Ep16kt 20kt MC

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99719-67110

EP16KT, EP18KT, EP20KT


Chassis, Mast, & Controller

EP16KT ETB4A-00011-99999 (48 V)


EP16KT ETB4B-00011-99999 (36 V)
EP18KT ETB5A-00011-49999 (48 V)
EP18KT ETB5B-00011-49999 (36 V)
EP20KT ETB5A-50001-99999 (48 V)
EP20KT ETB5B-50001-99999 (36 V)
FOREWORD

This service manual is a guide to servicing of Caterpillar® Lift Trucks. The


instructions are grouped by systems to serve the convenience of your ready ref-
erence.
Long productive life of your lift trucks depends to a great extent on correct ser-
vicing — the servicing consistent with what you will learn from this service man-
ual. We hope you read the respective sections of this manual carefully and know
all the components you will work on before attempting to start a test, repair or
rebuild job.
The descriptions, illustrations and specifications contained in this manual were of
the trucks of serial numbers in effect at the time it was approved for printing.
Caterpillar reserves the right to change specifications or design without notice
and without incurring obligation.

Safety Related Signs


The following safety related signs are used in
this service manual to emphasize important and
critical instructions:

WARNING Indicates a specific potential


hazard resulting in serious
bodily injury or death.

Indicates a specific potential


hazard resulting in bodily
injury, or damage to, or
destruction of, the machine.

NOTE Indicates a condition that


can cause damage to, or
shorten service life of, the
machine.

Pub. No. 99719-67110


HOW TO READ THIS MANUAL
Disassembly diagram (example)

1 Each disassembly diagram is followed


by Disassembly sequence and
4 Suggestion for disassembly.
3

Disassembly sequence

1 Cover, Bolt, Washer (part name)


2 Output shaft (part name)

Suggestion for disassembly


(1) Output shaft removal

Unit: mm (in.)
Clearance A 0.020 to 0.105
between (0.00079 to 0.00413)
cylinder and 0.15
piston B
(0.0059)
A: Assembly standard
B: Repair or service limit
GROUP INDEX

Group Items involved

GENERAL INFORMATION Serial number locations, Dimensions, Technical data 1


VEHICLE ELECTRICAL
COMPONENTS Console box, Key switch, Lamp specification chart 2

MAIN CONTROLLER Controller components, Inspection and adjustment, Service data 3


TROUBLESHOOTING FOR Faulty central vehicle monitor system, Faulty diagnosis indication, or Other
CONTROL CIRCUITS abnormalities 4

POWER TRAIN Procedure and key points for removal and installation 5
MOTORS Drive motor, Pump motor, EPS motor 6
TRANSFER UNIT Procedures and key Points for Disassembly and Assembly 7
REAR AXLE Rear axle, Rear wheels 8
BRAKE SYSTEM Caliper, Brake pedal, Master cylinder 9
STEERING SYSTEM Steering control valve
10
HYDRAULIC SYSTEM Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
Down safety valve 11

MASTS AND FORKS Simplex mast, Duplex mast, Triplex mast 12


Inspection standards, Periodic replacement of parts, Lubrication standards,
SERVICE DATA Main component weight, Tightening torque for standard bolts and nuts, 13
Special tools
GENERAL INFORMATION

Vehicle Exterior.......................................................................................................................... 1 - 1

Models........................................................................................................................................ 1 - 1
1
Vehicle Number Stamping Positions ........................................................................................ 1 - 2

External Specifications .............................................................................................................. 1 - 4

Technical Data............................................................................................................................ 1 - 5
GENERAL INFORMATION

Vehicle Exterior

102616

Models
This manual applies to EP16KT, EP18KT, and EP20KT.

Truck Models Serial Numbers


EP16KT EFB4A-00011-99999 (48 V)
EFB4B-00011-99999 (36 V)
EP18KT EFB5A-00011-49999 (48 V)
EFB5B-00011-49999 (36 V)
EP20KT EFB5A-50001-99999 (48 V)
EFB5B-50001-99999 (36 V)

1-1
GENERAL INFORMATION

Vehicle Number Stamping Positions

Mast number Nameplate Chassis number

206809

1-2
GENERAL INFORMATION

MEMO

1-3
GENERAL INFORMATION

External Specifications

B E F

206810

1-4
GENERAL INFORMATION

Technical Data

Truck Models EP16KT EP18KT EP20KT


Class 1.6t 1.8t 2.0t
Load Capacity/Load Center N (kgf)/mm 15680 (1600)/500 17640 (1800)/500 19600 (2000)/500
[lbf/in.] [3000/24] [3500/24] [4000/24]
Truck size Length to Fork Face A mm (in.) 1897 (78.2) 1997 (78.6) 2032 (80)
Width for MCFE (w/SE tire)B mm (in.) 1100 (43.3) 1100 (43.3) 1168 (46)
for MCFA (w/cushion tire) mm (in.) 1080 (42.5) 1080 (42.5) 1080 (42.5)
Height of Overhead Guard C mm (in.) 2040 (80.3) 2040 (80.3) 2040 (80.3)
Wheelbase D mm (in.) 1310 (51.6) 1410 (55.5) 1410 (55.5)
Service Weight (W/O Battery) kg (lb) 2164 (4769) 2324 (5122) 2344 (5166)
Tread Front/Rear E/F mm (in.) 913/170 (35.9/6.7) 913/170 (35.9/6.7) 947/170 (37.3/6.7)
Tires Number Front/Rear 2/2 2/2 2/2
Tires Size Front 18 ¥ 7.8 18 ¥ 7.8 200/50·10
Rear 15 ¥ 4.5-8 15 ¥ 4.5-8 15 ¥ 4.5-8
Turning Radius mm (in.) 1530 (60.2) 1630 (64.2) 1665 (65.6)
Travel Speeds 48 V km/h (mph) 16/14 (10/8.7) 16/14 (10/8.7) 16/14 (10/8.7)
Unloaded/Loaded 36 V km/h (mph) 15/13 (9.3/8) 15/13 (9.3/8) 15/13 (9.3/8)
Gradeability Loaded 48 V % 19 17 15
36 V % 19 17 15
Lift Speeds Loaded 48 V m (in.)/sec 0.42 (16.5) 0.41 (16.1) 0.4 (15.7)
36 V m (in.)/sec 0.32 (12.6) 0.31 (12.2) 0.3 (11.8)
Battery Voltage V 48 48 48
Battery Rated Capacity (5 hrs.) MAX Ah 600 720 720
Battery Compartment mm 531 ¥ 1016 ¥ 650 634 ¥ 1016 ¥ 650 634 ¥ 1016 ¥ 650
Length ¥ Width ¥ Height (in.) (20.9 ¥ 40 ¥ 25.6) (25 ¥ 40 ¥ 25.6) (25 ¥ 40 ¥ 25.6)
Traction Motor, 60 min rating kW 2 ¥ 4.5 2 ¥ 4.5 2 ¥ 4.5
Hydraulic Motor kW 11.5 11.5 11.5
Traction Motor Control Method IGBT/MOSFET IGBT/MOSFET IGBT/MOSFET
Hydraulic Motor Control Method IGBT/MOSFET IGBT/MOSFET IGBT/MOSFET

1-5
VEHICLE ELECTRICAL COMPONENTS

Console Box .............................................................................................................................. 2 - 1


Functions of Central Vehicle Monitor System .................................................................... 2 - 1
Electrical Components in Console Box .............................................................................. 2 - 3
Disassembly and Assembly ................................................................................................ 2 - 4

Forward/Reverse Lever .............................................................................................................. 2 - 5


2

Accelerator Control.................................................................................................................... 2 - 6

Key Switch ................................................................................................................................ 2 - 7

Light Switch .............................................................................................................................. 2 - 7

Fuses .......................................................................................................................................... 2 - 8

Lamp Specification Chart .......................................................................................................... 2 - 9

Electrical Schematic (Type: Chopper) ........................................................................................ 2- 11

Electrical Schematic (Type: Contactor) ...................................................................................... 2- 13

Electrical Diagram (Type: Chopper) .......................................................................................... 2- 15

Electrical Diagram (Type: Contactor) ........................................................................................ 2- 17


VEHICLE ELECTRICAL COMPONENTS

Console Box 1
1 Central vehicle monitor system (CVMS)
2 Mode selector button
3 Tilt steering lock lever 6
4 Key switch 2
5 Light switch
6 Mode check button
5

3
4

102620

Functions of Central Vehicle Monitor System (CVMS)

9 8

10

1 2 3 4 5 6 7
Operations 206798
No. Monitor name When OFF When ON or flashing Remarks
1 Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached.
2 Worn motor brush Drive motor and pump motor Worn brushes After brushes are replaced,
lamp brushes in operable condition lamp turns OFF.
Controller/motor Controller, drive motors and Overheat Overheat causes significant
overheat lamp pump motor in normal output loss. When component
3
temperature temperature lowers to normal
level, output power returns.
4 Remaining Normal battery condition Flashing indicates
battery charge battery need to be
warning lamp recharged soon.
ON indicates battery
needs to be recharged
and lifting function
inoperable.
5 Brake fluid level lamp Normal fluid level Low fluid level
2-1
VEHICLE ELECTRICAL COMPONENTS

6 Parking lamp Parking brake engaged Parking brake


disengaged
7 Malfunction lamp Normal Vehicle malfunction
8 Speedometer KPH, MPH
Error indicator
9 Battery discharge When no bars show, vehicle is drivable but lifting Indicates remaining battery
indicator function is inoperable. power.
10 Hour meter 1 2 3 4 5
Advances every 0.1 hour
(Number advances every 6 minutes.)
Hour indication

Error indicator
Indication Condition
When key switch is set to [ON] with forward/reverse lever in [F] or [R]
E
position. Turns OFF when the lever is set to [N].
E 0 ON Right drive motor overheat
E 1 ON Left drive motor overheat
E 2 ON Pump motor overheat
E 3 ON Controller overheat
E 4 ON Worn right drive motor brush
E 5 ON Worn left drive motor brush
E 6 ON Worn pump motor brush
H 1 ON Faulty setting of lift lever
H 2 ON Faulty setting of tilt lever
H 3 ON Faulty setting of attach-1 lever
H 4 ON Faulty setting of attach-1 lever (Option)

2-2
VEHICLE ELECTRICAL COMPONENTS

Electric Components in Console Box

206799

1 Key switch 3 Flash relay


2 Light switch

2-3
VEHICLE ELECTRICAL COMPONENTS

Disassembly and Assembly

Disassembly

4 206800

Sequence
1 Console box (front panel) 4 Tilt steering lock lever
2 Central vehicle monitor panel 5 Console box (rear panel)
3 Turn signal switch, forward/reverse lever

Disassembly procedure
(1) Remove the front panel and monitor panel
from the console box.
(2) Disconnect the harness connectors of the horn,
turn signal switch and forward/reverse lever.
(3) Remove the screw from the tilt steering lock
lever, and remove the lever from the rear panel
of the console box.
(4) Remove the rear panel.

Assembly
Follow the disassembly procedure in reverse.

2-4
VEHICLE ELECTRICAL COMPONENTS

Accelerator Control
1.5 to 2.6 mm
(0.06 to 0.10 in.)
Accelerator pedal

Stopper bolt

33 mm
(1.30 in.)
Accelerator

Adjusting screw

Position meter
206805A

Adjustment procedure
(1) Disconnect the battery plug.
(2) Fix the stopper bolt to 33 mm (1.30 in.) from
the floor to the upper face of bolt.
(3) Adjust the mounting angle of the position
meter using the adjusting screw so the switch
inside the position meter turns on when the
accelerator pedal is depressed 1.5 to 2.6 mm
(0.06 to 0.10 in.).
Make sure the inside switch ON by continuity
between two arrow terminals using a tester. 206805B
(4) Enter Self Diagnostics (Page 3-22.) Cycle to
the Accelerator Test (Page 3-27.) The display
should read OFF and Speed 0 without the
accelerator depressed. The display should
change to ON before the speed changes from 0
to 1. If not then readjust Accelerator switch.
(5) Make sure when the accelerator is fully
depressed the display reads Speed 16. If not
readjust the Stop Bolt.

2-5
VEHICLE ELECTRICAL COMPONENTS

Fuses
Capacity (A) Location Main connecting device
80
Battery
500 Main controller Refer to main controller section
325 Loading hydraulic motor

15 Electric parts
Fuse holder

10 Controller

102644

NOTE

Refer to Parts Manual for proper replacement


fuses.

2-6
VEHICLE ELECTRICAL COMPONENTS

Lamp Specification Chart


Items Bulb
Quantity Bulb color Remarks
Lamps 48 V/36 V External diagram

Head lamps 2 Clear 40 W

Turn signal 2 Orange 25 W


lamps
Combination
lamps
(front)
Clearance 2 Clear 10 W
lamps

Stop lamps and 2 Red 25 W/10 W


tail lamps

Combination
lamps Turn signal 2 Orange 25 W
(rear) lamps

Backup 2 Clear 10 W
lamps

Rear lamp 1 Clear 40 W

205833

2-7
ES019-67110 2-11
ES019-67110 2-13
ES019-67110 2-15
ES019-67110 2-17
VEHICLE ELECTRICAL COMPONENTS

Wire Color Code Diagram

Wire No. Wire Color Wire No. Wire Color B = BLACK


1 B 121 L R = RED
2 G 122 G G = GREEN
3 R 123 R Y = YELLOW
4 R 124 G L = BLUE
5 W 125 Y W = WHITE
6 B 126 V Br = BROWN
7 W 127 O O = ORANGE
8 B 128 W V = VIOLET
9 Y 129 G
10 B 130 Y
11 R 131 V
12 W 132 O
13 G 133 L
14 W 134 W
15 B 135 R
16 G 136 R
17 B 137 Y
18 L 138 V
19 B 139 O
20 Y 140 L
102 G 141 R
103 O 142 G
104 Br 143 B
105 W 144 L
106 W 145 Y
107 V 146 B
108 W 147 L
109 G 148 G
110 G 149 W
111 Y 150 B
112 R 151 R
113 B 152 B
114 G
115 W
116 Y
117 L
118 B
119 Y
120 W

2-17
MAIN CONTROLLER

Outline ........................................................................................................................................ 3 - 1

Controller Components (Part 1).................................................................................................. 3 - 2

Controller Components (Part 2).................................................................................................. 3 - 3

Logic Card Components ............................................................................................................ 3 - 4

Controller Models ...................................................................................................................... 3 - 5


3
Operation Outline........................................................................................................................ 3 - 6

Drive System .............................................................................................................................. 3 - 6


Neutral Position .................................................................................................................... 3 - 6
Powering .............................................................................................................................. 3 - 6
Traction Motor’s Current Table (48 V type) ........................................................................ 3 - 7
Traction Motor’s Current Table (36 V type) ........................................................................ 3 - 8
Regeneration ........................................................................................................................ 3 - 10
Steering and Turns................................................................................................................ 3 - 10
Lever Regeneration Characteristic (48 V type).................................................................... 3 - 11
Lever Regeneration Characteristic (36 V type and EE option type) .................................. 3 - 12
Auto Regeneration Characteristic (48 V type) .................................................................... 3 - 13
Auto Regeneration Characteristic (36 V type and EE option type) .................................... 3 - 14
Steering Characteristic (1.6 ton type) .................................................................................. 3 - 15
Steering Characteristic (1.8 ton type) .................................................................................. 3 - 16
Steering Characteristic (2.0 ton type) .................................................................................. 3 - 17

Hydraulic System ........................................................................................................................ 3 - 18


Chopper Model .................................................................................................................... 3 - 18

Fail-safe System .......................................................................................................................... 3 - 19


Output Power Control at Low Battery Voltage .................................................................... 3 - 19
Overheat................................................................................................................................ 3 - 20
Brush Wear .......................................................................................................................... 3 - 20
Maximum Vehicle Speed Control (SUO #7) ...................................................................... 3 - 20
Output Power Control During Braking ................................................................................ 3 - 20
Chat Timer (SUO #24) ........................................................................................................ 3 - 20
Seat Switch Timer (SUO #25) ............................................................................................ 3 - 20

Malfunction Detection (Run Time Diagnosis) .......................................................................... 3 - 20

Malfunction Data Record (History Folder) ................................................................................ 3 - 21


Data Storage ........................................................................................................................ 3 - 21
Review of Stored Data.......................................................................................................... 3 - 21

Setting ........................................................................................................................................ 3 - 21
Printed Circuit Board Settings.............................................................................................. 3 - 21
Adjustment of Remaining Battery Level.............................................................................. 3 - 21
Setup Options ...................................................................................................................... 3 - 21

Self-diagnosis .............................................................................................................................. 3 - 22

Other Functions .......................................................................................................................... 3 - 23

Display Unit ................................................................................................................................ 3 - 23


BDI (Battery Discharge Indicator) ...................................................................................... 3 - 23
Hourmeters and Time Display ............................................................................................ 3 - 23
Vehicle Speed and Error Code Display................................................................................ 3 - 24
Action Lights (LEDs) .......................................................................................................... 3 - 24

Inspection and Adjustment ........................................................................................................ 3 - 31


Inspection and Adjustment Tools ........................................................................................ 3 - 31
Removal and Installation of Logic Card .............................................................................. 3 - 31
Tightening of High-tension Cable Terminals ...................................................................... 3 - 32
Component Testing .............................................................................................................. 3 - 33

Service Data ................................................................................................................................ 3 -72

Tightening Torque ...................................................................................................................... 3 -76


MAIN CONTROLLER

Outline
Main controller
The main controller is the heart of the lift truck
operating system.
The logic card contains judgment-making
functions, and is equipped with a battery
discharge indicator and a malfunction
diagnostic function.
The main controller is used to operate the
drive motors, pump motor and power steering
system.

206793

Logic card
The logic card is a printed circuit board
located on the main controller panel. Most of
the circuits on the board are used to control
input and output voltages to and from the
microprocessor.
Selector
switches

Microprocessor (MPU)
The software in the microprocessor controls
the drive system, pump motor and central

Selector Dip Switches


They are used for setting the BDI and selection
of some options.

Volume Microprocessor

206794

3-1
MAIN CONTROLLER

Controller Components (Part 1)

2 1

3 5 4 7 6
8

206795

1 Logic Card 6 Line Contactor


2 Head Capacitors 7 Line Fuse (500 A)
3 Current Sensor (Right Drive Armature) 8 DRS switch
4 Regen Contactor 9 Power Steering Fuse (50 A)
5 Hydraulic Fuse (325 A)

3-2
MAIN CONTROLLER

Controller Components (Part 2)

5 3 4 2 8 6 1 7

206796

1 Hydraulic system diode (D1P) 5 Drive system IGBT (T1R)


2 Drive system diode (D1L) 6 Hydraulic system IGBT (T1P)
3 Drive system diode (D1R) 7 Regeneration system diodes (D2)
4 Drive system IGBT (T1L) 8 Temperature sensor

NOTE
IGBT stands for Insulated Gate Bipolar
Transistor.

3-3
MAIN CONTROLLER

Logic Card Components

Pin No. on Pin No. on


harness side logic card side

64 63
62 61
60 59
58 57 64 63
56 55 62 61
54 53 60 59
52 51 58
56
57
55
5
50 49
48 47 54 53
46 45 52 51
44 43 50 49
42 41 48 47
40 39 46 45
44 43
38 37
42 41
36 35 40 39 4
34 33 38 37
32 31 36 35
30 29 34 33
28 27 32 31
26 25 30 29
24 23 28 27
26 25
24 23 3
22 21 22 21
20 19 20 19
18 17 18 17
16 15 16 15
14 13 14 13
12 11 12 11
10 9 10 9
8 7 8 7
6 5 6 5
4 3 4 3
2 1 2 1

206797

1 Selector switches (SW1 to SW8) 4 CH2-P2 connector (pin Nos. 23 to 38)


2 Microprocessor (MPU) 5 CH2-P3 connector (pin Nos. 39 to 64)
3 CH2-P1 connector (pin Nos. 1 to 22)

3-4
MAIN CONTROLLER

Controller Models
(1) There are five controller models, as shown in
the table below. Each model has different
hardware and software.

Voltage Hydraulic control Remarks


1 Contactor Maximum drive motor current : 310A
2 36 V Chopper Hydraulic performance is approximately
3 Chopper (EE option) 3/4 of 48V model.
4 Contactor
48 V Maximum drive motor current : 250A
5 Chopper

(2) The DSWs of the logic card are set according


to vehicle weight (1.6, 1.8 and 2.0 tons). The
maximum vehicle speed varies depending on
vehicle weight, as shown in the table below.

