 550) [31.8 - 39.81
Differential case bearing cap set bolt Standard 117.7 - 137.3 (1200 - 1400) [86.82 - 101.31
Differential cover set bolt Standard 29.4 - 44.1 (300 - 450) [21.7 - 32.61
FRONT AXLE
-
Front axle shaft hub
Hub bolt set nut Standard 166.7 - 205.9 (1700 - 2100) [ I23.0 - 151.91
Bearing lock nut stopper bolt Standard 14.7 - 21.6 (150 - 220) [ I0.9 - 15.91
Axle shaft set bolt Standard 98.07 - 127.5 (1000 - 1300) [72.35 - 94.061
Front axle housing set bolts Standard 107.9 - 137.3 (1100 - 1400) [79.59 - 101.31
REAR AXLE
Rear axle ASSY
Rear axle ASSY front to rear clearance mm (in) Standard 0.7 (0.028) or less
Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.017)
Axle bracket cap set bolt Standard 117.7- 166.7 (1200 - 1700) [86.82 - 123.01
King pin lock bolt and lock nut Standard 44.1 - 53.9 (450 - 550) [32.6 - 39.81
Rear axle cylinder rod guide set nut Standard 88 - 118 (900 - 1200) [65.1 - 86.81
Mast support cap set bolt Standard 68.6 - 107.9 (700 - 1100) [50.6 - 79.571
Back rest set bolt Standard 99.54 - 184.9 (1015 - 1885) [73.42 - 136.31
Chain adjusting nut Standard 49.0 - 78.0 (500 - 800) [36.2 - 57.91
CYLINDER
Lift cylinder 01)