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Toyota 30 Series Manual

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This manual covers the service procedures for the modified portions of
-
TOYOTA BATTERY FORKLIFT 5FBCU15
30 series. Please use this
manual for quick accurate servicing of these vehicles and as the tool for
sales and service activities.
As this manual is edited as a supplement to Repair Manual for the
-
30 series, please refer to Repair Manual (Pub. No.CU305) for
the matters not covered herein.
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.
For your reference, we herewith indicate the titles of relevant manuals
TOYOTA INDUSTRIAL EQUIPMENT REPAIR MANUAL
-
30 (No.CU305)
TOYOTA MOTOR CORPORATION

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Summary of Contents for Toyota 30 Series

  • Page 1 As this manual is edited as a supplement to Repair Manual for the 30 series, please refer to Repair Manual (Pub. No.CU305) for the matters not covered herein. 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.
  • Page 2 SECTION INDEX NAME SECTION 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 TON SERIES) CYLINDER (2.3 TON SERIES) OIL CONTROL VALVE APPENDIX...

  • Page 3: Table Of Contents

    GENERAL EXTERIOR VIEWS VEHICLE MODEL LUBRICATION CHART TON SERIES) PERIODIC MAINTENANCE INFORMATION ON REFERENCE MANUAL MEANING OF LATEST MODIFICATION ON ......

  • Page 4: Exterior Views

    EXTERIOR VIEWS...

  • Page 5: Vehicle Model

    VEHICLE MODEL Load Capacity Model Types on Spec. Load center Load center 1500 3000 series 1750 3500 STD capacity battery 2-ton compartment 2000 4000 series STD spec. models 2500 5000 3-ton 3000 6000 series 2000 4000 High capacity 2-ton series 2500 5000 1500...

  • Page 6: Lubrication Chart (2.3 Ton Series)

    LUBRICATION CHART (2.3 TON SERIES) 1 1 * Chain lnspect every 8 hours (daily) Mast support bushing lnspect every 40 hours (weekly) Tilt cylinder front pin lnspect every 170 hours (monthly) Front wheel bearing lnspect every 1000 hours (6 monthly) lnspect every 2000 hours (annually) Differential &...

  • Page 7: Periodic Maintenance

    PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required. M: Measurement. Repair or adjustment if required. : For new vehicle *1: Flaw detector Note: This manual covers only the portions different from conventional models. Refer to the Repair Manual (No.CU305) for the maintenance of other portions. Months Inspection Period Hours...

  • Page 8: Information On Reference Manual

    INFORMATION ON REFERENCE MANUAL ng in accordance with the following instructions: Repair manual Remarks Section Pub. No. CU305 This book GENERAL ELECTRICAL SYSTEM TROUBLESHOOTING MOTOR Refer to Parts News GE-8031 of Dec. 1998. 1 ton series DRIVE UNIT 2.3 ton series 1 ton series FRONT AXLE 2.3 ton series...

  • Page 9: Meaning Of Latest Modification On

    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 &...
  • Page 10 DRIVE UNIT TON SERIES) GENERAL ............SPECIFICATIONS .............. COMPONENTS DRIVE UNIT ASSY ..........DIFFERENTIAL CASE ASSY 1-14 ....DISASSEMBLY-INSPECTION-REASSEMBLY 1-14...

  • Page 11: General

    GENERAL...

  • Page 12: Specifications

    SPECIFICATIONS Vehicle Series ton Series ton Series Dustproof Dustproof Ring gear teeth Drive pinion teeth Gear ratio (Differential) 5.833 Number of gears Pinion gear Teeth Number of gears Side gear Teeth Drive gear teeth Output gear teeth Gear ratio (Transmission) 2.727 3.824 2.727...

  • Page 13: Components

    COMPONENTS...