Truck Models EP16KT EP18KT EP20KT


Travel Speeds 48 V km/h (mph) 16/14 (10/8.7) 16/14 (10/8.7) 16/14 (10/8.7)
Unloaded/Loaded 36 V km/h (mph) 15/13 (9.3/8) 15/13 (9.3/8) 15/13 (9.3/8)
Gradeability Loaded 48 V % 19 17 15
36 V % 19 17 15

3-5
MAIN CONTROLLER

Operation Outline Drive System


(1) Power ON, default condition Neutral Position
• Turning on the key switch supplies power When the forward/reverse lever is in the
to the logic card and display unit. The neutral position, the controller turns the
display unit shows three hourmeters in regeneration contactor OFF and cuts off the
sequence, then resumes the normal current to the armature. When the lever is
display mode. moved to the neutral position while the
• About one second after power is supplied vehicle is moving, the vehicle continues
to the logic card, the controller turns the traveling due to inertia. When the lever is
line contactor ON to provide power to the shifted to neutral from forward or reverse
main circuit. When the line contactor position, the controller maintains the neutral
turns ON, the steering motor starts mode for five seconds, and the regeneration
rotation. contactor stays ON.
• Using the DRS switch set to D or S, it is Powering
possible to activate the self-diagnostic
function, set vehicle characteristic (1) Outline
parameters with setup options and • Powering is a condition in which the
perform an analysis of malfunction data. motors are powered by the battery and the
(2) Normal mode (RUN mode) controller supplies a current determined
• When the forward/reverse lever is operated by the powering characteristic. The
and the accelerator pedal is pressed, the powering characteristic is an electric
vehicle moves forward or backward. During current curve relative to vehicle speed
deceleration, the motors conduct various based on the acceleration parameter, as
regenerative operations according to the shown in the diagram. The current
settings. demand value is obtained from the
• The steering system creates a torque acceleration and vehicle speed.
difference between the right and left • The power characteristic can be selected
motors according to the steering wheel from three types by SUO #9(Set up
turning angle. option): Economy, Standard and High
• Operating a hydraulic lever activates the Power.
pump motor and provides hydraulic • The current demand rise rate is selectable.
power. (Acceleration rate: SUO #8)
• The controller monitors operating (2) Truck mode
conditions. When an abnormality occurs, • The truck mode can be selected from A
the display unit indicates an error code to E, each with preset values for
and activates an appropriate fail-safe maximum vehicle speed, acceleration
function. The error code is stored in the rate, power, automatic regeneration
logic card memory. power, start lift speed, top lift speed and
tilt speed.
• SUO #1 is used for setting the truck
mode.
• When the truck mode is set, the values
shown in the table are entered in the
applicable setup option items. When
default settings are changed, the
indication (A to E) flashes to indicate that
the settings are modified.
• If the truck is set in high power mode, the
battery life will be less than economy and
standard mode.
3-6
MAIN CONTROLLER

Traction Motor’s Current Table (48 V type)


Armature Current Table

300
250
200
I [A] 150
100
50
0
0 2 4 6 8 10 12 14 16 18 20
v [Km/h]

Powerful mode
Standard mode
Economy mode
Thermal & Low Battery mode
Brake Limit mode

207520

Shunt Current Table (Fields)

40

30

I [A] 20

10

0 0 2 4 6 8 10 12 14 16 18 20
v [Km/h]

Powerful & Standard & Economy mode

Thermal & Low Battery mode

Brake Limit mode

207521

3-7
MAIN CONTROLLER

Traction Motor’s Current Table (36 V type)


Armature Current Table
350
300
250
200
I [A]
150
100
50
0
0 2 4 6 8 10 12 14 16 18 20
v [Km/h]

Powerful mode
Standard mode
Economy mode
Thermal & Low Battery mode
Brake Limit mode
207522

Shunt Current Table (Fields)


40
35
30
25
I [A] 20
15
10
5
0
0 2 4 6 8 10 12 14 16 18 20
v [Km/h]

Powerful & Standard & Economy & Brake Limit mode

Thermal & Low Battery mode

207523

3-8
MAIN CONTROLLER

• 48 V type mode setting.


Setting Application Function Default value of SUO
Accel- Accel- Start Top Tilt Auto
Speed Power Lift Tilt Regen Speed Power
eration eration lift lift regen
A Normal M M Std. M M M 14 2 2 7 9 6 3
High
b performance F F Power. F M M 16 3 3 7 10 6 3

C Economy S S Eco. S M M 12 1 1 6 8 6 3
d Long travel F M Power. M M M 16 2 3 7 9 6 3
E Short shuttle S F Eco. F M M 12 3 2 7 10 6 3
SUO # 7 8 9 2 3 4 23

• 36 V type mode setting.


Setting Application Function Default value of SUO
Accel- Accel- Start Top Auto
Speed Power Lift Tilt Regen Speed Power Tilt
eration eration lift lift regen
A Normal M M Std. M M M 13 2 2 7 9 7 3
High
b performance F F Power. F M M 15 3 3 7 10 7 3

C Economy S S Eco. S M M 11 1 1 6 8 7 3
d Long travel F M Power. M M M 15 2 3 7 9 7 3
E Short shuttle S F Eco. F M M 11 3 2 7 10 7 3
SUO # 7 8 9 2 3 4 23

M: Medium F: Fast S: Slow

3-9
MAIN CONTROLLER

Regeneration
(1) Lever regeneration (4) Regenerative behavior when vehicle
When the forward/reverse lever is shifted movement is opposite to transmission
into the position opposite to the vehicle’s position
traveling direction, the regeneration When the vehicle is moving in the direction
function is activated. The amount of opposite to the transmission position such
regeneration is determined by the lever as on a slope, the regeneration function is
regeneration characteristic, as shown in the activated at a vehicle speed of 2 km/h (1.24
diagram. The regeneration characteristic mph) or higher.
curve is selected by SUO #22. The degree
of acceleration serves as the parameter.
Steering and Turns
The harder the accelerator pedal is pressed, The target current values for the right and left
the higher the amount of Regen current
wheels are determined individually based on
The lever regeneration function is always the powering characteristic and regeneration
operative regardless of the following
characteristic. When the steering wheel is
regeneration mode. turned, the final target current value is a value
obtained by multiplying the original target
(2) Regeneration modes current value by the rate determined by the
• One of the following two regeneration
steering characteristic. Regarding the steering
modes can be selected with SUO #21. characteristic, refer to the charts om pages 3-
(a) Mode 1: Brake regeneration with accelerator
15 through 3-17.
priority
The regeneration function is activated
when the brake is applied. When the
accelerator pedal is depressed, however,
the regeneration function becomes
inactive.
When the accelerator and brake pedals
are operated simultaneously, the drive
system provides normal driving power.
(b) Mode 2: Accelerator regeneration
The regeneration function is activated
when the accelerator pedal is released.
• The amount of regeneration is determined by
the automatic regeneration characteristic
selected by SUO #23.
When the vehicle speed is 1 km/h (0.61
mph) or slower, the regeneration function
is inactive.

(3) Regeneration mode priority


When the lever regeneration function and
one of the above two regeneration modes
demand different amounts of regeneration,
the amount requested by the lever regeneration
function takes precedence.

3-10
MAIN CONTROLLER

Lever Regeneration Characteristic (48 V type)


Armature Current Table

200
Range 5
180
160
140
I [A]
120
100 Range 1
80
60
40
20
0
0 2 4 6 8 10 12 14
Accelerator

Range 1 Range 2 Range 3

Range 4 Range 5

207524

Shunt Current Table (Fields)

40
35
Range 3&4&5
30
I [A]
25
Range 1&2
20
15
10
5
0
0 2 4 6 8 10 12 14
Accelerator

Range 1&2 Range 3&4&5

207525

3-11
MAIN CONTROLLER

Lever Regeneration Characteristic (36 V type and EE option type)


Armature Current Table
350
Range 5
300

250

200
I [A]
Range 1
150

100

50

0
0 2 4 6 8 10 12 14
Accelerator

Range 1 Range 2 Range 3

Range 4 Range 5

207526

Shunt Current Table (Fields)

40
35

I [A] 30
25
20
15
10
5
0
0 2 4 6 8 10 12 14
Accelerator

Range 1&2&3&4&5

207527

3-12
MAIN CONTROLLER

Auto Regeneration Characteristic (48 V type)


Armature Current Table
120
Range 5
100

80
I [A]
60
Range 1
40

20

0
0 2 4 6 8 10 12 14 16 18 20
v [km/h]

Range 1 Range 2 Range 3

Range 4 Range 5
207528

Shunt Current Table (Fields)


20

I [A] 15

Range 5
10

Range 1&2&3
5

0
0 2 4 6 8 10 12 14 16 18 20
v [km/h]

Range 1&2&3 Range 4 Range 5

207529

3-13
MAIN CONTROLLER

Auto Regeneration Characteristic (36 V type and EE option type)


Armature Current Table
180
160 Range 5
140
120
I [A] 100 Range 1
80
60
40
20
0
0 2 4 6 8 10 12 14 16 18 20
v [km/h]

Range 1 Range 2 Range 3

Range 4 Range 5
207530

Shunt Current Table (Fields)


20

Range 5
I [A] 15

10

Range 1
5

0
0 2 4 6 8 10 12 14 16 18 20
v [km/h]

Range 1&2 Range 3

Range 4 Range 5
207531

3-14
MAIN CONTROLLER

Steering Characteristic (1.6 ton type)


Armature Current Table

100

I [%]
80

60

40

20

0
-90 -60 -30 0 30 60 90
Steering Angle [degrees]
Left Right

Left Motor Right Motor

207532

Shunt Current Table (Fields)

100
80
60
40
I [%] 20
0
-90 -60 -30 0 30 60 90
-20
-40
-60
-80
-100
-120
Steering Angle [degrees]
Left Right

Left Motor Right Motor

207533

3-15
MAIN CONTROLLER

Steering Characteristic (1.8 ton type)


Armature Current Table

100

I [%]
80

60

40

20

0
-90 -60 -30 0 30 60 90
Steering Angle [degrees]
Left Right

Left Motor Right Motor

207534

Shunt Current Table (Fields)

100
80
60
40
I [%] 20
0
-90 -60 -30 0 30 60 90
-20
-40
-60
-80
-100
-120
Steering Angle [degrees]
Left Right

Left Motor Right Motor

207535

3-16
MAIN CONTROLLER

Steering Characteristic (2.0 ton type)


Armature Current Table

100

I [%]
80

60

40

20

0
-90 -60 -30 0 30 60 90
Steering Angle [degrees]
Left Right

Left Motor Right Motor

207536

Shunt Current Table (Fields)

100
80
60
40
I [%] 20
0
-90 -60 -30 0 30 60 90
-20
-40
-60
-80
-100
-120
Steering Angle [degrees]
Left Right

Left Motor Right Motor

207537

3-17
MAIN CONTROLLER

Hydraulic System
Chopper Model
The hydraulic levers are used to operate the
pump motor. The fixed duties selected by the
setup options below provide chopper control
for the IGBTs.
(1) Start lift speed (SUO #2) and top lift speed
(SUO #3)
The two-stage lift lever is used to set the
speed. The first stage is for the start lift
speed, and the second stage is for the top
lift speed. Do not set the start lift speed
faster than the top lift speed.
(2) Tilt speed (SUO #4)
This set up option is used to set the tilt
speed.
(3) Attach 1 speed (SUO #5) and attach 2
speed (SUO #6)
These set up options are used to set the
auxiliary speeds.
(4) Priority
When two or more levers are operated at
the same time, the following priority order
is effective.
(High priority) Tilt lever, Attach 1 lever,
Attach 2 lever, Lift (Low priority)
Contactor model
This model uses a contactor to operate the
pump motor instead of the IGBT chopper
control. The speed cannot be changed.

3-18
MAIN CONTROLLER
Fail-Safe System
Output Power Control at Low Battery Voltage
(1) Battery discharge characteristic
The BDI table shows the BDI indicator
patterns on the display and the corresponding
voltage ranges.
BDI Table
Normal BDI French BDI
BDI # 36 V 48 V BDI # 36 V 48 V
0 0 - 36. 0 - 48.0 0 0 - 36.0 0 - 48.0
1 36.0 - 36.2 48.0 - 48.5 1 36.0 - 36.2 48.0 - 48.2
2 36.2 - 36.7 48.5 - 48.9 2 36.2 - 36.5 48.2 - 48.7
3 36.7 - 36.9 48.9 - 49.4 3 36.5 - 36.7 48.7 - 48.9
4 36.9 - 37.1 49.4 - 49.6 4 36.7 - 36.9 48.9 - 49.4
5 37.1 - 37.6 49.6 - 50.1 5 36.9 - 37.4 49.4 - 49.6
6 37.6 - 37.9 50.1 - 50.6 6 37.4 - 37.6 49.6 - 50.1
7 37.9 - 38.1 50.6 - 51.0 7 37.6 - 37.9 50.1 - 50.3
8 38.1 - 38.6 51.0 - 51.3 8 37.9 - 38.1 50.3 - 50.8
9 38.6 - 38.8 51.3 - 51.8 9 38.1 - 38.3 50.8 - 51.0
10 38.8 - 39.1 51.8 - 52.1 10 38.3 - 51.0 -

(2) Output power control duty control is not possible.


When the BDI indicator shows zero, the When the lever is returned to the neutral
following output limit control is position, the equipment can be operated
activated.Once this occurs the battery for another one second.
must be charged to high enough level to On Contactor Hydraulic control the hydraulic
illuminate 5 segments on the display for operations cannot be conducted unless the
the BDI to reset. vehicle is stationary and the forward/reverse
lever is in the neutral position.
(3) Output limit control
(b) When the battery voltage momentary
(a) When the BDI display shows zero becomes higher than 22 V and less than
level, the following limit control is 25 V, the following limit control is
activated. When this happens, the activated. When this happens, the Battery
Battery LED on the display lights. LED on the display flashes.
Traction motors — The output power is
Traction motors — The output power is controlled according to the powering
controlled according to the powering characteristic. (See charts on pages 3-7
characteristic. (See charts on pages and 3-8)
3-7 and 3-8)
Pump motor — In the chopper models, the
output duty reduces by 50% in lifting
and attaching operations.
Tilt operations do not change the output duty.
In the contactor model, the contactor
opens after operating for one second since
3-19
MAIN CONTROLLER
• In the 48-V vehicle, the brake limit brush wear.
mode is activated. Maximum Vehicle Speed Control (SUO #7)
(Brake limit mode: Drive motor power The setup option setting limits the maximum
is controlled while the brake pedal is vehicle speed.
depressed)
• In the 36-V vehicle, the economy mode Output Power Control During Braking
is activated. The maximum current is controlled when the
Pump motor — No output limit control is service brake or parking brake is applied.
provided. (1) Service brake — Maximum shunt current:
15 A, maximum armature current: 125 A
(c) When the battery voltage momentary (2) Parking brake — Maximum shunt current:
becomes lower than 22 V, the line
15 A, maximum armature current: 125 A
contactor opens. When this happens, the (3) Normal — Maximum shunt current: 40
Battery LED on the display lights and
A (for both 36-V and 48-V vehicles),
the "Lo" indicator flashes. maximum armature current: 250 A for
48-V vehicle, 310 A for 36-V vehicle.
Overheat
(1) Traction motor overheat (Error codes Chat Timer (SUO #24)
E0, E1) • When the following conditions remain
The output limit control is provided only for the time duration set by SUO #24,
for traction motors due to the thermal the line contactor opens.
mode of the powering characteristic. Acceleration: 0
(2) Pump motor overheat (Error code E2) Forward/reverse lever: neutral
In the chopper model, the output duty Lift, tilt and attach levers: OFF
reduces by 50% in hydraulic operations. Steering: not operated
In the contactor model, the contactor • Operating any of the above resets the
opens one second after the detection of line contactor.
pump motor overheat.
(3) Controller overheat (Error code E3) Seat Switch Timer (SUO #25)
The output limit control is provided for • When the operator leaves the seat for the
traction motors due to the thermal mode. time duration set by SUO #25, the line
In the chopper hydraulic model, the out- contactor opens. When the power switch
put duty reduces by 50% in hydraulic is turned on without the operator sitting
operations. on the seat, the line contactor opens and
In the contactor hydraulic model, the the “E” indication flashes on the display
contactor opens one second after the unit.
detection of controller overheat. • With acceleration at 0, forward/reverse
lever in neutral and hydraulic levers
OFF, closing the seat switch resets the
Brush Wear
line contactor.
(1) Traction motor brush wear (Error
codes E4, E5) Malfunction Detection (Run Time
The output limit control is provided only Diagnosis)
for traction motors due to the brush mode If a malfunction is detected, the LED flashes
(same as thermal mode) of the powering and the error code is indicated on the display
characteristic. unit. The corresponding fail-safe function is
(2) Pump motor brush wear (Error code also activated at the same time. Regarding
E6) details, refer to the malfunction detection
In the chopper model, the output duty and main circuit errors tables.
reduces by 50% in hydraulic operations.
In the contactor model, the contactor
opens one second after the detection of
3-20
MAIN CONTROLLER
Malfunction Data Record adjuster so the bars on BDI corresponds to
(History Folder) the chart on page 3-19.
• Turn the key off and back on between
Data Storage adjustments to reset the control.
Errors are automatically stored in the logic
card memory. Stored data includes the
following information.
• Error code
• Battery discharge level at the time of
error generation
• Vehicle hourmeter reading at the time of
error generation Trimmer potential adjuster
A maximum of 32 sets of data can be stored.
If this capacity is exceeded, the oldest data
will be erased to accommodate new data.
Review of Stored Data
(1) To review data
• Set the DRS switch to D.
• The seat switch must be open.
• With the lift and tilt levers pulled
back, turn on the power switch.
• The display unit shows the above
mentioned data (three types of
information). To display previous
data, set the DRS switch to R then to
D. When there is no data to display, a
“done” indication appears. The
display shows data from the most
recent to the oldest.
(2) To delete data
• Operate the DRS switch until the display
shows “done.”
• With "done" on the display, set the
DRS switch at S for more than one 206794
second. This deletes all data in the
memory, then the "done" indication
on the display flashes. The data has Setup Options (SUO)
been deleted and the DRS switch may For details, refer to the setup options table.
be set to R. (Page 3-25)
(1) To enter setup option mode.
Setting Group 1: Set the DRS switch to S, and
turn on the power switch. The
Printed Circuit Board Settings
display shows “Option #1.”
Refer to the printed circuit board adjustment
Group 2: Set the DRS switch to S, the
and setting items table. (See page 3-29)
seat switch must be open, and
Adjustment of BDI turn on the switch while keep-
• Measure voltage between the POS and ing the lift and tilt levers
NEG terminals of the controller assembly pulled back. The display
with a tester. Adjust the trimmer potential shows “Option #11.”
3-21
MAIN CONTROLLER

(2) To select option # and set data • Shift the forward/reverse lever to R,
• The option # is indicated on the speed hold the accelerator pedal pressed,
indicator on the display unit, and the then turn the power switch on. The
data is shown on the hourmeter. display indicates “done.”
• To select option #, set the DRS switch • Set the DRS switch to R.
to R and then to S until the desired
option is displayed Self-diagnosis
• To set data, use the forward/reverse Check the input and output status. For
lever. To increase the value, move the details, refer to the self-diagnosis table.
lever to F. To decrease the value, move Page 3-27 . Remove the line fuse (500 A)
the lever to R. Set the DRS switch to D, and turn on the
power switch to enter the self-diagnosis
(3) To register data mode. To conduct a diagnosis, set the switch
• Setting the DRS switch back to R to R then to D.
registers the data. When the DRS switch • The table below shows the conditions under
is set to R, the data is written, and the which the controller can enter a certain mode.
display indicates triple bars. The key When the DRS switch and other conditions
switch may be turned OFF or another are set according to the table and the power
option may be selected. switch is turned on, the corresponding mode
(4) To set default values listed in the left column is activated. To exit
The following procedure sets default values from the selected mode, turn the power
in the setup option values. switch off.
• Set the DRS switch to S.
• The seat switch must be open.

Mode DRS switch position Other condition


Self-diagnosis D
Malfunction data history D Seat switch open and pull both lift and tilt levers.
Setup option group 1 S
Setup option group 2 S Seat switch open and pull both lift and tilt levers.
Setup option default setting S Seat switch open, shift forward/reverse lever to R
and press accelerator pedal.

3-22
MAIN CONTROLLER
Other Functions
(1) Service indicator (SUO #10)
When the vehicle hourmeter indication
reaches the set value, the service indicator
turns ON to notify the need for maintenance.
Output power control can be also activated at
the same time. The setting can be made in a
range of 100 to 500 at 50 increments. The
service indicator turns ON when the
hourmeter indication exceeds the value of
the current hourmeter reading plus the set
value. 206798
The indicator starts flashing 20 hours before
the set time, and remains lit when the
hourmeter indication reaches the set time. diagnosis operation.
Setting “0.1” activates the demo mode. In this Hourmeters and Time Display
mode, the service indicator turns on after six
minutes running time. (1) Normal operation
(2) Auxiliary input for function control • When the power switch is turned on, the
(SUO #11-#19) hourmeters for the vehicle, drive motors
Auxiliary inputs to the logic card can be and pump motor display indications in
used to limit the maximum vehicle speed, sequence. The hourmeters for the motors
prohibit lift and reduce output power. show cumulative operating hours, and the
The vehicle speed setting by auxiliary input vehicle hourmeter indicates cumulative
has precedence over the maximum vehicle line contactor ON hours.
speed set by SUO #7. • A clock display is shown under normal
condition.
(3) Speed alarm (SUO #26)
When the vehicle reaches the set speed, an (2) During setup option setting and self-
alarm signal (logic card hardware output diagnosis operation
signal) is generated. This signal can be used • The hourmeters are not displayed when
to activate an alarm. the power switch is turned on.
• Data are indicated on the display.
(4) Tire size adjustment (SUO #27)
This function provides a correction value to
compensate for a diameter change resulting
from tire wear. It is used to adjust the vehicle
speed data.
Display Unit
BDI (Battery Discharge Indicator)
• The battery discharge level is indicated by
the 10-segment LCD. This indication is
based on the BDI characteristic. When the
BDI shows only one segment, the LED starts
flashing to notify the low battery power
level. When the BDI indication disappears,
the LED remains lit and the output control is
activated. (see page 3-19 section 9-1)
• The BDI turns OFF when not necessary,
such as during setup option setting and self-
3-23
MAIN CONTROLLER
Vehicle Speed and Error Code Display
• The display indicates vehicle speed under
normal condition, and shows an error code when
an abnormality occurs.
• The display shows item number during setup
option setting and self-diagnosis operation.
Action Lights (LEDs)
The indicators are activated when an error is
detected during normal condition. They do not
turn on during setup option setting or self-
diagnosis operation.
(1) Service indicator (SUO #10)
The indicator starts flashing 20 hours before
maintenance is required and remains lit
when the set time is reached.
(2) Motor brush
The indicator turns ON when the motor
brush needs to be replaced.
(3) Thermal
The indicator turns ON when a motor or the
controller overheats.
(4) Battery
• The indicator flashes when the BDI has one
indicator segment, and stays lit when the
BDI has no segment.
• The indicator flashes when the battery
voltage momentarily becomes higher than
22 V and lower than 25 V. The indicator
turns off when the voltage exceeds 25 V.
• The indicator lights when the battery voltage
momentarily becomes lower than 22 V.
Once all the indicator segments of the BDI
turn off, the output limit control function
does not cancel until the battery is recharged
and five or more indicator segments light.
(5) Brake fluid
The indicator flashes when the brake fluid
level becomes low.
(6) Parking brake
The indicator flashes when the parking
brake is engaged.
(7) Malfunction lamp
The indicator flashes when a malfunction is
detected. Refer to the malfunction detection
table.
(8) Speedometer/Error indicator
Indicates speed of the truck. Or, error
conditions.
3-24
MAIN CONTROLLER
Setup Options (Group 1)

Option Default Value


Title of Option Description Range
#
48 V type 36 V type
A, B, C, D, E
If any of these
Application There are 5 truck modes and each has 7 option values
Pre-Sets option values: are changed,
#1 (Truck Operation Top travel speed, Acceleration rate, A~E will flash A A
Mode) Traveling power, Regen adjustment, Start in order to show
lift speed, Top lift speed, Tilt speed. that the truck
mode is not
default setting.
Lift speed when first lift switch is on.
#2 Start Lift Speed Start lift speed cannot exceed Top lift speed. 1-10 7 7
Maximum lift speed when second lift 1-10 9 9
#3 Top Lift Speed switch is on.
Tilt speed takes priority over Lift speed in case that
#4 Tilt Speed the two levers are simultaneously operated.
2-8 6 7
Speed setting for attachment 1
#5 Auxiliary 1 Speed (1: SLOW Æ 10: FAST) 1-10 3 3
Speed setting for attachment 2
#6 Auxiliary 2 Speed (1: SLOW Æ10: FAST) 1-10 1 1
48 Vtype : 5-16 km/h
#7 Top Travel Speed Maximum travel speed 36 Vtype : 5-16 km/h
Limit 36 VEEtype 14 13
: 5-12 km/h
(undecided)
#8 Acceleration rate Choice of acceleration rate
(1: SLOW, 2: MIDDLE, 3: FAST) 1,2,3 2 2

Choice of powering characteristic


#9 Traveling Power (1: ECONOMY, 2: STANDARD, 1,2,3 2 2
3: POWERFUL)
This option sets the time which indicates
the maintenance time for the operator. The 100-500 hours
amount of time set by this operation is in 50-hr.
added to the truck's hourmeter at that time increments.
and the total value is stored in memory as Attached "=" to
the "maintenance time". When the truck's the value, the
#10 Service Indicator hourmeter reaches to the maintenance power reduction 0 0
time, service indicator LED will turn on. function will be
It will flash 20 hours before the time. You effective.
can reduce the truck power when the LED Selecting 0.1
is solid on by selection. You can also set makes the truck
the demo-mode, which shows the Service demo-mode.
Indicator function quickly. (6 min after
setting 0.1)

NOTE
(1) The service indicator shows the set value, not the current value. If the power switch is turned
off without entering data (without setting the switch to R), the current value is maintained.
When data is entered, the current value is replaced by the setting value on the display.
(2) The output power control function of the service indicator is the same as the output power
control that is activated when the battery voltage level drops.
(3) When the truck mode is selected, all data is replaced by the set values of the selected mode.
When the set values are changed, the truck mode indicator (A to E) flashes to notify that the
settings are modified.
(4) In vehicles with EE option, the settings for the truck mode, start lift speed, top lift speed,
acceleration rate and travel power cannot be changed.
3-25
MAIN CONTROLLER

Setup Options (Group 2)


Option
Title of Option Description Range Default
#
When the auxiliary input signal is 0: Turned off 1: Disable lift (input;
low volts) 2: Speed limit (input;
Auxiliary Input for on, the controller will limit top speed
or inhibit lifting or reduce power low volts) 3: Power reduction
#11 Lift and Drive according to the selection. The speed (input; low volts) 4: Disable lift 0
Speed 1 limit set by this operation takes priority over (input; high volts) 5: Speed limit
#7 top travel speed limit. (input; high volts) 6: Power
reduction (input; high volts)
Auxiliary Travel 48 Vtype: 5-16 Km/h
#12 Speed Limit 1 Travel speed limit for #11 36 Vtype: 5-15 Km/h 10

#13 Auxiliary Power Power reduction ratio for #11 0-99% 0


Reduction 1
#14 Auxiliary Input for
Lift and Drive Same as #11 Same as #11 0
Speed 2
Auxiliary Travel 48 Vtype: 5-16 Km/h
#15 Speed Limit 2 Travel speed limit for #14 36 Vtype: 5-15 Km/h 10

#16 Auxiliary Power Power reduction ratio for #14 0-99% 0


Reduction 2
Auxiliary Input for
#17 Lift and Drive Same as #11 Same as #11 0
Speed 3
#18 Auxiliary Travel Travel speed limit for #17 48 Vtype: 5-16 Km/h 10
Speed Limit 3 36 Vtype: 5-15 Km/h
#19 Auxiliary Power Power reduction ratio for #17 0-99% 0
Reduction 3
If a drive motor stalls for the amount
#20 Stall Timer time set by this option, the motor 2-10 sec 5
current gets to 0.
1: Brake regen (accelerator must
#21 Regen Function 2 regen modes be off) 2
2: Accelerator regen (also called
"auto reg")
Regen Adjustment
#22 for Lever Reg 5 characteristic curves of lever regen 1-5 4
Regen Adjustment
#23 for Auto Reg 5 characteristic curves of #21 1-5 3

#24 Chat Timer Set the amount time before the truck 0-40 sec 20
enters chat mode.
If the operator leaves the seat for the
#25 Seat Switch Timer amount of time set by this option, 3-15 sec 5
the line contactor will open.
If the truck reaches the speed set
#26 Speed Alarm by this option, the controller provides an
48 Vtype: 5-16 Km/h 12
output to activate a speed alarm.
36 Vtype: 5-15 Km/h

Tire Size Adjust the tire diameter. It changes


#27 Adjustment the truck's speed recognition and the 0-40 20
speedmeter.

NOTE
In 36-V vehicles, the functions of options #12, #15 and #18 are inactive if set at a speed above the
vehicle speed set with option #7.

3-26
MAIN CONTROLLER
Self-diagnosis
Logics Normal condition Abnormal condition
Step Diagnosed item Operation Check item Monitor Monitor
display Operation display Operation
0 Power line voltage Turn the key Turn the line contactor 1 The line dd
switch ON. ON, and check the contactor operates
power line voltage. instantaneously
for reset.
1 Seat switch Close and Open Check the input: 2 1
the seat switch. OFFÆONÆOFF
2 Forward/reverse Shift the lever: Check that the input 3 2
lever switch NÆRÆNÆF status changes according
to the lever position.
3 Parking brake Engage and Check the input: 4 3
switch disengage the OFFÆONÆOFF
parking brake.
4 Foot brake switch Press and Check the input: 5 4
release the OFFÆONÆ OFF
foot brake.
5 Accelerator sensor Operate the Indicators flash to indicate The line Indication visual test only,
accelerator a value between 0 and 15 contactor closes. other than Logics will
pedal.(Then cycle according to the amount that at left not show
DRS to RUNÆDIAG of pedal depression. failed accel
for next test) 6
6 Steering sensor Turn the Neutral: Flashing 0 Indication
steering wheel. Right turn: Flashing r1-r7 other than
(Then cycle DRS to Left turn: Flashing L1-L7 that at left
RUNÆDIAG for 7 The line
next test) contactor opens.
7 Battery voltage (Automatic) Check the voltage: 8 7
36/48 V
8 Lift switch Pull and return Chopper: Check the 9 8
the lift lever. 2-stage switch input.
Contactor: Check the
switch input.
9 Tilt switch Pull and return Check the input: 10 9
the tilt lever. OFFÆONÆOFF
10 Attach 1 switch Pull and return Check the input: 11 10
the attach OFFÆONÆOFF
1 lever.
*11 Attach 2 switch Pull and return Check the input: Flashing 0 11
the attach OFFÆONÆOFF
2 lever.
12 Hydraulic pump Pull any hydraulic Pump speed indication Indication
speed check lever. Then cycle flashes according to the other than
DRS RUNÆDIAG lever operation. that at left
for next test 13
13 Line contactor Cycle DRS for 13 The contactor Indication The contactor
each contactor test closes. other than opens.
ÆRUN 14 The contactor that at left The contactor
ÆDIAG opens. closes.
14 Regeneration ÆRUN 14 The contactor Indication The contactor
contactor closes. other than opens.
ÆDIAG 15 The contactor that at left The contactor
opens. closes.
15 Pump contactor ÆRUN 15 The contactor Indication The contactor
closes. other than opens.
ÆDIAG done The contactor that at left The contactor
opens. closes.
* If not equipped with AUX 2 bypass test by cycling the DRS to RUN Æ DIAG
3-27
MAIN CONTROLLER

Logic Card Adjustment / Setting


Adjustment
No. Item Description How to set part Contents

Battery voltage See page 3-21


1 adjustment
.

on: AC control
2 AC control option For AC control Set DSW DSW8 off: normal control
DSW2 On DSW3 On 2.0 ton
Choice of 1.6/1.8/2.0 ton model. DSW2 On DSW3 Off 1.8 ton
3 Truck model Error 65 will occur if DSW is Set DSW DSW 2,3 DSW2 Off DSW3 On 1.6 ton
not set. DSW2 Off DSW3 Off error

French BDI For the battery which has on: French BDI option
4 option different BDI discharge curve. Set DSW DSW 7 off: normal battery

3-28
MAIN CONTROLLER
Run Time Diagnostics
Display

LED Code

To Return
Fault How to detect Result to normal

Over temperature R-motor Thermal contact (150ºC) * E0 Power reduction Cooling


Over temperature L-motor Thermal contact (150ºC) * E1 Power reduction Cooling
Over temperature P-motor Thermal contact (150ºC) * E2 Power reduction Cooling
Over temperature controller Thermistor (80ºC) * E3 Power reduction Cooling
Brush wear R-motor Brush wear sensor * E4 Power reduction Turn off key
Brush wear L-motor Brush wear sensor * E5 Power reduction Turn off key
Brush wear P-motor Brush wear sensor * E6 Power reduction Turn off key
Brake fluid low level Level sensor (Contact) * Turn off key

Armature fault R Check voltage and current of power circuit * 10 Line contactor open Turn off key
IGBT open R Check voltage and current of power circuit * 11 Line contactor open Turn off key
IGBT short R Check voltage and current of power circuit * 12 Line contactor open (✩) Turn off key
IGBT drive fault R Fault signal from the drive board * 13 Line contactor open (✩) Turn off key
Current sensor fault R Check the current sensor output * 14 Line contactor off Turn off key
Armature overcurrent R more than 350 A * 15 Line contactor open (✩) Turn off key
Stall timer R Measure the time (set by SUO#20) while stalling * 16 Line contactor open Turn off key
Field fault R Check voltage and current of power circuit * 17 Line contactor open Turn off key
Field drive fault R Fault signal from the H-bridge board * 18 Line contactor open (✩) Turn off key
Field overcurrent R more than 45 A * 19 Line contactor open (✩) Turn off key
Armature fault L Check voltage and current of power circuit * 20 Line contactor open Turn off key
IGBT open L Check voltage and current of power circuit * 21 Line contactor open Turn off key
IGBT short L Check voltage and current of power circuit * 22 Line contactor open (✩) Turn off key
IGBT drive fault L Fault signal from the drive board * 23 Line contactor open (✩) Turn off key
Current sensor fault L Check the current sensor output * 24 Line contactor open Turn off key
Armature overcurrent L more than 350 A * 25 Line contactor open (✩) Turn off key
Stall timer L Measure the time (set by SUO#20) while stalling * 26 Line contactor open Turn off key
Field fault L Check voltage and current of power circuit * 27 Line contactor open Turn off key
Field drive fault L Fault signal from the H-bridge board * 28 Line contactor open (✩) Turn off key
Field overcurrent L more than 45 A * 29 Line contactor open (✩) Turn off key
Armature fault P Check voltage and current of power circuit * 30 Line contactor open Turn off key
IGBT open P Check voltage and current of power circuit * 31 Line contactor open Turn off key
IGBT short P Check voltage and current of power circuit * 32 Line contactor open (✩) Turn off key
Field drive fault P Fault signal from the driver board * 33 Line contactor open Turn off key
Current sensor fault P Check the current sensor output * 34 Line contactor open Turn off key
Overcurrent P more than 450 A * 35 Line contactor open (✩) Turn off key

Line contactor fault Check voltage and current of power circuit * 40 Line contactor open Turn off key
Regen contactor fault Check voltage and current of power circuit * 41 Line contactor open Turn off key
Pump contactor fault Check voltage and current of power circuit * 42 Line contactor open Turn off key
Regen diode fault Check voltage and current of power circuit * 43 Line contactor open Turn off key
Armature diode fault R Check voltage and current of power circuit * 44 Line contactor open Turn off key

3-29
MAIN CONTROLLER

Armature diode fault L Check voltage and current of power circuit * 45 Line contactor open Turn off key
Armature diode fault P Check voltage and current of power circuit * 46 Line contactor open Turn off key
Armature open R Check voltage and current of power circuit * 47 Line contactor open Turn off key
Armature open L Check voltage and current of power circuit * 48 Line contactor open Turn off key
Armature open P Check voltage and current of power circuit * 49 Line contactor open Turn off key
Steering sensor fault Sensor output is 0 or intermittent * 50 Line contactor open Turn off key
Accelerator sensor fault Out of normal range * 51 Line contactor open Turn off key
Speed sensor fault R Check open or short * 52 Line contactor open Turn off key
Speed sensor fault L Check open or short * 53 Line contactor open Turn off key

Dirct. lever / accel not neutral The lever / accel is not neutral at power-on E Line contactor open Neutral
Seat switch not on The switch is off at power-on (E) Line contactor open switch on
Lift lever not neutral The lever is not neutral at power-on H1 Line contactor open Lever off
Tilt lever not neutral The lever is not neutral at power-on H2 Line contactor open Lever off
Aux1 lever not neutral The lever is not neutral at power-on H3 Line contactor open Lever off
Aux2 lever not neutral The lever is not neutral at power-on H4 Line contactor open Lever off

Serial communication fault When serial communication is not going on * 60 Line contactor open Turn off key
EPROM fault Parity check of SUO data * 61 Line contactor open Turn off key
Logic card not initialized DSW is not set * 65 Line contactor open Turn off key
Logic card fault Sum check of ROM & RAM * 66 Line contactor open Turn off key
Battery voltage too low Voltage is not correct (lower than 42 V) * 68 Line contactor open Turn off key
Battery voltage too high Voltage is not correct (higher than 36 V) * 69 Line contactor open Turn off key
Battery voltage low Voltage is between 22 V to 25 V (*) Power reduction At recovery voltage
Battery voltage low Voltage is lower than 22 V * (Lo) Line contactor open Turn off key

NOTE
(1) E0-E6 do not appear on the display, but are stored in the history folder.
(2) E, (E), H1-H5, 60, Lo appear on the display, but no history folder.
(3) (✩), (E), (Lo) means flashing.
(4) ’Line contactor open (✩)’ means that the contactor will break immediately after a fault is
detected.
’Line contactor open’ means that the contactor will break after a current gets to 0.

3-30
MAIN CONTROLLER

Inspection and Adjustment


Inspection and Adjustment Tools
(a) Circuit tester
(b) Clamp meter
(c) IC clip
(d) Dial adjustment screwdriver (precision
screwdriver)

NOTE
The diagram shows a digital circuit tester.
With this tester, the positive (+) terminal is
applied with positive charge, and the negative 206385
(–) terminal with negative charge..

WARNING
Disconnect the battery plug before inspecting
or adjusting the controller.

Removal and Installation of Logic Card

WARNING
Disconnect the battery plug before approaching
the controller.
Controller
cover
(1) Removal of rear cover
(a) Turn the key switch off.
(b) Disconnect the battery plug.
(c) Remove the rear cover of the counterweight.
(d) Remove the controller cover.
102627

(2) Removal of logic card cover


Remove the cover mounting screws (4
locations), and remove the logic card cover.

206979

3-31
MAIN CONTROLLER

(3) Removal of logic card


(a) Disconnect connectors CH2-P1, CH2-P2,
and CH2-P3.

NOTE Connector
Grip the connectors to unplug. Do not pull the CH2-P3
harnesses to disconnect the connectors. Connector
CH2-P2
(b) Remove the screws (5 locations) that mount Connector
the logic card to the control panel. CH2-P1
(c) Remove the logic card.

206975

(4) Installation
Follow the removal procedure in reverse.
Tightening of High-tension Cable Terminals

Be sure to regularly check the tightened torque of the high-tension battery cable terminals. If the
cables are loosely connected, excessive contact resistance results, and it can cause overheating
and lead to a fire in the worst case. When checking or adjusting the cable routing, avoid pulling
the cables. If the cables move even slightly at the terminals while working with the cables, be
sure to tighten the terminal connections.

• Stud terminals
7 stud terminals (indicated by arrows):
Tightening torque (See table below.)
11.8 ± 2.0 N·m (1.2 ± 0.2 kgf·m) [8.68 ± 1.45 lbf·ft]

Stud size: M8
Width across nut flats: 12 mm

(a) Note that a flat washer and a disc spring are Be sure to
installed on each connector terminal. mount in
the
(See diagram at right.) indicated
(b) The stud terminal sections have resin parts. direction
When tightening the nut, hold the resin parts busbar
with a wrench (17-mm size). (See following Flat washer (large)
diagram.) Disc spring
(small)
Observe
installation
direction

206246

3-32
MAIN CONTROLLER

Stud terminal section


Resin part (black)

206796

Component Testing

(a) Use compressed air to clean the controller.