  • Page 14: Drive Unit Assy

    DRIVE UNIT ASSY REMOVAL-INSTALLATION...
  • Page 15 Removal Procedure Remove the mast. (See page 4-7) Remove the battery hood Wldriver seat. Remove the battery ASSY. Jack up the vehicle and remove the front wheels. Drain differential oil. [Point 11 Disconnect the drive motor wiring. Disconnect the speed sensor sub-harness connector. Disconnect the brake pipe (from the wheel cylinder).
  • Page 16 [Point Install hub nuts on hub bolts on the left and right side, and sling wire at the tapered portion. [Point Removal: Remove the reamer bolts. (2 pcs. each at top and bottom on one side) SST 0931 0-23320-71 [Point 41 Operate carefully so as not to bring the axle shaft into con- tact with the oil seal lip to damage it.
  • Page 17 Disassembly Procedure Remove the differential cover. [Point 11 Measure the ring gear backlash. [Point 21 Remove the bearing cap and adjusting nut. [Point Remove the differential case ASSY. (See page 1-1 4 for the disassembly, inspection and reassembly procedure.) Remove the drive pinion ASSY. [Point 41 Remove the output gear.
  • Page 18 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:...
  • Page 19 If the standard is not satisfied, adjust by turning the adjust- ing nut to move the differential case ASSY in the thrust di- rection. (1) When the backlash is excessive: Loosen the adjusting nut on the ring gear teeth side and tighten the adjusting nut on the rear side as much to bring the ring gear closer to the drive pinion.
  • Page 20 (5) Flank contact (low shallow contact) Flank Move the pinion awayfrom the ring gear by increasing contact the drive pinion adjusting shim thickness. Then move the ring gear closer to the pinion to adjust the back- lash. (6) Face contact (high shallow contact) Face Move the pinion closer to the ring gear by decreasing contact...
  • Page 21 Reassembly: Adjust the drive pinion bearing starting torque. 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 (1 10 135 kg-cm) 9.77 ft-lb] 3. If the starting torque does not satisfy the standard make adjustment by changing the shim thickness.
  • Page 22 Reassembly: SST 093 1 6-600 1 1...

  • Page 23: Disassembly*Inspection*Reassembly

    DIFFERENTIAL CASE ASSY DISASSEMBLY INSPECTION-REASSEMBLY Disassembly Procedure Remove the differential case bearings. [Point Remove the differential upper case. [Point 21 Remove the side gear and pinion gear. [Point Remove the ring gear. [Point 4 1 Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
  • Page 24 Point Operations [Point Disassembly: SST 09950-4001 1 09950-6001 0 --- Reassembly: Install the side bearing. 1. Use the SST and drive in the side bearing to the end surface. SST 09950-60020 --- 09950-7001 0 --- 2. Use a striking driver and fully drive in the bearing. [Point Disassem bly-Reassembly: Check the match marks.
  • Page 25 Inspection: Measure the side gear thrust washer thickness. Standard: 1.6 mm (0.063 in) Limit: 1.3 mm (0.051 in) Inspection: Measure the pinion gear thrust washer thickness. Standard: 1.6 mm (0.063 in) Limit: 1.0 mm (0.039 in) Reassembly: Install the side gear thrust washer with its oil groove facing the gear.
  • Page 26 FRONT AXLE TON SERIES) Page ................ GENERAL ............SPECIFICATIONS .............. COMPONENTS FRONT AXLE SHAFTmAXLE HUB FRONT AXLE BRACKETmAXLE HOUSING...

  • Page 27: (2.3 Ton Series)

    GENERAL 2 ton series ton series...

  • Page 28: Specifications

    SPECIFICATIONS Vehicle model ton series 3 ton series Front axle type Full-floating Fixed to frame Suspension type Axle shaft diameter mm (in) 40 (1.57) Axle shaft diameter (spline portion) mm (in) 40 (1.57)

  • Page 29: Components

    COMPONENTS ton series series 3 ton...

  • Page 30: Front Axle Shaftmaxle Hub

    FRONT AXLE SHAFTeAXLE HUB REMOVAL- INSTALLATION...

  • Page 31: Removal*Installation

    Removal Procedure Drain differential oil. [Point Jack up the vehicle and remove front wheel Remove the front axle shaft. [Point Remove the axle shaft oil seal. [Point Remove the bearing lock nut and plate. [Point Remove the outer bearing roller and front axle hub. [Point Remove the oil seal and inner bearing roller.