Using steam or a solvent for cleaning can
damage parts.
(b) For cleaning, use an air compressor
equipped with a moisture-removing filter.
Do not set the air pressure above 196 kPa
(2 kgf/cm2) [28 psi] .
(c) When connecting the battery plug for the
first time after maintenance work, check to
make sure that resistance between the
positive (+) and negative (–) battery
terminals on the vehicle body side to the
frame is 10 kW or higher.

NOTE
When installing wires and cables, be sure to
bind them together.

3-33
MAIN CONTROLLER

(1) Measurement of logic card voltage

WARNING
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possi-
ble. Safely lift the drive wheels off the floor.
Put blocks of wood under the frame so that
both drive wheels are free to turn.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) Remove the cover of the logic card.
(d) Reconnect the battery plug.
(e) Turn the key switch on. Connect the negative
(–) terminal of the circuit tester to the NEG
terminal of the control panel.
(f) Set the circuit tester to the 50- or 100-VDC
range.
(g) Connect the positive (+) terminal of the circuit
tester to each pin of connectors CN1, using the
IC clip, and measure voltage.

NOTE
Be careful not to short-circuit pins.
For the normal voltage value, refer to the
logic card voltage chart on the following
page.

IC clip

NEG terminal

206977

3-34
MAIN CONTROLLER
Logic Voltage Checks
Logic Wire No. Function *Normal Activated Test Procedures
Terminal MC (AC) Voltage Voltage
(CN1) 1 4 (4) B V (FROM KEY) B+ B+ 0 V = key SW OFF, B+ = key SW ON
2 B V (FROM KEY) B+ B+ 0 V = key SW OFF, B+ = key SW ON
3 B VE B1+ B1+
4 B VE B1+ B1+
5 103 (103) GO AHEAD LEVER SW High (15 V) Low Activate shift lever from NEU to FWD
6 104 (104) GO BACK LEVER SW High (15 V) Low Activate shift lever from NEU to REV
7 107 (107) FOOT BRAKE SW High (15 V) Low Activate foot brake pedal pushed
8 109 (109) PARKING BRAKE SW Low High (15 V) Activate parking brake lever pulled
9 111 (348) SEAT SW High (15 V) Low High = seat SW open, Low = seat SW closed
10 114 (114) STEERING1 High High or Low Turn steer wheel lock to lock (High = 15 V)
11 115 (115) STEERING2 High High or Low Turn steer wheel lock to lock (High = 15 V)
12 116 (116) STEERING3 High High or Low Turn steer wheel lock to lock (High = 15 V)
13 117 (117) STEERING4 Low High or Low Turn steer wheel lock to lock (High = 15 V)
14 144 (144) ACCELE SW High (15 V) Low High = accele SW open, Low = accele SW closed
15 (301) AC CONTROL High (15 V) High or Low F/L Truck Type : High = MC, Low = AC
16 119 (304) LIFT LEVER SW1 High (15 V) Low High = lift lever SW1 open
Low = lift lever SW1 closed
17 120 (303) LIFT LEVER SW2 High (15 V) Low High = lift lever SW2 open
Low = lift lever SW2 closed
18 121 (302) TILT LEVER SW High (15 V) Low High = tilt lever SW open
Low = tilt lever SW closed
19 122 (329) ATTACH LEVER SW1 High (15 V) Low attach = 1 : High = SW open, Low = SW closed
20 123 (330) ATTACH LEVER SW2 High (15 V) Low attach = 2 : High = SW open, Low = SW closed
21 108 (108) GND 0V 0V signal GND
22 110 (349) GND 0V 0V signal GND
(CN2) 23 (optional) LIFT STOP SW1 High (15 V) Low LIFT Limit Switch 1
24 (optional) LIFT STOP SW2 High (15 V) Low LIFT Limit Switch 2
25 (optional) LIFT STOP SW3 High (15 V) Low LIFT Limit Switch 3
26 125 (125) TRA.MOTOR RIGHT Low High (15 V) Activated by over-temp of Right traction motor
THERMO.SW
27 128 (128) TRA.MOTOR RIGHT BRUSH SW High (15 V) Low Traction Right BWI SW
28 130 (130) TRA.MOTOR LEFT Low High (15 V) Activated by over-temp of Left traction motor
THERMO.SW
29 133 (133) TRA.MOTOR LEFT BRUSH SW High (15 V) Low Traction Left BWI SW
30 135 (135) PUMP MOTOR THERMO.SW Low High (15 V) Activated by over-temp of pump motor
31 138 (136) PUMP MOTOR BRUSH SW High (15 V) Low Pump BWI SW
32 139 (139) BRAKE FLUID SENSOR SW High (15 V) Low Activate the brake reserver tank empty
33 142 (142) ACCELE ANGLE 0V 0 to 5 V Voltage increases with pushing accele pedal
34 SPARE
35 124 (124) GND 0V 0V signal GND
36 134 (134) GND 0V 0V signal GND
37 140 (140) GND 0V 0V signal GND
38 (301) GND 0V 0V signal GND
(CN3) 39 141 (141) 5V 5V 5V 0 V = key SW OFF, 5 V = key SW ON
40 15 V 15 V 15 V 0 V = key SW OFF, 5 V = key SW ON
41 GND 0V 0V signal GND
42 GND 0V 0V signal GND
43 145 (145) R-SPEED SENSOR PHASE A+ Low Voltage increases with vehicle speed increase
44 EMPTY
45 146 (146) R-SPEED SENSOR PHASE A- Low Low
46 EMPTY
47 147 (147) L-SPEED SENSOR PHASE A+ Low Voltage increases with vehicle speed increase
48 EMPTY
49 148 (148) L-SPEED SENSOR PHASE A- Low Low
50 EMPTY
51 (optional) ALARM OUTPUT1 B1+ Low or B1+ Speed Alarm 1 : Low = Alarm
52 EMPTY
53 (optional) ALARM OUTPUT2 B1+ Low or B1+ Speed Alarm 2 : Low = Alarm
54 EMPTY
55 EMPTY
56 EMPTY
57 EMPTY
58 EMPTY
59 149 (149) DISPLAY TXD High or Low High or Low LCD. Display T ¥ data : (High = 12 V)
60 GND 0V 0V signal GND
61 150 (150) DISPLAY RXD High or Low High or Low LCD. Display R ¥ data : (High = 12 V)
62 EMPTY
63 GND 0V 0V signal GND
64 GND 0V 0V signal GND
* All tests with relationship to battery NEG.
3-35
MAIN CONTROLLER

Logic Voltage Checks CH2


Logic Terminal Function *Normal Activated Test Procedures
Voltage Voltage
(P1) 1 GND 0V 0V signal GND
2 B VE B1+ B1+ 0 V = key SW OFF, B1+ = key SW ON
3 GND 0V 0V signal GND
4 B VE B1+ B1+ 0 V = key SW OFF, B1+ = key SW ON
5 R. FIELD FWD ON/OFF High (5 V) Low R. FIELD FWD: Low = ON, High = OFF
(Activated by traction mode ON)
6 R. FIELD REV ON/OFF High (5 V) Low R. FIELD FWD: Low = ON, High = OFF (5 V)
(Activated by traction mode ON)
7 R. FIELD FWD PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
8 R. FIELD REV PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
9 L. FIELD FWD ON/OFF High (5 V) Low L. FIELD FWD: Low = ON, High = OFF (5 V)
(Activated by traction mode ON)
10 L. FIELD REV ON/OFF High (5 V) Low L. FIELD REV: Low = ON, High = OFF (5 V)
(Activated by traction mode ON)
11 L. FIELD FWD PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
12 L. FIELD REV PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
13 R. FIELD ERROR High (15 V) High or Low R. FIELD ERR: Low = error, High = Normal (15 V)
14 L. FIELD ERROR High (15 V) High or Low L. FIELD ERR: Low = error, High = Normal (15 V)
15 R. FIELD CURRENT SIG 0V 0 to 5 V R. FIELD Current: 0 V = OFF, 5 V = MAX
16 R. FIELD CURRENT RTN 0V 0V R. FIELD Current Return
17 L. FIELD CURRENT SIG 0V 0 to 5 V L. FIELD Current: 0 V = OFF, 5 V = MAX
18 L. FIELD CURRENT RTN 0V 0V L. FIELD Current Return
19 EMPTY
20 EMPTY
21 GND 0V 0V signal GND
22 5V 5V 5V 0 V = key SW OFF, 5 V = key SW ON
(P2) 23 GND 0V 0V signal GND
24 5V 5V 5V 0 V = key SW OFF, 5 V = key SW ON
25 GND 0V 0V signal GND
26 B VE B1+ B1+ 0 V = key SW OFF, B1+ = key SW ON
27 PUMP PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by pump motor ON
28 L. ARMATURE PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
29 R. ARMATURE PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
30 R. ARMATURE ERROR High (15 V) High or Low R. Armature error: Low = error
31 L. ARMATURE ERROR High (15 V) High or Low L. Armature error: Low = error
32 PUMP ERROR High (15 V) High or Low Pump error: Low = error
33 B VPOS B+ B+
34 PUMP MOTOR VOLTAGE Low B+ Low: Line contactor opens
B+: Line contactor closes (no pump motor operation
35 EMPTY
36 SET High (15 V) High or Low SET Switch: Low = SET SW ON
37 DIAG High (15 V) High or Low DIAG Switch: Low = DIAG SW ON
38 GND 0V 0V signal GND

3-36
MAIN CONTROLLER

Logic Voltage Checks CH2


Logic Terminal Function *Normal Activated Test Procedures
Voltage Voltage
(P3) 39 L&R ARMATURE VOLTAGE Low 5 to 20 V Low: Line contactor open
5 to 20 V: Line contactor closed
(Forward/reverse lever in neutral,
accelerator pedal OFF)
40 PUMP Tr. VOLTAGE Low B+ Low: Line contactor open
B+: Line contactor closed (no pump motor operation)
41 R. Tr. VOLTAGE Low 5 to 20 V Low: Line contactor open
5 to 20 V: Line contactor closed
(Forward/reverse lever in neutral,
accelerator pedal OFF)
42 L. Tr. VOLTAGE Low 5 to 20 V Low: Line contactor open
5 to 20 V: Line contactor closed
(Forward/reverse lever in neutral,
accelerator pedal OFF)
43 CONT THERRMO SENSOR 0 to 5 V 0 to 5 V Controller Temperature
44 GND 0V 0V signal GND
45 R.ARMATURE CURRENT 0 to 0.3 V 0 to 4.2 V R. ARM Current: Activated by traction motor ON
46 R.ARMATURE CURRENT RTN 0V 0V R. Armature Current Return
47 L.ARMATURE CURRENT 0 to 0.3 V 0 to 4.2 V L. ARM Current: Activated by traction motor ON
48 L.ARMATURE CURRENT RTN 0V 0V L. Armature Current Return
49 PUMP CURRENT 0 to 0.3 V 0 to 4.2 V Pump Current: Activated by pump motor ON
50 PUMP CURRENT RTN 0V 0V Pump Current Return
51 15 V 15 V 15 V 15 V = key SW ON, 0 V = key SW OFF
52 15 V 15 V 15 V 15 V = key SW ON, 0 V = key SW OFF
53 15 V 15 V 15 V 15 V = key SW ON, 0 V = key SW OFF
54 EMPTY
55 PUMP CONTACTOR B1+ 33 to 39 V B1+: Contactor open, 24 Contactor closes
56 REGEN CONTACTOR B1+ 33 to 39 V B1+: Contactor open, 24 Contactor closes
57 LINE CONTACTOR B1+ 33 to 39 V B1+: Contactor open, 24 Contactor closes
58 SPARE
59 BVE pump cont B+ B1+ 0 V = key SW OFF, B1+ = key SW ON
60 VE B+ B1+ 0 V = key SW OFF, B1+ = key SW ON
61 BVE Regen cont B+ B1+ 0 V = key SW OFF, B1+ = key SW ON
62 BVE Line cont B+ B1+ 0 V = key SW OFF, B1+ = key SW ON
63 GND 0V 0V signal GND
64 GND 0V 0V signal GND

3-37
MAIN CONTROLLER

(2) Head capacitors


WARNING
Disconnect the battery plug before approaching
the controller.

Be careful not to damage the head capacitors.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) With the positive-side bus bar and negative-
side bus bar mounted, remove the head
capacitors from the controller.
(d) Visually inspect the head capacitor terminal
sections.
(e) Check to make sure the contents of the head
capacitors have not melted or leaked.
(f) Set the circuit tester to 20-kohm range. Positive-side busbar

Measuring locations
Standard tester
(+) terminal (–) terminal indication
Positive (+) side Negative (–) side
of head capaci- of head capaci- 10 kW or Negative-side busbar
tor higher
tors 206387A

NOTE
The above instruction describes the connec-
tion of terminals for a digital tester.

(g) If the measured value deviates from the above


standard, test individual head capacitors using
2
the same test procedure and replace faulty
units.
(h) When reinstalling the head capacitors, tighten
the mounting bolts to the specified torque.
1
N·m (kgf·m)
Tightening torque 1
(head capacitor 3 ± 0.5 (0.3 ± 0.05)
mounting bolts)
Tightening torque 2 2
206980
(head capacitor bus 4.5 ± 0.5 (0.45 ± 0.05)
and plate mounting bolts)

3-38
MAIN CONTROLLER

(3) Contactor coils


• Resistance test

WARNING
Disconnect the battery plug before approaching
the controller.

(a) Disconnect the lead wire of coil.


(b) Set the circuit tester to 200-ohm range.
(c) Measure coil resistance.

Normal value
Line, pump and
regeneration contactors 118 to 145 W

(d) If the measured value deviates from the


above range, replace the contactor assembly.

• Pulse signal test


(a) With the lead wire of contactor coil connected,
set the circuit tester to 200-VDC range.
(b) Connect the negative (–) terminal of the
circuit tester to the negative-side coil
terminal (small fasten terminal) and the
positive (+) terminal of the circuit tester to
the positive-side coil terminal (large fasten
terminal).
(c) Connect the battery, and operate the control
device that activates the contactor.
(d) The circuit tester should indicate approx.
battery voltage after the contactor closes. Positive-side coil
terminal
When the contactor is found normal in the
coil resistance test and if the measured
voltage is not within this range, replace the
logic card.

Negative-side coil terminal 206390A

3-39
MAIN CONTROLLER

(4) Contactor tips


(a) Visually inspect the contactor tips for
melting, adhesion, heat seizure and pitting
corrosion.
(b) To check for interference, press the tips and
release it.
(c) Visually inspect the contactor assemblies.
Make sure there are no foreign materials in
the assemblies to interfere with contactor
movement.
(d) Measure the gap at each contactor tips using
a thickness gauge.
205817A

Contactor bridge
tightening torque 2 N·m (0.2 kgf·m)

Contactor tip gap mm (in.)


Line contactor 3.15 ± 0.10 (0.12 ± 0.004)
Regeneration contactor 3.15 ± 0.10 (0.12 ± 0.004)
Pump contactor 3.15 ± 0.10 (0.12 ± 0.004)

(5) Armature (right) current sensor

WARNING
Disconnect the battery plug before approaching
the controller.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) Disconnect connector CH2-P3 from the
logic card.
(d) Disconnect current sensor connector CS1.
Right Connector Left Connector Pump Connector
armature CS1 armature CS2 current CS3
current current sensor
sensor sensor 206391A

3-40
MAIN CONTROLLER
(e) Check continuity at locations indicated
below. (Figure 206392A
Current sensor Pin No. on logic
connector side card harness side
CS1-4GR CH2 P3-51
CS1-3B CH2 P3-63
CS1-2BrY CH2 P3-45
CS1-1LR CH2 P3-46

If there is no continuity, repair or replace wires. Connector


(f) Connect connector CH2-P3 to the logic card. CH2-P3
64 63
(g) Set the circuit tester to 20-VDC range. 62 61
60 59
(Voltage test) 58 57
56 55
(h) With connector CS1 disconnected, connect 54 53
52 51
the positive (+) terminal of the circuit tester 50
48
49
47
to CS1-4GR. (Figure 206393A) 46
44
45
43
Connect the negative (–) terminal of the 42
40
41
39
circuit tester to the NEG terminal.
(i) Connect the battery plug and turn the key
switch on.
Connector CS1

Standard circuit tester indication 14 to 16 V


CS1-4GR
CS1-3B
(j) Then, connect the positive (+) terminal of the CS1-2BrY
circuit tester to CS1-2BrY. CS1-LR

Standard circuit tester indication 4 to 6 V

(k) If both values measured in the above steps (i)


and (j) deviate from the specified ranges,
replace the logic card. 206392A

Continuity test
WARNING
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possi-
ble. Safely lift the drive wheels off the floor.
Put blocks of wood under the frame so that
both drive wheels are free to turn.

(l) Connect connector CS1.


(m)Place wood blocks under the vehicle to lift CS1-4GR
the front wheels off the ground. Engage the CS1-2BrY
parking brake.
(n) Set the circuit tester to 20-VDC range.
206393A
(o) Connect the positive (+) terminal of the
circuit tester to P3-45 on the logic card, and Voltage test
connect the negative (–) terminal to the NEG
terminal.(Figure 206393B page 3-42)
3-41
MAIN CONTROLLER

Standard circuit tester indication 019 to .21 V

If the measured value deviates from the


above standard, adjust per steps A - J page 3-
46.
(p) Shift the forward/reverse lever to Forward.
Gradually depress the accelerator pedal
(with front wheels stationary) and read the
voltage change.
Voltage increase Normal To PH2-P3-45
Voltage at 0 or no change Replace current sensor.
206393B
(6) Armature (left) current sensor

WARNING
Disconnect the battery plug before approaching
the controller.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) Disconnect connector CN2-P3 from the
logic card.
(d) Disconnect current sensor connector CS2. Right
armature
Connector
CS1
Left
armature
Connector Pump
CS2 current
Connector
CS3
current current sensor
sensor sensor 206391A

3-42
MAIN CONTROLLER

(f) Check continuity at locations indicated


below.
Current sensor Pin No. on logic
connector side card harness side
CS2-4GR CH2 P3-52
CS2-3B CH2 P3-63
CS2-2LO CH2 P3-47
CS2-1BrW CH2 P3-48 Connector
CH2-P3
64 63
If there is no continuity, repair or replace 62 61
60 59
wires. 58 57
56 55
(g) Connect connector CH2-P3 to the logic card. 54 53
52 51
(h) Set the circuit tester to 20-VDC range. 50
48
49
47
(Voltage test) (Figure 206393C Page 3-44) 46
44
45
43
(i) With connector CS2 disconnected, connect 42
40
41
39
the positive (+) terminal of the circuit tester
to CS2-4GR.
Connect the negative (–) terminal of the
circuit tester to the NEG terminal. Connector CS2
(j) Connect the battery plug and turn the key
switch on. CS2-4GR
CS2-3B
CS2-2LO
CS2-1BrW
Standard circuit tester indication 14 to 16 V

(k) Then, connect the positive (+) terminal of


the circuit tester to CS2-2LO.

Standard circuit tester indication 4 to 6 V


206392A
(l) If both values measured in the above steps
(j) and (k) deviate from the specified ranges, Continuity test
replace the logic card.

3-43
MAIN CONTROLLER

WARNING
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possi-
ble. Safely lift the drive wheels off the floor.
Put blocks of wood under the frame so that
both drive wheels are free to turn.

(m) Connect connector CS2.


(n) Place wooden blocks under the vehicle to lift CS2-4GR
the front wheels off the ground. Engage the CS2-2LO
parking brake.
(o) Set the circuit tester to 20-VDC range.
(p) Connect the positive (+) terminal of the 206393C
circuit tester to P3-47 on the logic card, and Voltage test
connect the negative (–) terminal to the NEG
terminal (Figure 206393D).
Standard circuit tester indication .19 to .21 V

If the measured value deviates from the above


standard, adjust per steps A - J page 3-46.
(q) Shift the forward/reverse lever to Forward.
Gradually depress the accelerator pedal (with
front wheels stationary) and read voltage
change. To PH2-P3-47

Voltage increase Normal 206393D


Voltage at 0 or no change Replace current sensor.

(8) Pump current sensor


Anode side
WARNING D1R D1R D1P D2 D2
Disconnect the battery plug before approaching
the controller.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) Disconnect connector CH2-P3 from the logic
card.
(d) Disconnect current sensor connector CS3.