  • Page 32: Removal*Installation

    [Point 3 1 Removal: SST 09320-23000-71 Installation: SST 09950-6001 0 09950-7001 0 [Point SST 09509-55020 Installation: Adjust the front axle hub starting force. 2. Fully tighten the bearing lock nut, and rotate the hub by to 5 turns to run in the bearing. 3.
  • Page 33 [Point Installation: Fill MP grease in the hub before installing the front axle hub. Installation: SST 09370- 1041 0-7 1 [Point 61 Removal: Use a screwdriver or the like to remove the oil seal. Installation: SST 09950-60020 --- 09950-7001 0 [Point 71 Removal: Use a brass bar to remove the bearing outer race.
  • Page 34 FRONT AXLE BRACKET*AXLE HOUSING REMOVAL. INSTALLATION T = 265 343 (2700 3500) [195.3 253.21 137.3 (1100 1400) 179.59 137 (1200 1400) [86.8 101.31 Removal Procedure Remove the front axle & drive motor ASSY. (See page 1-5) Remove the front axle shaft and axle hub. (See page 2-5) Remove the brake ASSY.
  • Page 35 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.
  • Page 36 REAR AXLE TON SERIES) Page GENERAL SPECIFICATIONS .............. COMPONENTS AXLE ASSY REAR ..........STEERING KNUCKLE AXLE CYLINDER REAR 3-11 3-11 ....3-13 ........REAR WHEEL ALIGNMENT 3-15...

  • Page 37: General

    GENERAL...

  • Page 38: Specifications

    Rear Axle Cylinder SPECIFICATIONS Rear axle type Elliot type Rear axle suspension type Center-supported right-left rocking type Toe-in mm (in) Camber degree 1.5" Wheel alignment Caster degree King pin angle 1 740 (68.5) 1 765 (69.5) 1790 (70.5) Minimum turning radius (outermost) mm (in) 1 960 (66.0) 1 920 (75.5)

  • Page 39: Components

    COMPONENTS 4302 L...

  • Page 40: Rear Axle Assy

    AXLE ASSY REAR REMOVAL- INSTALLATION Removal Procedure Remove the counter weight. Apply the parking brake and chock the front wheels. Jack up the frame and support it with the wooden block. Remove the rear wheels (See removal procedure steps 2 to in steering knuckle removal section on page 3-7).
  • Page 41 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. Standard clearance: 0.7 mm (0.028 in) or less 2. If the measured value does not satisfy the standard, re- move the rear axle ASSY and make adjustment by se- lecting the spacer.

  • Page 42: Steering Knuckle

    STEERING KNUCKLE REMOVAL-INSTALLATION Removal Procedure Jack up the vehicle. Remove the hub cap. [Point 11 Remove the castle nut and claw washer. [Point 21 Remove the outer bearing and rear wheel. [Point 3 1 Remove the bearing outer race from the rear wheel. [Point Remove the inner bearing roller and oil seal.
  • Page 43 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 (1 50 to 330 kgf-cm) [I 0.9 to 23.9 ft-lbfl.
  • Page 44 [Point 41 Removal: Use a brass bar and remove the bearing outer race Installation: SST 09950-60020 09950-7001 0 [Point Removal: SST 09950-4001 1 Installation: Install the oil seal and inner bearing roller. SST 09370-1 041 0-71 2. Use the SST and install the inner bearing roller. SST 09370-20270-71 [Point 61 Inspection:...
  • Page 45 Installation: Measure the steering knuckle starting force. 1. Temporarily install the king pin and king pin lock bolt. Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing. 2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.
  • Page 46 3-1 1 REAR AXLE CYLINDER Removal Procedure Jack up the vehicle. Disconnect the tie rod (on the piston rod side). [Point 11 Disconnect the rear axle cylinder hose and remove the fitting. [Point 21 Remove the rear axle cylinder. Installation Procedure The installation procedure is the reverse of the removal procedure.
  • Page 47 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.
  • Page 48 Disassembly Procedure Remove the through bolt. Remove the piston rod guide. Remove the piston rod. [Point I ] Inspect the cylinder. [Point Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. Note: Coat hydraulic oil before reassembly.
  • Page 49 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: ring to a little below 80°C (1 76°F) in hot oil Warm the seal or water before installation.

  • Page 50: Rear Wheel Alignment

    REAR WHEEL ALIGNMENT Toe-in Inspection Check to see that dimensions Ar and A ! of the rear axle cylinder are equal. Measure the toe-in (Bf - Br). Standard: 0 mm (0 0.16 in) Toe-in Adjustment equal. 2. Align the punch mark on the cylinder end pin (eccentric pin) Punch mark on plate side with the punch mark on the plate on the front side for both the LH and RH sides.
  • Page 51 MAST TON SERIES) Page ..............V MAST ASSY COMPONENTS REMOVAL* INSTALLATION REMOVAL-INSTALLATION (WJLIFT BRACKET) MAST DISASSEMBLY*INSPECTION*REASSEMBLY REASSEMBLY 4-11 ........MAST ADJUSTMENT (V MAST) 4-13 MAST ROLLER REMOVAL-INSTALLATION 4-18 4-19 ..............INSPECTION 4-19 REASSEMBLY O/.FV*FSV) 4-19 ............REASSEMBLY 4-20 ADJUSTMENT 4-21 .................

  • Page 52: Mast Assy

    COMPONENTS 6301 series 6301-467A...
  • Page 53 6301...
  • Page 54 6302 3 ton series...

  • Page 55: Removal* Installation

    REMOVAL* INSTALLATION Removal Procedure Set the mast vertical and fully lower the fork. Disconnect the chain. [Point 11 Remove the chain wheel. [Point 21 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.) Remove the toe board.

  • Page 56: Removal-Installation (Wjlift Bracket)

    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. Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced.
  • Page 57 REMOVAL. INSTALLATION (WILI FT BRACKET) Removal Procedure Set the mast vertical. Remove the forks. Remove the toe board. 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.) Slightly hoist the mast.
  • Page 58 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.

  • Page 59: Mast Disassembly*Inspection*Reassembly

    MAST DISASSEMBLY-INSPECTION-REASSEMBLY Disassembly Procedure Remove the hose cover. Disconnect the high pressure hose. Remove each cylinder rod end set bolt, and take each rod end off. [Point 11 Remove each cylinder support. [Point 21 Remove each cylinder bottom set bolt, and remove each lift cylinder. Slide the inner mast in the lowering direction, and remove the lift rollers.
  • Page 60 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.
  • Page 61 Disassembly Procedure Remove lift rollers. [Point 11 Remove side rollers. [Point 21 Remove the back rest. Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. Point Operations [Point Disassembly: 09950-400 1 1...
  • Page 62 [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.

  • Page 63: Mast Adjustment (V Mast)

    MAST ADJUSTMENT (V MAST) Lift Roller Adjustment at Mast Clearance between inner mast roller and outer mast Inner mast into These Adjust the mast overlap to approx. 450 mm (1 7.72 in). 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.
  • Page 64 Clearance between outer mast roller and inner mast These rollers Outer mast mast Adjust the mast overlap to approx. 450 mm (1 in). 7.72 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.
  • Page 65 Roller Adjustment at Lift Bracket lnner mast bracket 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.
  • Page 66 Distribute shims equally to the left and right side. Install side rollers. 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.
  • Page 67 Mast Strip Adjustment Mast strip clearance adjustment Roller Bring into contact Outward Note: The strip is of tapered shape, thicker side of the width must be placed outward. (1) Lower the inner mast fully. (2) With the inner mast in contact with the outer mast roller, measure the clearance between the mast strip and in- ner mast.

  • Page 68: Mast Roller Removal-Installation

    MAST ROLLER REMOVAL-INSTALLATION Remove the lift bracket. (See steps 1 to 4 of the mast ASSY removal procedure on page 4-5.) Jack up the vehicle, and support tires with wooden blocks. Also lock the front and rear tires from rotation. 3.

  • Page 69: Chain

    INSPECTION lnspect the chain elongation according to the following procedure: SST 09631 -22000-71 (1) Since the SST measurement line varies with the chain type, set the corresponding line on the chain as illustrated. (2) Check the number of the chain to be inspected, and check the pin center position.

  • Page 70: Reassembly (Qfv)

    REASSEMBLY (QFV) Installing direction As shown in the table below. Chain adjusting nut tightening order Tighten nuts 49.0 78.0 (500 kgf-cm) 57.9 Tighten nut Outer chain Middle chain 147.0 N m (1 000 1500 kgf-cm) 98.0 108.5 ft-lbfl Upper middle Split pin lnner mast Installation side of split pin is at center...

  • Page 71: Adjustment

    ADJUSTMENT Park the vehicle on a flat ground and set the mast vertical. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting nut. Check to see that the chain tension is equal on the left and right side. Check to see no chain twist.

  • Page 72: Fv* Fsv Mast Assy

    COMPONENTS 61 O I 6101-491A...
  • Page 73 6302 ton series FV 3 ton series...
  • Page 74 6302 2 ton series 3 ton series 6302-296...