Cathode side 206394A

3-44
MAIN CONTROLLER

(e) Check continuity at locations indicated


below.
Current sensor Pin No. on logic
connector side card harness side
CS3-4GR CH2 P3-53
CS3-3B CH2 P3-63
CS3-2Br CH2 P3-49
CS3-1YG CH2 P3-50

If there is no continuity, repair or replace Connector


wires. CH2-P3
64 63
(f) Connect connector CH2-P3 to the logic card. 62 61
60 59
(g) Set the circuit tester to 20-VDC range. 58 57
56 55
(Voltage test) 54 53
52 51
(h) With connector CS3 disconnected, connect 50
48
49
47
the positive (+) terminal of the circuit tester 46
44
45
43
to CS3-4GR. (Figure 206393E) 42
40
41
39
Connect the negative (–) terminal of the
circuit tester to the NEG terminal.
(i) Connect the battery plug and turn the key
switch on. Connector CS3

CS3-4GR
Standard circuit tester indication 14 to 16 V CS3-3B
CS3-2BrY
(j) Then, connect the positive (+) terminal of the CS3-1YG
circuit tester to CS3-2Br.

Standard circuit tester indication 4 to 6 V

(k) If both values measured in the above steps (i)


and (j) deviate from the specified ranges, 206392A
replace the logic card.
Continuity test
WARNING
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possi-
ble. Safely lift the drive wheels off the floor.
Put blocks of wood under the frame so that
both drive wheels are free to turn.

(l) Connect connector CS3.


(m) Place wooden blocks under the vehicle to lift
CS3-4GR
the front wheels off the ground. Engage the CS3-2Br
parking brake.
(n) Set the circuit tester to 20-VDC range.
(o) Connect the positive (+) terminal of the 206393E
circuit tester to P3-49 on the logic card, and
connect the negative (–) terminal to the NEG Voltage test
terminal. (Figure 206393F) page 3-46
3-45
MAIN CONTROLLER

Standard circuit tester indication .19 to .21 V

If the measured value deviates from the above


standard, adjust per steps A - J page 3-46.
(p) Gradually pull the lift lever (lifting operation)
and read voltage change.
To PH2-P3-49

Voltage increase Normal


Voltage at 0 or no change Replace current sensor. 206393F

WARNING
To prevent the vehicle from moving suddenly, lift the front wheels off the ground by placing wooden
blocks under the vehicle. Do not approach the front wheels during testing.
(a) Place wooden blocks under the vehicle to lift the front wheels off the ground. Engage the parking
brake.
(b) Set the circuit tester to 20-VDC range.
(c) Connect the positive (+) terminal of the circuit tester to CH2 P3-49 on the logic card, and connect
the negative (-) terminal to the NEG terminal.
(d) Connect the battery plug and turn the key switch on.
(e) Standard circuit tester indication as follows.
0.19 to 0.21 v (0.20v means 0A for software, ³0.01v means ³1.5A)
If the measured value deviates from the above data, repair the value by adjusting offset-POT of
pump current sensor.
(f) Turn the key switch off.
(g) Put off the A screw for comfortable adjustment.
(h) Turn the key switch on.
(i) Turn the offset-POT and set the measured value between 0.19v and 0.21v.
(j) Put on the A screw.

A screw

IC clip

NEG terminal

Right armature
current sensor

Left armature Connector Pump Connector


Connector
current sensor CS2 current CS3
CS1
Offset pot Top Side sensor

3-46
MAIN CONTROLLER

(9) Diodes Anode side


D1R D1R D1P D2 D2
WARNING
Disconnect the battery plug before approaching
the controller.

The following describes the inspection


procedure for diode D1R.
Follow the same procedure for all other
diodes.
(a) Turn the key switch off.
(b) Disconnect the battery plug. Cathode side 206394A
(c) Remove the busbar and other parts from
diode D1R.
(d) Set the circuit tester to diode range, and
measure voltage between the following
terminals.

Measuring locations Standard tester


Test lead (+) terminal (–) terminal indication
Forward
direction Anode side of D1R Cathode side of D1R 0.1 to 0.3 V

Reverse
direction Cathode side of D1R Anode side of D1R •

NOTE
If the resistance range is used to measure
voltage of the reverse direction, the tester
indicates • W.

(e) If the measured values deviate from the stan-


dard, replace the diode.

3-47
MAIN CONTROLLER

• Replacement procedure

WARNING
Disconnect the battery plug before approaching
the controller.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) Remove the logic card.
(d) Remove the busbar and other parts, then
remove the diode.
(e) Clean contact surface 1, and place a silicone
sheet under the diode. 1
(f) Install the diode, and tighten mounting bolts 206395
to the following torque.
(g) Connect the busbar and other parts.

Diode Tightening torque

D1R, D1L, D1P, D2 4.5 ± 0.5 N·m


(0.45 ± 0.05 kgf·m)

(10) Drive board


• On-vehicle test CN2 Drive board

WARNING
Disconnect the battery plug before approaching
the controller.

Inspection before test


(a) Inspect head capacitors.
(b) Inspect diodes D1R, D1L, D1P and DZ.
(c) Inspect IGBTs T1D and T2D. Connector
CN1
(d) Inspect current sensors.
(e) Check continuity between drive board CN1 Connector CN1 and CN2
and logic card. CH2-P2
1 2 3 4 5 6
7 8 9 10 11 12

36 35
34 33
32 31
30 29
28 27
26 25
24 23

207468

3-48
MAIN CONTROLLER

Drive board CN1 continuity test


Drive board CN1 Pin No. on logic card
connector side CH2-P2 harness side
CN1-1 B P2-25
CN1-2 R P2-26
CN1-3 BrR P2-24
CN1-4 Br P2-27
CN1-5 BrW P2-28
CN1-6 LR P2-29
CN1-9 B P2-23
CN1-10 G P2-32
CN1-11 YL P2-31
CN1-12 YG P2-30

(f) Remove the head capacitors.


(g) Check continuity between drive board CN2
and logic card.
Drive board CN2 continuity test
Drive board CN2 Terminal on Collector Collector Collector
connector side IGBT side terminal T1L terminal T1P terminal

CN2-7 R IGBT T1R - Gate terminal


T1R
CN2-8 WR IGBT T1R - Emitter terminal
CN2-1 GR IGBT T1R - Collector terminal
CN2-3 WL IGBT T1L - Gate terminal
CN2-2 L IGBT T1L - Emitter terminal Emitter
terminal
CN2-4 GL IGBT T1L - Collector terminal Gate
terminal
CN2-6 WY IGBT T1P - Gate terminal
Emitter Gate Emitter Gate
CN2-5 Y IGBT T1P - Emitter terminal terminal terminal terminal terminal 207469

CN2-12GY IGBT T1P - Collector terminal

3-49
MAIN CONTROLLER

• Unit test
Disconnect the terminals, and inspect the test circuits indicated below. If abnormalities are found,
replace the drive board.
CN1/CN2 connector pin Nos.

6 5 4 3 21

CN2

CN1
12 1110 9 8 7
206400A

Diagram of traction motor drive board terminal connections

3-50
MAIN CONTROLLER
Drive Board CN1 Test (Off Vehicle)
Terminal Function Multimeter + – Results
(CN1) Range Lead Lead
CN1- 1 Power supply input circuit 20 kW CN1-2 CN1-1 10 kW or higher
2
3 T1P pulse input circuit Diode CN1-3 CN1-4 1.2 to 1.8 V
4 CN1-4 CN1-3 OL (•)
5 T1L pulse input circuit Diode CN1-3 CN1-5 1.2 to 1.8 V
CN1-5 CN1-3 OL (•)
6 T1R pulse input circuit Diode CN1-3 CN1-6 1.2 to 1.8 V
CN1-6 CN1-3 OL (•)
9 T1P error signal output circuit 20 KW CN1-10 CN1-9 OL (•)
10 CN1-9 CN1-10 OL (•)
11 T1L error signal output circuit 20 KW CN1-11 CN1-9 OL (•)
CN1-9 CN1-11 OL (•)
12 T1R error signal output circuit 20 KW CN1-12 CN1-9 OL (•)
CN1-9 CN1-12 OL (•)

Drive Board CN2 Test (Off Vehicle)


Terminal Function Multimeter + – Results
(CN2) Range Lead Lead
CN2- 1 T1R output circuit (between E and C) 20 kW CN2-1 CN2-8 OL (•)
CN2-8 CN2-1 OL (•)
7
8 T1R output circuit (between E and G) 20 kW CN2-7 CN2-8 10 kW or higher
CN2-8 CN2-7 10 kW or higher
4 T1L output circuit (between E and C) 20 kW CN2-4 CN2-2 OL (•)
CN2-2 CN2-4 OL (•)
3
2 T1L output circuit (between E and G) 20 kW CN2-3 CN2-2 10 kW or higher
CN2-2 CN2-3 10 kW or higher
12 T1P output circuit (between E and C) 20 kW CN2-12 CN2-5 OL (•)
CN2-5 CN2-12 OL (•)
6
5 T1P output circuit (between E and G) 20 kW CN2-6 CN2-5 10 kW or higher
CN2-5 CN2-6 10 kW or higher

NOTE
With circuit tester in resistance measurement range, positive terminal is applied with positive
power supply and negative terminal is applied with negative power supply.

E: EMITTER
C: COLLECTOR
G: GATE

H bridge board

WARNING POS plate


Disconnect the battery plug before approaching
the controller.

(a) Turn the key switch off.


(b) Disconnect the batter plug.
(c) Remove the logic card and drive board.

Inspection of H bridge board installation condition


(a) Set the circuit tester to 20-kohm range, and
NEG HEAT HEAT HEAT HEAT
measure resistance between NEG and heat terminal SINK A SINK B SINK C SINK D
sink blocks. 207471

3-51
MAIN CONTROLLER

Measuring locations Standard tester


(+) terminal (–) terminal indication
Heat sink A NEG 10 kW or higher
Heat sink B NEG 10 kW or higher
Heat sink C NEG 10 kW or higher
Heat sink D NEG 10 kW or higher

NOTE
On heat sink, measurement should be taken
on 5.5-mm2 area at harness terminal mounting
location.

(b) Set the circuit tester to 20-kohm range, and


measure resistance between the POS plate
and heat sink blocks.

Measuring locations Standard tester


(+) terminal (–) terminal indication
POS plate Heat sink A 10 kW or higher
POS plate Heat sink B 10 kW or higher
POS plate Heat sink C 10 kW or higher
POS plate Heat sink D 10 kW or higher

NOTE
On heat sink, measurement should be taken
on 5.5-mm2 area at harness terminal mounting
location.

If the results of the above tests (a) and (b)


deviate from the standards, conduct the
following tests.
(c) Conduct a unit test with the H bridge board.
(d) Set the circuit tester to 200-ohm range, and
measure resistance between heat sinks A and
B and between heat sinks C and D.

Measuring locations Standard tester


(+) terminal (–) terminal indication
Heat sink A Heat sink B 0.5 to 1.5 W
Heat sink C Heat sink D 0.5 to 1.5 W

(e) If the results of the above test (d) deviate


from the standards, inspect the traction
motor field circuits and wiring, and
insulation between heat sink blocks A, B and
base plates.
3-52
MAIN CONTROLLER
(f) Check continuity between H bridge board
connector CN1 and the logic card. CH2-P1

H bridge connector continuity test


Pin No. on logic
CN2 connector side card harness side
CN2-1 BrR P1-22
CN2-2 B P1-21
CN2-3 GB P1-15
CN2-4 GW P1-16
CN2-5 G P1-17
CN2-6 GL P1-18
CN2-7 LB P1-9
CN2-8 LY P1-10
CN2-9 BrR P1-5
CN2-10 BrY P1-6
CN2-11 LR P1-11
CN2-12 LO P1-12
CN2-13 BrW P1-7
CN2-14 Br P1-8
CN2-15 YG P1-14
CN2-16 YL P1-13
CN2-17 R P1-2
CN2-18 R P1-4
CN2-19 B P1-1
CN2-20 B P1-3

• Unit test
Disconnect the terminals, and inspect the test circuits indicated below. If abnormalities are found,
replace the H bridge board.
CN1 connector pin Nos.

11 13 15 17 19
12 14 16 18 20

CN2
Connector
2 4 6 8 10
1 3 5 7 9
207472

Diagram of H bridge board terminal connections

3-53
MAIN CONTROLLER

H — Bridge Board Test (Off Vehicle)


Test Function Multimeter + – Results
Range Lead Lead
CN1 1 Power supply input circuit 20 KW CN1-1 CN1-2 10 KW or higher
2 (5 V GND)
3 Current output 20 KW CN1-3 CN1-4 5 to 6 KW
4 (R. FIELD CURRENT, RETURN) CN1-4 CN1-3 5 to 6 KW
5 Current output 20 KW CN1-5 CN1-6 5 to 6 KW
6 (L/ FIELD CURRENT, RETURN) CN1-6 CN1-5 5 to 6 KW
7 Pulse input circuit Diode CN1-7 CN1-1 OL (•)
(L. FIELD FWD ON/OFF) CN1-1 CN1-7 1.2 to 1.8 V
8 Pulse input circuit Diode CN1-8 CN1-1 OL (•)
(L. FIELD REV ON/OFF) CN1-1 CN1-8 1.2 to 1.8 V
9 Pulse input circuit Diode CN1-9 CN1-1 OL (•)
(R. FIELD FWD ON/OFF) CN1-1 CN1-9 1.2 to 1.8 V
10 Pulse input circuit Diode CN1-10 CN1-1 OL (•)
(R. FIELD REV ON/OFF) CN1-1 CN1-10 1.2 to 1.8 V
11 Pulse input circuit Diode CN1-11 CN1-1 OL (•)
(L. FIELD FWD PWM) CN1-1 CN1-11 1.2 to 1.8 V
12 Pulse input circuit Diode CN1-12 CN1-1 OL (•)
(L. FIELD REV PWM) CN1-1 CN1-12 1.2 to 1.8 V
13 Pulse input circuit Diode CN1-13 CN1-1 OL (•)
(R. FIELD FWD PWM) CN1-1 CN1-13 1.2 to 1.8 V
14 Pulse input circuit Diode CN1-14 CN1-1 OL (•)
(R. FIELD REV PWM) CN1-1 CN1-14 1.2 to 1.8 V
15 Error signal output circuit 20 KW CN1-15 CN1-2 OL (•)
(L. FIELD ERROR) CN1-2 CN1-15 OL (•)
16 Error signal output circuit 20 KW CN1-16 CN1-2 OL (•)
(R. FIELD ERROR) CN1-2 CN1-16 OL (•)
17 Power supply input circuit 20 KW CN1-17 CN1-19 10 KW or higher
18 (48 VE, GND) CN1-18 CN1-20 10 KW or higher
19
20
FET, L Output circuit 20 KW FET5 (fin) NEG (busbar) OL (•)
(L.R. ON/OFF (FET5)) NEG (busbar) FET5 (fin) OL (•)
Output circuit 20 KW FET3 (fin) FET6 (busbar) OL (•)
(L.R. PWM (FET3)) FET6 (busbar) FET3 (fin) OL (•)
Output circuit 20 KW FET6 (fin) NEG (busbar) OL (•)
(L.F. ON/OFF (FET6)) NEG (busbar) FET6 (fin) OL (•)
Output circuit 20 KW FET4 (fin) FET5 (busbar) OL (•)
(L.F. PWM (FET4)) FET5 (busbar) FET4 (fin) OL (•)
FET, R Output circuit 20 KW FET7 (fin) NEG (busbar) OL (•)
(R.R. ON/OFF (FET7)) NEG (busbar) FET7 (fin) OL (•)
Output circuit 20 KW FET1 (fin) FET8 (busbar) OL (•)
(R.R. PWM (FET1)) FET8 (busbar) FET1 (fin) OL (•)
Output circuit 20 KW FET8 (fin) NEG (busbar) OL (•)
(R.F. ON/OFF (FET8)) NEG (busbar) FET8 (fin) OL (•)
Output circuit 20 KW FET2 (fin) FET7 (busbar) OL (•)
(R.F. PWM (FET2)) FET7 (busbar) FET2 (fin) OL (•)

NOTE
With circuit tester in resistance measurement range, positive terminal is applied with positive
power supply and negative terminal is applied with negative power supply.

3-54
MAIN CONTROLLER

Procedure for replacing H bridge board

(1) Disconnect the battery plug (for safety).

206994

(2) Loosen 4 screws (M4¥8) with washers from


bracket D located on the logic card.

206793

(3) Remove bracket D.

Bracket D

206795

3-55
MAIN CONTROLLER

(4) Disconnect the cable from the yellow


connector of the logic board.

Cable

207473

(5) Loosen 5 screws (M4¥8) with washers from


1 2
bracket E located under the logic board.
. 3

4
5

207474

(6) Remove bracket E together with the logic


board.
Bracket E with
logic board

207475

3-56
MAIN CONTROLLER

(7) Disconnect the harness from the black


connector of the drive board assembly. 1
Loosen 4 screws (M3¥6) with washers from 2
the drive board assembly.

4 3

Harness
207476

(8) Loosen 3 screws (M6¥14) with washers from Bracket C 1


bracket C, then remove bracket C.
.

3 2

207477

(9) Loosen the screw (M6¥14) that connects


cable B (16A50-03602) to bus plate A.

Bus plate A 1 Cable B


207478

3-57
MAIN CONTROLLER

(10) Loosen the screw (M3¥6) with washer that Bracket A


connects bracket A to the H bridge board
assembly.
. 1

207478A

(11) Loosen 8 screws (M3¥8) with washers from MOS-FET 1 2 3 4


the MOS-FETs on the H bridge board
assembly.

8 7 6 5
207478B

(12) Remove the H bridge board assembly from


the controller.
Loosen the screw (M5¥10) with washer that
connects the cable, then disconnect harness A
.
Cable B
NOTE
After dismounting the H bridge board assem-
bly from the controller, harness A can be dis- 1 2
connected easily from the connector. Harness A
Gently jiggle harness A to disconnect.
207479

3-58
MAIN CONTROLLER

(13) Wipe white silicone from the surface of alu- Heat sink A
minum heat sink A. Clean heat sink B with a
clean cloth.
1234
NOTE
8 7 6 5
If old silicone or dust remains on the surface
of the HEAT SINK, H BRIDGE BOARD’S
circuit is broken and may over heat.

Heat sink B
207480

(14) Connect cable B using the screw (M5¥ 10)


with washer, and connect harness A to the H
bridge board assembly.

Cable B

1 2
Harness A

207479

3-59
MAIN CONTROLLER

(15) Apply a thin and uniform coat of silicone to 1 2 3 4


the back side of each MOS-FET.
When reusing the H bridge board assembly,
wipe old white silicone completely and apply
new silicone.

NOTE
1 Silicone should be applied in a thickness
of 100-200 µm.
The silicone coat should feel extremely
thin to the touch.
207481
(Make sure the silicone coat is not too 8 7 6 5
thick or too thin.)
2 Do not apply silicone to the surfaces or
metallic-parts of the MOS-FETs.
(If metallic-parts are coated with silicone,
field current cannot flow and a
malfunction can result.)
3 Be careful not to bend or break the legs of
the MOS-FETs.

(16) Mount the H bridge board assembly in the MOS-FET 1 2 3 4


controller.
Install the 8 screws (M3¥8) with washers
(05847-00308) to mount the MOS-FETs.
.

8 7 6 5
207478B

(17) Install the screw (M3¥6) with washer to Bracket A


mount bracket A on the H bridge board
assembly.
1

207478A

3-60
MAIN CONTROLLER

(18) Fasten the 8 screws (M3¥8) with washers MOS-FET 1 2 3 4


tightly to secure the MOS-FETs in place.

NOTE
Be careful not to tighten the M3¥8 screws
with excessive force to prevent damage to
aluminum heat sink A and heat sink B.

8 7 6 5
207478B

(19) Check continuity (0 W) between the metallic


part (excluding M3¥8 screw) of each MOS-
FET and heat sink A (and B) using a tester. Heat sink

207482

(20) Install the screw (M6¥14) with washer to con-


nect cable B to bus plate A.

Bus plate A 1 Cable B


207478

3-61
MAIN CONTROLLER

(21) Install the 3 screws (M6¥14) with washers to Bracket C 1


install bracket C.

3 2

207477

(22) Install the 4 screws (M3¥6) with washers to


mount bracket C. 1
Connect the harness to the black connector of 2
the drive board assembly.

4 3

Harness
207476

(23) Install bracket E mounted with the logic board


to the controller.
Bracket E
with logic board

207475A

3-62
MAIN CONTROLLER

(24) Install the 5 screws (M4¥8) with washers to


bracket E (underplate of the logic board), and 1 2
tighten to 1.5 N·m (15 kgf-cm). 3

4
5

207474

(25) Connect the cable to the yellow connector of


the logic board.