  • Page 75: Mast Adjustment (Fv-Fsv)

    MAST ADJUSTMENT (FV-FSV) Lift Roller Adjustment at Mast 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). Position where the roller is the closest FSV mast lnner mast Outer mast...
  • Page 76 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) mast FSV mast These rollers These rollers Outer mast Outer mast Middle mast Inner mast (1) Adjust the mast overlap to approx.
  • Page 77 FV-FSV mast Lower lift roller (3.94 in) Lift bracket FSV Mast Mast (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.
  • Page 78 Mast Strip Adjustment Mast strip clearance adjustment FV mast Bring into contact FSV mast Bring into contact (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.

  • Page 79: Qfv Mast Assy

    4-29 COMPONENTS...
  • Page 81 MAST ADJUSTMENT (QFV) Lift Roller Adjustment The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown: Channel seen from the top Channel seen from the bottom 0.5 mm 0.02 in) < 0.5 mm 0.02 in) 0.8 mm...
  • Page 82 Lift Roller Position on Each Upright: Inner Upper Middle Lower Middle Outer...
  • Page 83 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 Inspection method...
  • Page 84 CYLINDER TON SERIES) Page LlFT CYLINDER (V) REAR LIFT CYLINDER (FV-FSV*QFV) GENERAL SPECIFICATIONS ..............COMPONENTS FLOW REGULATOR VALVE (V*FV*FSV-QFV) 5-22 GENERAL 5-22 SPECIFICATIONS 5-22 SAFETY DOWN VALVE (V-FV-FSVoQFV) 5-23 GENERAL 5-23 FRONT LIFT CYLINDER (W-FSV-QFV) 5-24 G EN ERA1 5-24 SPECIFICATIONS 5-25 COMPONENTS...

  • Page 85: General

    GENERAL Ton Series) Lift Cylinder (V13 Ton Series)
  • Page 86 Rear (FV) Lift Cylinder...
  • Page 87 Rear Lift Cylinder (FSV12 Ton Series) Rear Lift Cylinder (FSVl3 Ton Series)

  • Page 88: Specifications

    Rear Lift Cylinder (QFV) SPECIFICATIONS Lift Cylinder Vehicle model 2 ton series 3 ton series Single-acting Single-acting Cylinder type Cylinder bore mrn (in) 50.0 (1.97) 55.0 (2.1 7) Piston rod outside diameter 42.0 (1.65) 45.0 (1.77) Piston seal type U packing U packing Rod seal type U packing...
  • Page 89 Rear Lift Cylinder (FV) Vehicle model ton series 3 ton series ltem Cylinder type Single acting Single acting Cylinder bore mm (in) 50.0 (1.97) 55.0 (2.1 7) 34.9 (1.37) Piston rod outside diameter mm (in) 40.0 (1 57) Rod seal type U packing U packing Others...

  • Page 90: Components

    COMPONENTS Lift Cylinder for V Mast Ton Series) Lift Cylinder for V Mast (3 Ton Series)
  • Page 91 Rear Lift Cylinder for Mast on 2 Ton & 3 Ton Series 6503 6503-113A Rear Lift Cylinder for FSV Mast on 2 Ton Series...
  • Page 92 Rear Lift Cylinder for FSV Mast on 3 Ton Series 6503 [RH]...
  • Page 93 Rear Lift Cylinder for QFV Mast 6503 02 [LH] - 01 K...
  • Page 94 REMOVAL-INSTALLATION Removal Procedure Set the mast vertical and lower the fork fully. Remove the lift cylinder rod end set bolt. Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space. Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.
  • Page 95 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 of the cylinder to bleed air and check normal function- ing. 2. Check the hydraulic oil level and add if insufficient. 3.
  • Page 96 Lift Cylinder for V Mast Cylinder cover 3 ton series: series: 265 (2345 2703) 305 (2695 3 1 10) Disassembly Procedure Remove the safety down valve. Remove the cylinder cover. [Point 11 Remove the seals from the cylinder cover Remove the piston rod. [Point 21 Remove the seals on the piston rod Remove the check valve from the piston rod.
  • Page 97 Point Operations [Point Disassem bly-Reassembly: SST 09620-1 01 00-71 [Point Inspection: Measure the piston rod outside diameter. 2 ton series Standard: 42.0 (1.654 Limit: 41.92 (1.6504 3 ton series Standard: 45.0 (1.772 Limit: 44.92 (1.7685 Inspection: Measure the piston rod bend. Limit: 2 .
  • Page 98 Rear Lift Cylinder for FV Mast *-2 Air bleed screw: Cylinder cover T = 4.5 2 ton series: 5.0 (46 51) [3.33 3.691 T = 203 271 (2073 2764) [ I 50 3 ton series:...
  • Page 99 Disassembly Procedure (1) LH Rear Lift Cylinder. Remove the safety down valve. Remove the cylinder cover. [Point Remove the seals from the cylinder cover. Remove the piston rod. [Point Remove the wear ring. Remove the bleed screw. Remove the cylinder. [Point (2) RH Lift Cylinder.
  • Page 100 [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) ton series Standard: 40.0 mm (1.575 in) Limit: 39.92 mm (1.5717 in) Inspection: Measure the piston rod bend. Limit: 2.0 mm (0.079 in) [Point 31 Follow the procedure view.
  • Page 101 Rear Lift Cylinder for Mast ton series and ton series *Cylinder cover: ton series 265 (2345 2702) [I70 ton series 305 (241 9 3 1 10) [ I 75 Disassembly Procedure Remove the safety down valve. Remove the cylinder cover. [Point Remove the seals from the cylinder cover.
  • Page 102 Point Operations [Point Disassembly- Reassembly: SST 09620-1 01 00-71 [Point Inspection: Measure the piston rod outside diameter. ton series Standard: 42.0 (1.654 Limit: 41.92 (1.6504 ton series Standard: 45.0 (1.772 Limit: 44.92 (1.7685 Inspection: Measure the piston rod bend. Limit: 2 .
  • Page 103 Rear Lift Cylinder for QFV Mast Disassembly Procedure Remove the safety down valve. Remove the plug. Remove the cylinder cover. Remove the seals from the cylinder cover. Remove the piston rod. [Point 11 Remove the piston seals. Remove the cylinder. [Point 21 Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
  • Page 104 Point Operations [Point Inspection: Measure the piston rod outside diameter. Standard: 50.8 mm (2.00 in) Limit: 50.72 mm (1.9969 in) Inspection: Measure the piston rod bend. Limit: 2.0 mm (0.079 in) [Point 21 Inspection: Measure the lift cylinder bore. Standard: 63.5 mm (2.50 in) Limit: 63.85 mm (2.5138 in)

  • Page 105: Flow Regulator Valve (V*Fv*Fsv-Qfv)

    FLOW REGULATOR VALVE (V-FV-FSV-QFV) G E N E R A L Piston 58.8 68.6 (600 700) 50.61 SPECIFICATIONS Fork Lowering Speed Unit: mmtsec (fpm) No-load 500 (98) 420 (83) 450 (89) 400 (79) ton series Loaded 500 (98) 480 (94) 480 (94) 510 (100) No-load...

  • Page 106: General

    SAFETY DOWN VALVE (V*FV*FSV-QFV) GENERAL Cartridge type Ex. FSV Rear Cyl. on 2.3 ton series...

  • Page 107: General

    FRONT LIFT CYLINDER (FV-FSVQFV) GENERAL FV: 2 ton series FSV: 2 ton series QFV : 2 ton series FSV: 3 ton series...

  • Page 108: Specifications

    5-25 SPECIFICATIONS Front Lift Cylinder (FV) Vehicle model 2 ton series 3 ton series Single acting Cylinder type Single acting 75.0 (2.95) Cylinder bore mm (in) 85.0 (3.35) 50.8 (2.00) 50.8 (2.00) Piston rod outside diameter U packing U packing Rod seal type U packing Piston seal type...

  • Page 109: Components

    COMPONENTS Front Lift Cylinder for Mast Front Lift Cylinder for FSV and QFV Mast...

  • Page 110: Removal~Installation

    REMOVAL-INSTALLATION Removal Procedure Remove the lift bracket Wlfork. Disconnect the piping. Remove the front lift cylinder 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.
  • Page 111 Front Lift Cylinder for FV-FSV-QFV FSVQFV Cylinder cover FVIFSVIQFV on ton series 407 (3455 41 47) [250 FVIFSV on ton series 454 (4283 4630) [310 Disassembly Procedure Remove the safety down valve. Remove the cylinder cover. [Point I ] Remove the cover seals. Remove the piston rod.
  • Page 112 Point Operations [Point I] Disassem bly.Reassembly: SST 09620-1 01 00-71 [Point 21 Inspection: Measure the piston rod outside diameter. 2 ton series and 3 ton series: Standard: 50.8 mm (2.0 in) Limit: 50.72 mm (1.9969 in) Inspection: Measure the piston rod bend. Limit: 2.0 mm (0.079 in) [Point 31 Assembly:...