Cable

207473

(26) Mount bracket D, then install the 4 screws 1


(M4¥8) with washers and tighten to 1.5 N·m 2
(15 kgf-cm).

3
4

207474A

3-63
MAIN CONTROLLER

(27) H bridge board replacement is completed.


Bracket D
with Logics

IGBT OFF test


(a) Disconnect the battery plug.
(b) Remove the line fuse.
(c) Disconnect the gate and emitter wires of
IGBTs T1R, T1L and T1P. 207475A
(d) Connect the battery plug, and turn the key
switch on.
(e) Set the circuit tester to 200-VDC range.
(f) Measure voltages between disconnected
gate and emitter wires.

Measuring locations Standard tester


(+) terminal (–) terminal indication Line fuse
T1R gate T1R emitter –9 to –16 V
terminal R terminal WR
T1L gate T1L emitter –9 to –16 V
terminal WL terminal L
T1P gate T1P emitter –9 to –16 V
terminal WY terminal Y 206397A

Drive IGBT ON test


(a) Turn the key switch off, and disconnect the
battery plug.
(b) Connect the gate and emitter wires to
original positions.
(c) Connect the battery plug, and turn the key
switch on.
(d) Shift the forward/reverse lever to either
Forward or Reverse.
(e) Depress the accelerator pedal, and measure
voltages between connected gate and emitter
wires. Collector Collector
terminal T1L terminal T1P
Collector
terminal

Measuring locations Standard tester


T1R
(+) terminal (–) terminal indication
T1R gate T1R emitter –9 to +16 V
terminal R terminal WR
T1L gate T1L emitter –9 to +16 V Emitter
terminal WL terminal WR terminal
Gate
terminal
If no abnormality is found in the IGBT OFF
Emitter Gate Emitter Gate
and ON tests, replace the drive board and terminal terminal terminal terminal 207469
T1R or T1L.

3-64
MAIN CONTROLLER
Pump motor IGBT ON test
(a) Turn the key switch off, and disconnect the T1P
battery plug.
(b) Connect the gate and emitter wires to
original positions.
(c) Connect the battery plug, and turn the key
switch on.
(d) Set the lift speed to maximum setting using
the program option.
Gate terminal
(e) Pull the lift lever, and measure voltages
between connected gate and emitter wires.

Emitter terminal 207470


Measuring locations Standard tester
(+) terminal (–) terminal indication
T1P gate T1P emitter –9 to +16 V
terminal WY terminal Y

If no abnormality is found in the IGBT OFF


and ON tests, replace the drive board and
T1P. Busbar

(11) IBGTs
WARNING
Disconnect the battery plug before approaching
the controller.
Harness
The following describes the inspection
procedure for IGBT T1R. 206408A
Follow the same procedure for all other
IGBTs.
Preparation
(a) Turn the key switch off.
(b) Disconnect the battery plug.
(c) Remove the busbar and harness from T1R.
G-E short-circuit test
(a) Short terminals G and E with a wire.
(b) Set the circuit tester to 2 MEG ž range, and
measure resistance between the following
terminals.
Measuring locations Tester
Test rod (+) terminal (–) terminal indication Short-circuit 206409

1 Terminal C Terminal E charges to OL


2 Terminal E Terminal C 1 MEG MW NOTE
Handle the G and E terminals with extreme
Resistance values should have the following care since they can be easily damaged by
relationship. static electricity.
Resistance 1 > Resistance 2 (Do not touch the G and E terminals.)

3-65
MAIN CONTROLLER

• G-E resistance test


(a) Set the circuit tester to 200-ohm range, and
measure resistance between terminals G and
E.

Measuring locations Standard tester indication


Terminals G and E Charges to OL
E G
NOTE
It takes some time for the circuit tester to
indicate infinity (•) in normal condition.
206410
(b) If the results of the G-E short-circuit and
resistance tests deviate from the standards,
replace the IGBT.

• Replacement procedure

WARNING
Disconnect the battery plug before approaching
the controller.

(a) Turn the key switch off.


(b) Disconnect the battery plug.
(c) Remove the logic card.
(d) Remove the busbar and other parts, then
remove the IGBT.
(e) Clean contact surfaces 1.
(f) Place a silicone sheet under the IGBT.
(g) Install the IGBT, and tighten to the specified
torque.
1
IGBT Tightening torque
T1R, T1L, T1P 3 ± 0.5 N·m (0.3 ± 0.05 kgf·m) 206395

NOTE
New IGBTs are provided with black
sponges to protect the G and E terminals
from damage caused by static electricity. Do
not remove the sponges until the G and E
terminals are connected.

(h) Install the busbar and other parts.

3-66
MAIN CONTROLLER

(12) Controller thermistor

WARNING
Thermistor
Disconnect the battery plug before approaching
the controller.

(a) Disconnect the thermistor connector.


(b) Set the circuit tester to 200-kohm or
20-kohm range.
(c) Measure temperature at the test site, and
allow the thermistor temperature to settle.
Then, measure resistance at the connector.
(d) Compare the measured value with the values
in the table on the following page. If the 206413A
measured value deviates from the specified
range, replace the thermistor.
(e) Power Cutback starts at 90°C and is not
restored until the control cool to 70°C.

3-67
MAIN CONTROLLER

Standard resistance-temperature relationships


Temperature Lower limit Standard value Upper limit
°C KW KW KW
–20.0 427.4 487.4 555.3
–19.0 403.6 459.6 523.0
–18.0 381.2 433.6 492.8
–17.0 360.2 409.3 464.6
–16.0 340.6 386.5 438.1
–15.0 322.1 365.0 413.4
–14.0 304.7 344.9 390.1
–13.0 288.4 326.1 368.4
–12.0 273.0 308.4 348.0
–11.0 258.6 291.7 328.8
–10.0 245.0 276.1 310.8
–9.0 232.2 261.4 293.9
–8.0 220.2 247.5 278.0
–7.0 208.8 234.5 263.1
–6.0 198.1 222.2 249.1
–5.0 188.0 210.7 235.9
–4.0 178.5 199.8 233.5
–3.0 169.6 189.6 211.8
–2.0 161.1 179.9 200.8
–1.0 153.1 170.8 190.4
4.8 V 0.0 145.6 162.2 180.6
1.0 138.4 154.1 171.4
2.0 131.6 146.4 162.6
3.0 125.2 139.1 154.4
4.0 119.2 132.3 146.6
4.74 V 5.0 113.5 125.8 139.3
6.0 108.0 119.7 132.4
7.0 102.9 113.9 125.9
8.0 98.07 108.4 119.7
9.0 93.48 103.2 113.9
4.68 V 10.0 89.14 98.32 108.4
11.0 85.02 93.68 103.1
12.0 81.11 89.29 98.21
13.0 77.41 85.13 93.55
14.0 73.89 81.19 89.13
4.60 V 15.0 70.56 77.45 84.95
16.0 67.40 73.91 80.98
17.0 64.39 70.55 77.23
18.0 61.54 67.36 73.67
19.0 58.83 64.34 70.29
4.50 V 20.0 56.26 61.47 67.09

R (100°C) = 3.3 KW ± 3%

B (0/100) = 3970 K ± 2%

3-68
MAIN CONTROLLER

Standard resistance-temperature relationships


Temperature Lower limit Standard value Upper limit
°C KW KW KW
20.0 56.26 61.47 67.09
21.0 53.81 58.74 64.06
22.0 51.48 56.15 61.18
23.0 49.27 53.68 58.44
24.0 47.17 51.34 55.84
4.39 V 25.0 45.16 49.12 53.38
26.0 43.26 47.00 51.03
27.0 41.44 44.99 48.80
28.0 39.71 43.08 46.68
29.0 38.06 41.25 44.67
4.27 V 30.0 36.49 39.52 42.75
31.0 35.00 37.86 40.93
32.0 33.57 36.29 39.19
33.0 32.21 34.79 37.54
34.0 30.91 33.36 35.97
4.12 V 35.0 29.67 32.00 34.47
36.0 28.49 30.70 33.04
37.0 27.36 29.46 31.68
38.0 26.29 28.27 30.38
39.0 25.26 27.14 29.14
3.97 V 40.0 24.27 26.06 27.96
41.0 23.33 25.04 26.84
42.0 22.43 24.05 25.76
43.0 21.58 23.11 24.74
44.0 20.75 22.22 23.76
3.79 V 45.0 19.97 21.36 22.82
46.0 19.22 20.54 21.93
47.0 18.50 19.75 21.08
48.0 17.81 19.00 20.26
49.0 17.15 18.29 19.48
3.61 V 50.0 16.52 17.60 18.73
51.0 15.91 16.94 18.02
52.0 15.33 16.31 17.34
53.0 14.78 15.71 16.68
54.0 14.25 15.13 16.06
3.41 V 55.0 13.74 14.58 15.46
56.0 13.25 14.05 14.89
57.0 12.78 13.54 14.34
58.0 12.33 13.05 13.81
59.0 11.89 12.59 13.31
3.20 V 60.0 11.48 12.14 12.83

R (100°C) = 3.3 KW ± 3%

B (0/100) = 3970 K ± 2%

3-69
MAIN CONTROLLER

Standard resistance-temperature relationships


Temperature Lower limit Standard value Upper limit
°C KW KW KW
60.0 11.48 12.14 12.83
61.0 11.08 11.71 12.37
62.0 10.70 11.30 11.92
63.0 10.33 10.90 11.50
64.0 9.978 10.52 11.09
3.0 V 65.0 9.640 10.16 10.70
66.0 9.314 9.809 10.32
67.0 9.001 9.473 9.961
68.0 8.700 9.150 9.614
69.0 8.411 8.840 9.282
2.78 V 70.0 8.133 8.541 8.963
71.0 7.865 8.255 8.656
72.0 7.607 7.979 8.362
73.0 7.360 7.714 8.079
74.0 7.121 7.459 7.807
2.57 V 75.0 6.892 7.214 7.545
76.0 6.671 6.978 7.294
77.0 6.458 6.751 7.052
78.0 6.253 6.533 6.819
79.0 6.055 6.322 6.595
2.36 V 80.0 5.865 6.120 6.380
81.0 5.682 5.925 6.173
82.0 5.505 5.737 5.973
83.0 5.335 5.556 5.781
84.0 5.170 5.381 5.596
2.17 V 85.0 5.012 5.213 5.418
86.0 4.859 5.051 5.246
87.0 4.712 4.895 5.081
88.0 4.570 4.744 4.921
89.0 4.433 4.599 4.768
1.98 V 90.0 4.300 4.459 4.620
91.0 4.172 4.324 4.477
92.0 4.049 4.193 4.339
93.0 3.930 4.068 4.207
94.0 3.814 3.946 4.079
1.80 V 95.0 3.703 3.829 3.955
96.0 3.596 3.716 3.836
97.0 3.492 3.606 3.721
98.0 3.392 3.501 3.610
99.0 3.295 3.399 3.503
1.63 V 100.0 3.201 3.300 3.399

R (100°C) = 3.3 KW ± 3%

B (0/100) = 3970 K ± 2%

3-70
MAIN CONTROLLER

(13) Right speed sensor (Speed sensor 1)


(a) Turn the key switch off. Left pulse sensor
(b) Disconnect the battery plug.
(c) Remove the logic card cover, and disconnect
Connector side
connector CN1.
(d) Disconnect the right speed sensor connector. CN15-148G CN15-147L
(e) Check continuity at locations indicated
below.

Right speed sensor Logic card


connector side harness side Logic card harness side
CN16-145Y CN1-43 206414

CN16-146B CN1-45

If there is no continuity, repair or replace


wires.
(f) Set the circuit tester to 2-kohm range.
(g) Measure resistance between CN16-145Y
and CN16-146B on the sensor side of the
right speed sensor connector.

Standard tester indication 1.8 to 2.2 kW

If the measured value deviates from the


standard, replace the right speed sensor.
206415

(14) Left speed sensor (Speed sensor 2)


(a) Turn the key switch off. Right pulse sensor
(b) Disconnect the battery plug.
(c) Remove the logic card cover, and disconnect
Connector side
connector CN1.
(d) Disconnect the left speed sensor connector. CN16-146B CN16-145Y
(e) Check continuity at locations indicated
below.

Left speed sensor Logic card


connector side harness side Logic card harness side
CN15-147L CN1-47 206416

CN15-148G CN1-49

If there is no continuity, repair or replace


wires.

3-71
MAIN CONTROLLER

(f) Set the circuit tester to 2-kohm range.


(g) Measure resistance between CN15-147L and
CN15-148G on the sensor side of the left
speed sensor connector.

Standard tester indication 1.8 to 2.2 kW

If the measured value deviates from the


standard, replace the left pulse sensor.

206417

3-72
MAIN CONTROLLER

Service Data

Circuit tester
Parts to be tested Standard value
(+) terminal (–) terminal
Logic card volume POS NEG Battery voltage
Logic card — — Refer to logic card
voltage measurement table
Contactor coils (line, pump and (+) coil terminal (–) coil terminal 118 to 145 W
regeneration coils)
Contactor coils (line, pump and (+) coil terminal (–) coil terminal 23.4-52 V
regeneration coils)
(pulse signal) (small fasten terminal) (large fasten terminal) (after coil activation)
Current sensors (continuity on CS1-1 LR P3-46
current sensor connector side CS1-2 BrY P3-45
and logic card harness side) CS1-3 B P3-63
CS1-4 GR P3-51
CS2-1 BrW P3-48
CS2-2 LO P3-47 Confirmation
CS2-3 B P3-63 of continuity
CS2-4 GR P3-52
CS3-1 VG P3-50
CS3-2 Br P3-49
CS3-3 B P3-63
CS3-4 GR P3-53
CS1-4 GR
CS2-4 GR NEG 14 to 16 V
CS3-4 GR
CS1-2 BrY
CS2-2 LO NEG 4 to 6 V
CS3-2 Br
P3-45
P3-47 NEG 0 to 0.3 V
P3-49
Diodes (diode range) Anode side Cathode side 0.1 to 0.3 V
Cathode side Anode side •

3-73
MAIN CONTROLLER

Circuit tester
Parts to be tested Standard value
(+) terminal (–) terminal
Drive board Drive board connector Pin No. on logic card
CN1 side P2 harness side
CN1-1 B P2-25
CN1-2 R P2-26
CN1-3 BrR P2-24
CN14 Br P2-27 Confirmation
CN1-5 BrW P2-28 of continuity
CN1-6 LR P2-29
CN1-9 B P2-23
CN1-10 G P2-32
CN1-11 YL P2-31
CN1-12 YG P2-30
Drive board connector Terminals
CN2 side on IGBT side
CN2-7 R IGBT T1R-Gate terminal
CN2-8 WR IGBT T1R-Emitter terminal
CN2-1 GR IGBT T1R-Collector terminal Confirmation
CN2-3 WL IGBT T1R-Gate terminal of continuity
CN2-2 L IGBT T1R-Emitter terminal
CN2-4 GL IGBT T1R-Collector terminal
CN2-6 WY IGBT T1R-Gate terminal
CN2-5 Y IGBT T1R-Emitter terminal
CN2-12 GY IGBT T1R-Collector terminal
(IGBT OFF test) T1R gate terminal R T1R emitter terminal WR –9 to –16 V
T1L gate terminal WL T1L emitter terminal L –9 to –16 V
T1P gate terminal WY T1P emitter terminal Y –9 to –16 V

3-74
MAIN CONTROLLER

Circuit tester
Parts to be tested Standard value
(+) terminal (–) terminal
Drive board
(IGBT ON test) T1R gate terminal R T1R emitter terminal WR –9 to –16 V
T1L gate terminal WL T1L emitter terminal L –9 to –16 V
T1P gate terminal WY T1P emitter terminal Y –9 to –16 V
(Unit test) — — Refer to section on
unit test of drive board
H bridge board Heat sink A NEG
Heat sink B NEG 10 kW or higher
Heat sink C NEG (Range: 20 kW)
Heat sink D NEG
POS plate Heat sink A
POS plate Heat sink B 10 kW or higher
POS plate Heat sink C (Range: 20 kW)
POS plate Heat sink D
Heat sink A Heat sink B 0.5 to 1.5 W
Heat sink C Heat sink D (Range: 200 W)
H bridge board Pin No. on logic
connector CN2 side card harness side
CN2-1 BrR P1-22
CN2-2 B P1-21
CN2-3 GB P1-15
CN2-4 GW P1-16
CN2-5 G P1-17 Confirmation
CN2-6 GL P1-18 of continuity
CN2-7 LB P1-9
CN2-8 LY P1-10
CN2-9 BrR P1-5
CN2-10 BrY P1-6
CN2-11 LR P1-11
CN2-12 LO P1-12

3-75
MAIN CONTROLLER

Circuit tester
Parts to be tested Standard value
(+) terminal (–) terminal
H bridge board H bridge board Pin Nos. on logic
connector CN1 side card harness side
CN2-13 BrW P1-7
CN2-14 Br P1-8
CN2-15 YG P1-14
CN2-16 YL P1-13
CN2-17 R P1-2
CN2-18 R P1-4
CN2-19 B P1-1
CN2-20 B P1-3
(Unit test) — — Refer to section on
unit test of H bridge board
IGBT
(G-E short-circuit test) Terminal C Terminal E •
Terminal E Terminal C 1 MEG M W
(G-E resistance test) Terminal G Terminal E •
Thermistor Refer to thermistor
Thermistor connector (no polarity)
characteristic table
Right speed sensor CN16-145 Y CN1-43 Confirmation of continuity
(Continuity) CN16-146 B CN1-45 Confirmation of continuity
(Resistance) CN16-145 Y CN16-146 B 1.8 to 2.2 kW
Left speed sensor (Continuity) CN15-147 L CN1-47 Confirmation of continuity
CN15-148 G CN1-49 Confirmation of continuity
(Resistance) CN15-147 L CN15-148 G 1.8 to 2.2 kW

3-76
MAIN CONTROLLER

Tightening Torque

2 9

6 9

7
4

8
1

207486

Tightened parts Quantity Tightening torque N·m (kgf·m) [lbf·ft]


1 Stud terminals 7 12 ± 2 (1.2 ± 0.2) [8.68 ± 1.45]
2 Head capacitor bus plates 6 4.5 ± 0.5 (0.45 ± 0.05) [3.25 ± 0.36]
3 Head capacitors 12 3.0 ± 0.5 (0.3 ± 0.05) [2.17 ± 0.36]
4 Contactor bridges 2 2.0 ± 0.5 (0.2 ± 0.05) [1.45 ± 0.36]
5 Diodes D1D through D2P 6 4.5 ± 0.5 (0.45 ± 0.05) [3.25 ± 0.36]
6 Diodes D5D 4 4.5 ± 0.5 (0.45 ± 0.05) [3.25 ± 0.36]
7 IGBTs 8 4.5 ± 0.5 (0.45 ± 0.05) [3.25 ± 0.36]
8 Contactor terminals 4 12 ± 2 (1.2 ± 0.2) [8.68 ± 1.45]
9 Logic card cover 9 1.5 ± 0.5 (0.15 ± 0.05) [1.08 ± 0.36]

3-77
TROUBLESHOOTING FOR CONTROL CIRCUITS

EO Right Motor, Overheating ...................................................................................................... 4- 1