  • Page 113: Disassembly.inspecti0N.reassembly

    OIL CONTROL VALVE Page GENERAL SPECIFICATIONS COMPONENTS OIL CONTROL VALVE ASSY RELIEF PRESSURE ADJUSTMENT...

  • Page 114: Oil Control Valve

    GENERAL Oil Control Valve Relief Valve Tilt relief valve Lift relief valve...
  • Page 115 Tilt Lock Valve Hydraulic Circuit ..-....P: Pump port : To tank...

  • Page 116: Specifications

    SPECIFICATIONS Spec. item Type & values Add on type of 3 spools (Monoblock for each spool section) Oil control valve type Lift relief valve set pressure 171 60 (1 75) [2490] ) [psi] Tilt relief valve set pressure 15690 (1 60) [2280] ) [psi] COMPONENTS...

  • Page 117: Oil Control Valve Assy

    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 Remove the toe board.
  • Page 118 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 Remove the through bolt. Separate each housing. Remove the O-ring, spring and check valve. Remove the seal holder. Remove the spring holder.
  • Page 119 Point Operations [Point 11 SST 0961 0-1 01 61 -71 [Point 21 Reassembly: When the relief valve is disassembled, always loosen the adjust screw fully.

  • Page 120: Relief Pressure Adjustment

    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. Install an oil pressure gage. 2B) installed on top of the oil control valve, and install the oil pressure gage.
  • Page 121 APPENDIX Page ..............SST LlST ........SERVICE STANDARDS LlST...
  • Page 122 SST LIST Part No Part Name transfer bearlng 0931 6-6001 1 replacer Rear wheel bearlng nut 09509-55020 Front hub inner bearlng cone replacer 09950-4001 1 Puller B set Replacer set 09950-6001 0 Replacer set No 2 09950-60020 Front axle bearlng...
  • Page 123 Inner mast stopper 0961 0-22000-71 Cylinder cap remover 09620-1 01 00-71 remover and replacer Deep socket A 09630-23600-71 Wear scale chain 09631-22000-71 0981 0-201 72-71...
  • Page 124 SERVICE STANDARDS LIST DRIVE UNIT Differential Ring gear backlash mm (in) Standard 0.3 (0.008 0.012) Standard 22.12 (0.8709) Differential pinion bore mm (in) Limit 22.22 (0.8748) Standard 22.00 (0.8661) Spider outside diameter mm (in) Limit 21.75 (0.8563) Standard 1.6 (0.063) Side gear thrust washer thickness mm (in) Limit...
  • Page 125 FRONT AXLE Front axle shaft hub Front axle bearing starting force Standard 25.5 72.6 (2.6 7.4) [5.7 16.31 Tightening torque Unit: N.m (kgf-cm) [ft-lbf] Hub bolt set nut Standard 166.7 205.9 (1 700 21 00) [ I 23.0 151.91 Bearing lock nut stopper bolt Standard 14.7 21.6 (1 50...
  • Page 126 Mast adjustment (V mast) Inner mast roller clearance mm (in) Standard 0.8 (0 0.031) Outer mast roller clearance Standard mm (in) 0.5 (0 0.020) Middle and lower lift roller clearance Lift Standard 0.5 (0 0.020) mm (in) bracket Side roller clearance mm (in) Standard 0.5 (0...
  • Page 127 CYLINDER Lift cylinder 01) 2 ton series Limit 41.92 (1.6504) Piston rod outside diameter 3 ton series Limit 44.92 (1.7685) 2 ton series Limit 50.20 (1.9764) Cylinder bore mm (in) Limit 55.35 (2.1 791) 3 ton series Piston rod bend mm (in) Limit 2.0 (0.079)
  • Page 128 Front lift cylinder (FV.FSV.QFV) Limit 50.72 (1.9969) 2 ton series Limit Piston rod outside Limit diameter Limit 2 ton series Limit Limit 75.35 (2.9665) 2 ton series Limit Limit 85.40 (3.3622) Cylinder bore mm (in) 3 ton series Limit 2 ton series Limit 75.35 (2.9665) Piston rod bend...

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