E1 Left Motor, Overheating.......................................................................................................... 4- 2
E2 Pump Motor, Overheating ...................................................................................................... 4- 3
E3 Controller, Overheating .......................................................................................................... 4- 4
E4 Right Motor, Worn Brushes .................................................................................................... 4- 5
E5 Left Motor, Worn Brushes ...................................................................................................... 4- 6
E6 Pump Motor, Worn Brushes .................................................................................................... 4- 7
Brake Oil, Low Level .............................................................................................................. 4- 8
10 Right Motor, Faulty Armature Circuit .................................................................................... 4- 9
11 Right Motor, Transistor Open.................................................................................................. 4-10
12 Right Motor, Shorted Transistor .............................................................................................. 4-11
13 Right Motor, Faulty Transistor Drive ...................................................................................... 4-12
14 Right Motor, Faulty Current Sensor ........................................................................................ 4-13
15 Right Motor, Armature Over-current ...................................................................................... 4-14
16 Right Motor, Stall Timer.......................................................................................................... 4-15
17 Right Motor, Faulty Field Circuit ............................................................................................ 4-16 4
18 Right Motor, Faulty Field Drive .............................................................................................. 4-17
19 Right Motor, Field Over-current.............................................................................................. 4-18
20 Left Motor, Faulty Armature Circuit ...................................................................................... 4-19
21 Left Motor, Transistor Open .................................................................................................... 4-20
22 Left Motor, Shorted Transistor ................................................................................................ 4-21
23 Left Motor, Faulty Transistor Drive ........................................................................................ 4-22
24 Left Motor, Faulty Current Sensor .......................................................................................... 4-23
25 Left Motor, Armature Over-current ........................................................................................ 4-24
26 Left Motor, Stall Timer............................................................................................................ 4-25
27 Left Motor, Faulty Field Circuit .............................................................................................. 4-26
28 Left Motor, Faulty Field Drive ................................................................................................ 4-27
29 Left Motor, Field Over-current ................................................................................................ 4-28
30 Pump Motor, Faulty Circuit .................................................................................................... 4-29
31 Pump Motor, Transistor Open ................................................................................................ 4-30
32 Pump Motor, Shorted Transistor.............................................................................................. 4-31
33 Pump Motor, Faulty Transistor Drive...................................................................................... 4-32
34 Pump Motor, Faulty Current Sensor........................................................................................ 4-33
35 Pump Motor, Armature Over-current ...................................................................................... 4-34
40 Line Contactor, Abnormality .................................................................................................. 4-35
41 Regeneration Contactor, Abnormality .................................................................................... 4-36
42 Pump Contactor, Abnormality ................................................................................................ 4-37
43 Regeneration Diode, Abnormality .......................................................................................... 4-38
44 Right Diode, Abnormality ...................................................................................................... 4-39
45 Left Diode, Abnormality.......................................................................................................... 4-40
46 Pump Diode, Abnormality ...................................................................................................... 4-41
47 Right Motor, Open .................................................................................................................. 4-42
48 Left Motor, Open .................................................................................................................... 4-43
49 Pump Motor, Open .................................................................................................................. 4-44
50 Steering Sensor, Abnormality .................................................................................................. 4-45
51 Accelerator, Abnormality ........................................................................................................ 4-46
52 Right Vehicle Speed Sensor, Abnormality .............................................................................. 4 -47
53 Left Vehicle Speed Sensor, Abnormality ................................................................................ 4 -48
E Forward/reverse Lever and Accelerator, Faulty Setting.......................................................... 4 -49
(E) Seat Switch, Faulty Setting .................................................................................................... 4 -50
H1 Lift Lever, Faulty Setting ........................................................................................................ 4 -51
H2 Tilt Lever, Faulty Setting ........................................................................................................ 4 -52
H3 Attach 1 Lever, Faulty Setting ................................................................................................ 4 -53
H4 Attach 2 Lever, Faulty Setting ................................................................................................ 4 -54
60 Data Communication, Abnormality ........................................................................................ 4 -55
61 EEPROM, Abnormality .......................................................................................................... 4 -56
65 Logic Card, Faulty Initial Setting ............................................................................................ 4 -57
66 Controller, Abnormality .......................................................................................................... 4 -58
68 Battery Voltage, Excessively Low (For 48-V Vehicles Only) ................................................ 4 -59
69 Battery Voltage, Excessively High (For 36-V Vehicles Only) ................................................ 4 -60

NOTE
(E) Means E is flashing

NOTE
For your reference, most pages are provided
with schematics of pertinent electrical
circuits.
Before conducting troubleshooting, read the
procedures carefully and also refer to the
Electrical Schematics in the VEHICLE
ELECTRICAL COMPONENTS section.
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Right Motor, Overheating

Indication: “E0” display, controller/motor overheat indicator ON. Poor pulling power and
acceleration. Normal pump motor and power steering operations. (Activation of right drive motor
thermal switch)

(1) Situation
Indication: “E0” only history folder not shown on dash, controller/motor overheat indicator
ON. Poor pulling power and acceleration. Normal pump motor and power steering opera-
tions.

(2) Cause
Overheating of right drive motor, abnormality or wire break in right drive motor thermal
switch (temperature sensor), faulty logic card.

(3) Inspection
Let vehicle cool for 15 minutes.
Overheat indicator ON Normal indication

(4) Disconnect battery plug. Wait until (11) Operate vehicle and check overheating
right drive motor temperature of right drive motor. If problem recurs,
becomes close to room temperature. check power supply to right drive motor
Disconnect right drive motor thermal or operating cycle. Also check if vehicle
switch. Check thermal switch is operated on steep upgrade or with
continuity. There should be large cargo load.
continuity below 130°C.
Continuity No continuity
(10) Replace thermal switch.
(5) Check continuity between wire 124G
(Green) of thermal switch harness
connector and NEG.
Continuity No continuity
(9) Correct or replace wiring.

(6) Remove logic card cover. Check Right drive motor thermal switch:
continuity between motor sensor Normally Closed
125Y (yellow) and logic card CN2-
26, and shorting of these terminals
with NEG.
Drive
Continuity, No continuity, motor (R)
no shorting or shorted
To Negative To Negative

(7) Faulty logic card (8) Correct or replace wiring.


207691
4-1
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Left Motor, Overheating

Indication: “E1” display, controller/motor overheat indicator ON. Poor pulling power and
acceleration. Normal pump motor and power steering operations. (Activation of left drive motor
thermal switch)

(1) Situation
Indication: “E 1” only history folder not shown on dash, controller/motor overheat indi-
cator ON. Poor pulling power and acceleration. Normal pump motor and power steering
operations.
(2) Cause
Overheating of left drive motor, abnormality or wire break in left drive motor thermal
switch (temperature sensor), faulty logic card.

(3) Inspection
Let vehicle cool for 15 minutes.
Overheat indicator ON Normal indication

(4) Disconnect battery plug. Wait until (11) Operate vehicle and check overheating
left drive motor temperature becomes of left drive motor. If problem recurs,
close to room temperature. check power supply to left drive motor or
Disconnect left drive motor thermal operating cycle. Also check if vehicle is
switch. Check thermal switch operated on steep upgrade or with large
continuity. There should be electric cargo load.
continuity below 130°C.
Continuity No continuity
(10) Replace thermal switch.
(5) Check continuity between wire 129G
(Green) of thermal switch harness
connector and NEG.
Continuity No continuity

(9) Correct or replace wiring.


(6) Remove logic card cover. Check
continuity between motor sensor
130Y (yellow) and logic card CN2- Left drive motor thermal switch:
28, and shorting of these terminals Normally Closed
with NEG. Drive
motor (L)
Continuity, no No continuity,
shorting or shorted
To Negative To Negative

(7) Faulty logic card (8) Correct or replace wiring.

207692

4-2
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Pump Motor, Overheating

Indication: “E2” display, controller/motor overheat indicator ON. Pump motor lifting speed
slower than normal. Normal drive motor and power steering operation. (Activation of pump motor
thermal switch)

(1) Situation
Indication: “E2” only history folder not shown on dash, controller/motor overheat indi-
cator ON. Pump motor lifting speed slower than normal. Normal drive motor and power
steering operations.

(2) Cause
Overheating of pump motor, abnormality or wire break in pump motor thermal switch
(temperature sensor), faulty logic card.

(3) Inspection
Let vehicle cool for 15 minutes.
Overheat indicator ON Normal indication

(4) Disconnect battery plug. Wait until (11) Operate vehicle and check overheating
pump motor temperature becomes of pump motor. If problem recurs, check
close to room temperature. Disconnect power supply to pump motor or
pump motor thermal switch. Check operating cycle. Also check if vehicle is
thermal switch continuity. There operated to lift large cargo load.
should electric continuity below
130°C.
Continuity No continuity
(10) Replace thermal switch.
(5) Check continuity between wire 134W
(white) of thermal switch harness
connector and NEG.
Continuity No continuity
(9) Correct or replace wiring.

(6) Remove logic card. Check continuity


Pump motor temperature sensor:
and shorting between motor sensor
Normally Closed
135R (red) and logic card CN2-30.
Pump motor

Continuity, no No continuity,
shorting or shorted
To Negative To Negative

(7) Faulty logic card (8) Correct or replace wiring.

207693
4-3
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Controller, Overheating

Indication: “E3” display, controller/motor overheat indicator ON. Poor pulling power and
acceleration. Lifting speed slower than normal. Normal power steering operation. (Controller
thermal control activation)

(1) Situation
Indication: “E3” only history folder not shown on dash, controller/motor overheat indi-
cator ON. Poor pulling power and acceleration. Lifting speed slower than normal. Normal
power steering operation.

(2) Cause
Overheating of controller panel, abnormality or wire break in controller thermistor
(temperature sensor), faulty logic card.

(3) Inspection
Let vehicle cool for 15 minutes.
Overheat indicator ON Normal indication

(4) Disconnect battery plug. Wait until (8) Correct or replace wiring.
controller temperature becomes close
to room temperature. Disconnect (11) Operate vehicle and check overheating
controller thermistor connector. of controller. If problem recurs, check
Measure thermistor resistance. power supply to drive and pump motors
Measured resistance should be 8 kW or operating cycle. Also check if vehicle
or higher at temperature below 70°C.
8 kW or higher Less than 8
is operated on steep upgrade
or to pull or lift large cargo
kW
(5) Check continuity between harness
connector-2B (black) and NEG.
Continuity No continuity
load.

(6) Remove logic card cover. Check


continuity between logic card CH2-43
BrR (brown, red) and harness
connector 1 BrR (brown, red).

Continuity
No continuity
(7) Faulty logic card

207694

4-4
TROUBLESHOOTING FOR CONTROL CIRCUITS

(10) Replace thermal switch.

(9) Correct or replace wiring.


Problem: Right Motor, Worn Brushes

Indication: “E4” display, worn brush indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations.

(1) Situation
Indication: “E4” only history folder not shown on dash, worn brush indicator ON. Power
pulling power and acceleration. Normal pump motor and power steering operations.

(2) Cause
Worn right motor brushes, wire breakage, faulty indication, faulty logic card.

(3) Inspection
Disconnect battery plug. Disconnect brush wear detector wires 126-V (purple) and
127-O (orange) from right drive Controller CN2-27W (white) - Right motor
motor. Reconnect battery plug, and 126-V (purple)/127-O (orange)
close key switch. Check to see if indi-
cator turns OFF.
Indicator ON
Drive
Indicator OFF motor (R)

(4) Disconnect battery plug. Check


continuity in brush wear detector

wires. With connectors


wires and disconnected,

also check shorting and negative (-) sides of


between positive (+) batteries.

207695

4-5
TROUBLESHOOTING FOR CONTROL CIRCUITS

Continuity, no shorting No continuity, or shorted

(5) Replace logic card.

(6) Correct or replace wiring.

(7) Inspect brushes and replace, if necessary.


Problem: Left Motor, Worn Brushes

Indication: “E5” display, worn brush indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations.

(1) Situation
Indication: “E5” only history folder not shown on dash, worn brush indicator ON. Power
pulling power and acceleration. Normal pump motor and P/S operations.

(2) Cause

Indicator ON
Worn left motor brushes, wire break- Indicator OFF
age, faulty indication, faulty logic
card.

(3) Inspection
Drive
Disconnect battery plug. Disconnect
motor (L)
brush wear detector wires 131-V (pur-
ple) and

132-O (orange) m o t o r .
from left drive Reconnect bat-
tery plug, and close
key switch. Check to see if indicator turns OFF.

207696

4-6
TROUBLESHOOTING FOR CONTROL CIRCUITS

(4) Disconnect battery plug. Check continuity in brush wear detector wires. With
wires and connectors disconnected, also check shorting between positive (+) and
negative (-) sides of batteries.
Controller CN2-29L (blue) - Left motor 131-V (purple)/132-O (orange)

Continuity, no shorting
No continuity, or shorted

(5) Replace logic card.


(6) Correct or replace wiring.

(7) Inspect brushes and replace, if necessary.

Problem: Pump Motor, Worn Brushes

Indication: “E6” display, worn brush indicator ON. Pump motor lifting speed slower than
normal. Normal drive motor and power steering operations.
(1) Situation
Indication: “E6” only history folder not shown on dash, worn brush indicator ON. Pump

motor lifting speed slower than nor- 137-Y (yellow) from pump motor.
mal. Normal drive motor and power
steering operations.

(2) Cause Pump motor


Worn pump motor brushes, wire
breakage, faulty indication, faulty
logic card.

Disconnect
(3) Inspection battery plug.

Disconnect brush wires 136-R (red) and


wear detector 207697

4-7
TROUBLESHOOTING FOR CONTROL CIRCUITS

Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Indicator ON Indicator OFF
(4) Disconnect battery plug. Check continuity in brush wear detector wires. With wires and

connectors disconnected, also check shorting between positive (+) and negative (-) sides
of batteries.
Controller CN2-31V (purple) - Pump motor 136-R (red)/137-Y (yellow)

Continuity, no shorting
No continuity, or shorted
(5)Replace logic card.

(6) Correct or replace wiring.


(7) Inspect brushes and replace, if necessary.
Problem: Brake Oil, Low Level

Indication: Low brake oil indicator


ON. Normal vehicle operation.
(1) Situation
Indication: Low brake oil indicator

ON. Normal vehicle

Brake oil level sensor


operation. Normally Open
(Low oil level: Closed)
(2) Cause
Insufficient brake oil, wire break-
age, faulty indication, faulty logic
card.

Check oil level in brake oil


(3) Inspection reservoir tank.

Brake
fluid
switch
207698

4-8
TROUBLESHOOTING FOR CONTROL CIRCUITS

Oil level higher than LOW mark Oil level lower than LOW mark
(4) Disconnect battery plug. Disconnect level sensor connector CN10, and check continuity.
No continuity Continuity

(8) Replace level sensor.


(5) With connector CN10 disconnected, check continuity between harness connector socket wire

140L (blue) and NEG, and between 139O (orange) and controller CN2-32.
Continuity No continuity
(6) Faulty logic card

(7) Correct or replace wiring.

(9) Add brake oil.


Problem: Right Motor, Faulty Armature Circuit

(4) Inspect right motor armature wiring for (7) Check CS1 current sensor for abnormality.
wire open and/or short.
No open or Open or short-
shorted armature ed armature
winding winding

(5) Check T1R IGBT, D1R diode, D2 diode (8) Replace logic card.
and head capacitor for abnormality.
Acceptable Unacceptable

(6) Test drive board. (9) Correct or replace faulty components


(regeneration contactor, line contactor).

When T1R IGBT, D1R diode, D2 diode and head capacitor are normal, consult your lift truck
manufacturer because the Drive Board, H Bridge Card and CS1 current sensor may be abnormal.

207699

4-9
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “10” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “10” display. Vehicle operation disabled.

(2) Cause
Faulty right motor armature circuit, faulty line contactor, faulty regeneration contactor,

faulty D1R diode, faulty D2 diode, faulty right motor armature wiring, faulty head
capacitor, faulty T1R IGBT, faulty CS1 current sensor, faulty wiring in other parts, faulty
logic card, faulty drive board, faulty H bridge card.
(3) Inspection

Disconnect battery plug. Inspect line


and regeneration contactor tips for wire
breakage and melting. Make sure each

contactor tips moves freely.


No broken or shorted wire motors) disabled.
Broken or shorted

wire
Problem: Right Motor, Transistor Open

Indication: “11” display. Vehicle


operation (drive and pump (1) Situation

207700

4-10
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “11” display. Vehicle operation disabled.

(2) Cause

Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty
wiring.

(3) Check T1R for abnormality.


Acceptable Unacceptable

(4) Test drive board.

Acceptable Unacceptable
(8) Replace drive board.
(5) Check CS1 for abnormality. (7) Replace CS1 current sensor.

Acceptable Unacceptable
Problem: Right Motor, Shorted
(6) Replace logic card.

(9) Replace faulty com-


ponent. (TIR) Transistor

207700

4-11
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “12” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation

Indication: “12” display. Vehicle operation disabled.


(2) Cause
Shorting in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.
(3) Check T1R for abnormality.

Acceptable Unacceptable

(4) Test drive board.

Acceptable Unacceptable

(5) Check CS1 current sensor for abnormality.


Acceptable Unacceptable

(6) Replace logic card.


(9) Replace faulty component (T1R).

(8) Replace drive board.


(7) Replace CS1 current sensor.

Indication: “13” display. Vehicle opera-

Problem: Right Motor, Faulty Transistor Drive

207700

4-12
TROUBLESHOOTING FOR CONTROL CIRCUITS

tion (drive and pump motors) disabled.

(1) Situation

Indication: “13” display. Vehicle operation disabled.

(2) Cause

Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty
wiring.
(3) Inspection

Disconnect battery plug.


Check T1R for abnormality.
Acceptable Unacceptable

(4) Test drive board.


Acceptable Unacceptable (5) Check CS1 current sensor for abnormal-

207701

4-13
TROUBLESHOOTING FOR CONTROL CIRCUITS

ity.
Acceptable Unacceptable

(6) Replace logic card.


(7) Replace CS1 current sensor.
(9) Replace faulty component (T1R).

(8) Replace drive board.


Problem: Right Motor, Faulty Current Sensor

Indication: “14” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “14” display. Vehicle operation disabled.

(2) Cause

Faulty CS1 current sensor, faulty wiring,


faulty logic card. Unacceptable

(4) Replace logic card.

(3) Inspection

Test CS1 current sensor.


Acceptable

207700

4-14
TROUBLESHOOTING FOR CONTROL CIRCUITS

(5) Replace CS1 current sensor.

Problem: Right Motor, Armature Over-current

Indication: “15” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation
Indication: “15” display. Vehicle operation disabled.

(2) Cause

Faulty CS1 current sensor, faulty wiring, faulty logic card.

(3) Inspection
Disconnect battery plug. Inspect regen and line contactor for welded tips. Make sure each

contactor tips moves freely. Unacceptable


No shorted wire (5) Replace output T1R IGBT.
Shorted wire (6) If replacement of output IGBT does not
correct problem, replace logic card.

sor.
(4) Test CS1 current sen- Acceptable

207701

4-15
TROUBLESHOOTING FOR CONTROL CIRCUITS

(8) Correct or replace faulty contactors.

(7) Replace CS1 current sensor.

Problem: Right Motor, Stall Timer

Indication: “16” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “16” display. Vehicle operation disabled.

(2) Cause
Stall current flowed more than set time in right drive motor. Faulty CS1 current sensor,
faulty wiring, faulty logic card.

Check to see if vehicle is operated on steep


(3) Inspection

H bridge
card

207702

4-16
TROUBLESHOOTING FOR CONTROL CIRCUITS

upgrade or to pull large cargo load when motor stalls.


Operated under normal condition Operated under heavy load
(4) Test CS1 current sensor.

Acceptable Unacceptable

(5) Replace logic card.

(6) Replace CS1 current sensor.

(7) Do not operate vehicle for more than set time under a condition that causes the motor to
stall.

Problem: Right Motor, Faulty Field Circuit

Indication: “17” display. Vehicle operation disabled. (7) Replace H bridge card.

(1) Situation

Indication: “17” dis- tion disabled.


play. Vehicle opera-

H bridge
card

207702

4-17
TROUBLESHOOTING FOR CONTROL CIRCUITS

(2) Cause
Faulty right motor field circuit (wire breakage, shorting), faulty logic card.

(3) Inspection

Disconnect battery plug.


Check H bridge card for abnormality.
Acceptable Unacceptable

(4) Replace logic card.

(5) Replace H bridge card.

(3) Inspection
Disconnect battery plug.
Check H bridge card for abnormality.
Acceptable Unacceptable

(4) Check right motor field wiring for short- (7) Replace H bridge card.
ing.
Shorted fields No shorted fields

(5) Replace right (6) Replace logic card.


motor field wiring.

H bridge
card

207702

4-18
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Right Motor, Faulty Field Drive

Indication: “18” display. Vehicle operation disabled.

(1) Situation
Indication: “18” display. Vehicle operation disabled.

(2) Cause
Faulty right motor field circuit, faulty logic card.

(3) Inspection
Disconnect battery plug.

Check to see if there is shorting near H bridge heat sink.


Acceptable Unacceptable
(4) Check H bridge card for abnormality.
Acceptable Unacceptable

logic card.
(5) Replace logic card.
card.
(6) Replace H bridge Problem: Right

Motor, Field Over-current Problem: Left Motor, Faulty Armature


Circuit
Indication: “19” display. Vehicle opera-

tion disabled.
Indication: “20” display. Vehicle opera-

(1) Situation tion (drive and pump motors) disabled.


Indication: “19” display. Vehicle

operation disabled. (1) Situation

(2) Cause

Faulty right motor field circuit, faulty Indication: “20” display. Vehicle opera-

4-19
TROUBLESHOOTING FOR CONTROL CIRCUITS

tion disabled.

(2) Cause
Faulty left motor armature circuit, faulty line contactor, faulty regeneration contactor, faulty D1L

diode, faulty D2 diode, faulty left motor armature wiring, faulty head capacitor, faulty T1L
IGBT, faulty CS2 current sensor, faulty wiring in other parts, faulty logic card, faulty drive
board, faulty H bridge card.

(3) Inspection
Disconnect battery plug. Inspect line and regeneration contactor tips for wire breakage and
melting. Make sure each contactor tips moves freely.

No broken or shorted wire


Broken or shorted wire
(4) Inspect left motor armature wiring for

wire breakage and shorting. Acceptable Unacceptable


No broken or shorted armature Broken (7) Test H bridge card.
or shorted armature

(5) Check T1L IGBT, D1L diode, D2 diode Acceptable Unacceptable


and head capacitor for abnormality. (8) Check CS2 current sensor for abnormality.
Acceptable Unacceptable

(6) Test drive board.


Acceptable Unacceptable

207703

4-20
TROUBLESHOOTING FOR CONTROL CIRCUITS

(9) Replace logic card.


(15) Correct or replace faulty components (regeneration contactor, line contactor).
(14) Correct or replace left motor, or correct or replace wiring.
(13) Replace faulty components (T1L, D1L, D2, head capacitor).

(12) Replace drive board.


(11) Replace H bridge card.
(10) Replace CS2 current sensor.

(2) Cause
Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty
wiring.

(3) Check T1L for abnormality.


Acceptable Unacceptable

(4) Test drive board.


Acceptable Unacceptable Indication: “21” display. Vehicle opera-
tion (drive and pump motors) disabled.

(5) Check CS2 current sensor for abnormality.


Acceptable Unacceptable (1) Situation

Problem: Left Motor, Transistor Open (7) Replace CS2 current sensor.

207703

4-21
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “21” display. Vehicle operation disabled.

(2) Cause
Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

(3) Check T1L for abnormality.


Acceptable Unacceptable

(4) Test drive motor drive board.


Acceptable Unacceptable

(5) Check CS2 current sensor for abnormality.


Acceptable Unacceptable

(6) Replace logic card.


(9) Replace faulty component (T1L).

abled.
(8) Replace drive motor drive board.

(7) Replace CS2 current sensor.

Problem: Left Motor, Shorted Transistor


(1) Situation

play. Vehicle operation


Indication: “22” dis- (drive and pump motors) dis-

207703

4-22
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “22” display. Vehicle operation disabled.

(6) Replace logic card.

(9) Replace faulty component (T1L).

(8) Replace drive board.

Problem: Left Motor, Faulty Transistor Drive

Indication: “23” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation
Indication: “23” display. Vehicle operation disabled.

Wire break in T1L, faulty


(2) Cause drive board, faulty CS2 cur-

CS2

207701

4-23
TROUBLESHOOTING FOR CONTROL CIRCUITS

rent sensor, faulty logic card, faulty wiring.

(3) Inspection
Disconnect battery plug.

Check T1L for abnormality.


Acceptable Unacceptable

(4) Test drive board.

Acceptable Unacceptable

(5) Check CS2 current sensor for abnormality.


Acceptable Unacceptable

(6) Replace logic card.

(8) Replace drive board.


Problem: Left Motor, Faulty Current Sensor

(7) Replace CS2 current sensor.

(9) Replace faulty component (T1L).

207703

4-24
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “24” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation

Indication: “24” display. Vehicle operation disabled.

(2) Cause
Faulty CS2 current sensor, faulty wiring, faulty logic card.

(3) Inspection
Test CS2 current sensor.
Acceptable Unacceptable

(4) Replace logic card.


Problem: Left Motor, Armature Over-cur-
rent

(5) Replace CS2 current sensor.

CS2

207701

4-25
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “25” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation
Indication: “25” display. Vehicle operation disabled.

(2) Cause
Faulty CS2 current sensor, faulty wiring, faulty logic card.
(3) Inspection

Disconnect battery plug. Inspect Regen and line contactor for welded tips. Make sure
contactor tips moves freely.
No shorted wire Shorted wire

(4) Test CS2 current sensor.


Acceptable Unacceptable
(5) Replace output T1L IGBT.
(6) If replacement of output IGBT does not correct problem, replace logic card.

(7) Replace CS2 current sensor.


(8) Correct or replace faulty contactors.

H bridge
card

207702

4-26
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Left Motor, Stall Timer

Indication: “26” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation

Indication: “26” display. Vehicle operation disabled.


(2) Cause
Stall current flowed more than set time in left drive motor. Faulty CS2 current sensor, faulty

(3) Inspection
Disconnect battery plug.
Check to see if there is shorting near H bridge heat sink.
Acceptable Unacceptable

(4) Check H bridge card for abnormality. (7) Replace H bridge card.
Acceptable Unacceptable

(5) Replace logic card. (6) Replace H bridge card.

H bridge
card

207702

4-27
TROUBLESHOOTING FOR CONTROL CIRCUITS

wiring, faulty logic card.


(3) Inspection
Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
Operated under normal condition Operated under heavy load

(4) Test CS2 current sensor.


Acceptable Unacceptable
(5) Replace logic card.

(6) Replace CS2 current sensor.


(7) Do not operate vehicle for more than set time under a condition that causes motor to stall.

(3) Inspection
Disconnect battery plug.
Check H bridge card for abnormality.
Acceptable Unacceptable

(4) Check left motor field wiring for shorting. (7) Replace H bridge card.
Shorted fields No shorted fields

(5) Correct or replace left (6) Replace logic card.


motor field wiring.

H bridge
card

207702

4-28
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Left Motor, Faulty Field Circuit

Indication: “27” display. Vehicle operation disabled.

(1) Situation

Indication: “27” display. Vehicle operation disabled.

(2) Cause
Faulty left motor field circuit (wire breakage, shorting) faulty logic card.

(3) Inspection
Disconnect battery plug.
Check H bridge card for abnormality.
Acceptable Unacceptable
(4) Replace logic card.

(5) Replace H bridge card. Problem: Left Motor, Field Over-current


Motor, Faulty
Problem: Left Field Drive

Indication: “28” display. Vehicle opera- Indication: “29” display. Vehicle oper-
tion disabled.

(1) Situation ation disabled.


Indication: “28” display. Vehicle opera-

(1) Situation
tion disabled.
Indication: “29” display. Vehicle opera-
(2) Cause
tion disabled.

Faulty left cuit, faulty logic


motor field cir- card.

207704

4-29
TROUBLESHOOTING FOR CONTROL CIRCUITS

(2) Cause
Faulty left motor field circuit, faulty logic card.
Problem: Pump Motor, Faulty Circuit

Indication: “30” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation

Indication: “30” display. Vehicle operation disabled.

(2) Cause
Faulty pump motor circuit, faulty line contactor, faulty D1P diode, faulty pump motor

wiring, faulty head capacitor, faulty T1P


IGBT, faulty CS3 current sensor, faulty
wiring in other parts, faulty logic card,
faulty drive board.

(3) Inspection (4) Inspect pump motor wiring for open


Disconnect battery plug. Inspect line and

regeneration contactor tips for wire fields or armature.


breakage and melting. Make sure each No open or short in motor
contactor tips moves freely.

No broken or shorted Broken or


wire shorted wire

CS3

T1P

207703

4-30
TROUBLESHOOTING FOR CONTROL CIRCUITS

Open or short in motor.


(5) Check T1P IGBT, D1P diode and head capacitor for abnormality.
Acceptable Unacceptable
(6) Test drive board.

Acceptable Unacceptable
(7) Check CS3 current sensor for abnormality.
Acceptable Unacceptable

(8) Replace logic card.


(9) Replace CS3
current sensor.

(3) Inspection
Check T1P for abnormality.
Acceptable Unacceptable

(4) Test drive board. (13) Correct or replace faulty component (line
Acceptable Unacceptable contactor).

(5) Check CS3 current sensor for abnormality. (8) Replace drive board.
Acceptable Unacceptable

(6) Replace logic card. (7) Replace CS3 current sensor.

CS3

T1P

207703

4-31
TROUBLESHOOTING FOR CONTROL CIRCUITS

(12) Correct or replace right motor, or correct or replace wiring.


(11) Replace faulty components (T1P, D1P, head capacitor).
(10) Replace drive board.

See Inspection and Adjustment section


page 3-46

(2) Cause
Wire breakage in T1P, faulty drive board, faulty CS3 current sensor, faulty logic card, faulty
wiring.

(3) Inspection
Check T1P for abnormality.
Acceptable Unacceptable

(4) Test drive board. (9) Replace faulty component (T1P).


Acceptable Unacceptable

Problem: Pump Motor, Transistor Open (8) Replace drive board.

(6) Replace logic card. (7) Replace CS3 current sensor.

CS3

T1P

207703

4-32
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “31” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation
Indication: “31” display. Vehicle operation disabled.

(2) Cause
Wire breakage in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic

card.

(3) Inspection

Check T1P for abnormality.


Acceptable Unacceptable

(4) Test drive board.

Acceptable Unacceptable (5) Check CS3 current sensor for abnormality.


Acceptable Unacceptable

CS3

207701

4-33
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor, Armature Over-current

Indication: “35” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation
Indication: “35” display. Vehicle operation disabled.

(2) Cause
Faulty CS3 current sensor, faulty wiring, faulty logic card.

(3) Inspection
Disconnect battery plug. Inspect line contactor for welded tips. Make sure contactor tips
moves freely.
No shorted wire Shorted wire

(4) Test CS3 current sensor. (8) Correct or replace faulty contactors.
Acceptable Unacceptable

(5) Replace output T1P IGBT. (7) Replace CS3 current sensor.

(6) If replacement of output IGBT does not


correct problem, replace logic card.

CS3

T1P

207703

4-34
TROUBLESHOOTING FOR CONTROL CIRCUITS

(6) Replace logic card.

(7) Replace CS3 current sensor.

(9) Replace faulty component (T1P).

(8) Replace drive board.

Problem: Pump Motor, Shorted Transistor

Indication: “32” display. Vehicle motors) disabled.


operation (drive and pump
(1) Situation

Line
contactor
207705

4-35
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “32” display. Vehicle operation disabled.

(2) Cause
Shorting in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic card.

(9) Replace faulty component (T1P).

Problem: Pump Motor, Faulty Transistor Drive

Indication: “33” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “33” display. Vehicle operation disabled.
(5) Test CS3 current sensor.

Acceptable Unacceptable Current Sensor


Problem: Pump Motor, Faulty
Indication: “34” display. Vehicle opera-

REGEN
CTR

207706

4-36
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Contactor, Abnormality

Indication: “42” display. Vehicle operation disabled.

(1) Situation
Indication: “42” display. Vehicle operation disabled.

(2) Cause
Faulty pump contactor (wire breakage, shorting), faulty logic card.

(3) Inspection
Disconnect battery plug. Check pump contactor tip for wire breakage and shorting
(melting). Check that contactor tip moves freely.
No broken or shorted wire Broken or shorted wire

(4) Replace logic card. (5) Correct or replace faulty component


(pump contactor).

Pump
contactor

207706

4-37
TROUBLESHOOTING FOR CONTROL CIRCUITS

tion (drive and pump motors) disabled.

(1) Situation

Indication: “34” display. Vehicle operation disabled.

(2) Cause
Faulty CS3 current sensor, faulty wiring, faulty logic card.

(3) Inspection
Test CS3 current sensor.

(4) Check CS1 and CS2 current sensors for (7) Replace faulty component (D2).
abnormality.
Acceptable Unacceptable

Acceptable (6) Replace CS1 and/or CS2


current sensors.

207707

4-38
TROUBLESHOOTING FOR CONTROL CIRCUITS

Unacceptable

(4) Replace logic card.

(5) Replace CS3 current sensor.

Problem: Line Contactor, Abnormality

Indication: “40” display. Vehicle operation disabled.


(1) Situation

Indication: “40” display. Vehicle operation disabled.


(2) Cause
Faulty line contactor (wire breakage, shorting), faulty logic card.

(3) Inspection No broken or shorted wire


Disconnect battery plug. Check line con- Broken or shorted wire
tactor tip for wire breakage and shorting

(melting). Check moves freely.


that contactor tip

207708

4-39
TROUBLESHOOTING FOR CONTROL CIRCUITS

(4) Replace logic card.

(5) Correct or replace faulty component (line contactor).

Problem: Regeneration Contactor, Abnormality

Indication: “41” display. Vehicle operation disabled.

(1) Situation
Indication: “41” display. Vehicle operation disabled.

(4) Check CS2 current sensor for abnormality (7) Replace faulty component (D1L).
Acceptable Unacceptable

(5) Replace logic card. (6) Replace CS2 current sensor.

207709

4-40
TROUBLESHOOTING FOR CONTROL CIRCUITS

(2) Cause
Faulty regeneration contactor (wire breakage, shorting), faulty logic card.
(3) Inspection
Disconnect battery plug. Check regeneration contactor tip for wire breakage and shorting (melt-

ing). Check that contactor tip moves freely.


No broken or shorted wire Broken or shorted wire

(4) Replace logic card.

(5) Correct or replace faulty component (regeneration contactor).

Problem: Regeneration Diode, Abnormality

(4) Check CS3 current sensor for abnormality (7) Replace faulty component (D1P).
Acceptable Unacceptable

(5) Replace logic card. (6) Replace CS3 current sensor.

D1P

CS3

207709

4-41
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “43” display. Vehicle operation disabled.


(1) Situation

Indication: “43” display. Vehicle operation disabled.


(2) Cause

Faulty regeneration diode (wire breakage, shorting), faulty CS1/CS2 current sensors, faulty
logic card.

(3) Disconnect battery plug. Check D2 regeneration diode for abnormality.


Acceptable Unacceptable
(5) Replace logic card.

Problem: Right Diode, Abnormality


(1) Situation

Indication: “44” dis- tion disabled.


play. Vehicle opera-

Drive
motor (R)

207710

4-42
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “44” display. Vehicle operation disabled.

(2) Cause
Faulty right diode (wire breakage, shorting), faulty CS1 current sensor, faulty logic card.

(3) Inspection

Disconnect battery plug. Check right diode D1R for abnormality.


Acceptable Unacceptable

(3) Inspection
Disconnect controller terminals A1L, A2L and field wiring connector (4 pins), and measure
resistance between A1L and A2L and between S1L and S2L.
Continuity High resistance

(4) Check CS2 current sensor for abnormality (7) Replace left motor, or correct or replace
Acceptable Unacceptable left motor wiring.

(5) Replace logic card. (6) Replace CS2 current sensor.

Drive
motor (L)

207711

4-43
TROUBLESHOOTING FOR CONTROL CIRCUITS

(4) Check CS1 current sensor for abnormality


Acceptable Unacceptable

(5) Replace logic card.

(6) Replace CS1 current sensor.


(7) Replace faulty component (D1R).

Problem: Left Diode, Abnormality

Indication: “45” display. Vehicle operation disabled.

(1) Situation
Indication: “45” display. Vehicle operation disabled.

(4) Check CS3 current sensor for abnormality (2) Cause


Acceptable Unacceptable Faulty left diode (wire breakage, short-

(5) Replace logic card. (6) Replace CS3 current sensor.

Pump
fuse
Pump motor

207712

4-44
TROUBLESHOOTING FOR CONTROL CIRCUITS

ing), faulty CS2 current sensor, faulty logic card.


(3) Inspection
Disconnect battery plug. Check left diode D1L for abnormality.
Acceptable Unacceptable

Problem: Pump Diode, Abnormality

Indication: “46” display. Vehicle operation disabled.

(1) Situation
Indication: “46” display. Vehicle operation disabled.
(2) Cause
Faulty pump diode (wire breakage, shorting), faulty CS3 current sensor, faulty logic card.
(3) Inspection
Disconnect battery plug. Check pump diode D1P for abnormality.
Acceptable Unacceptable
Problem: Right Motor, Open

Indication: “47” display. Vehicle operation disabled.

(1) Situation logic card.


Indication: “47” display. Vehicle oper- (3) Inspection
ation disabled.

(2) Cause Wire breakage in right motor,


faulty CS1 current sensor, faulty

207713

Wheel angle
sensor

4-45
TROUBLESHOOTING FOR CONTROL CIRCUITS
Disconnect controller terminals A1R, A2R and field wiring connector (4
pins), and measure resistance between A1R and A2R and between S1R
and S2R.
Continuity High Resistance

(4) Check CS1 current sensor for abnormality


Acceptable Unacceptable

(5) Replace logic card.

(6) Replace CS1 current sensor.


(7) Replace right motor, or correct or repair right motor wiring.
Problem: Left Motor, Open

Indication: “48” display. Vehicle operation disabled.

(1) Situation
Indication: “48” display. Vehicle operation disabled.

(2) Cause Wire breakage in pump motor, faulty CS3


Wire breakage in left motor, faulty CS2
current sensor, faulty logic card.
Problem: Pump Motor, Open

play. Vehicle operation disabled.


Indication: “49” dis-
(1) Situation
Indication: “49” display. Vehicle operation dis-

abled.
(2) Cause

Accelerator
control switch

207714

4-46
TROUBLESHOOTING FOR CONTROL CIRCUITS

current sensor, faulty logic card.


(3) Inspection
Disconnect battery plug. Disconnect controller terminals PA1 and PS2, and measure resistance
between terminals.

Continuity High resistance

(7) Replace pump motor, or correct or replace pump motor wiring.

Problem: Steering Sensor, Abnormality

Indication: “50” display. Vehicle operation (drive and pump motors) disabled.

(1) Situation
Indication: “50” display. Vehicle operation disabled.

(2) Cause

Faulty steering sensor, faulty wiring


(wire breakage, shorting), faulty logic

card.
(3) Inspection
Check continuity between steering sensor and logic card.
CN12-117L (blue) - CN1-13L (blue)
CN12-116Y (yellow) - CN1-12Y (yellow)
CN12-115W (white) - CN1-11W (white)

CN12-114G (green) - CN1-10G (green) CN12-112R (red) - CN1-1R (red)


CN12-113B (black) - NEG

Speed
sensor
Right

207715

4-47
TROUBLESHOOTING FOR CONTROL CIRCUITS

Continuity No continuity

(4) Check steering sensor with self-diagnostics


Acceptable Unacceptable
(5) Replace logic card.
(6) Replace steering sensor.

(7) Correct or replace wiring.

Problem: Accelerator, Abnormality

Indication: “51” display. Faulty accelerator circuit.

(1) Situation
Indication: “51” display. Faulty acceler-

ator circuit.
(2) Cause
Faulty accelerator, faulty wiring (wire breakage, shorting), faulty logic card.
(3) Inspection
Check continuity and shorting between accelerator socket and logic card.

(5) Faulty logic card (6) Correct or replace wiring.

Speed
sensor
Left

207716

4-48
TROUBLESHOOTING FOR CONTROL CIRCUITS

CN7-141R - Logic card CN3-39R


CN7-142G - CN2-33G
CN7-143B - CN2-37L
CN7-144L - CN1-14L

Conduction No conduction

(4) Check voltage without pressing accelerator pedal and while pressing accelerator pedal

fully.
Acceptable Unacceptable
(5) Replace logic card.

(6) Check accelerator return adjustment and interference.

Properly adjusted Adjustment necessary

(7) Replace accelerator.


(8) Adjust accelerator linkage per instructions page 3 -46.

(9) Correct or replace wiring. motors inoperable.


Problem: Right Vehicle Speed Sensor, normal power steering operation
Abnormality (1) Situation
Indication: “52” display. Drive and
pump motors inoperable.

Indication: “52” display. Faulty right


speed sensor circuit. Drive and pump

Forward/Reverse
lever assembly Accelerator pedal

Accelerator
control
switch

207718

4-49
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Seat Switch, Faulty Setting

Indication: Flashing “E” display. Vehicle operation disabled.

(1) Situation
Indication: Flashing “E” display. Vehicle operation disabled.

(2) Cause
Operator not in seat. Faulty seat switch (option), wire breakage, faulty logic card. Open
circuit in seat switch.

(3) Inspection
Disconnect battery plug. Remove logic card cover. Disconnect connector CN1. Check
continuity between harness connector CN1-9Y (yellow) and CN1-22G (green). Circuit
must close when seat is pressed, and must open when no force is applied on seat.
No continuity Acceptable

(4) With seat pressed, check continuity (9) Faulty logic card
between seat switch wires 356-Y (yellow)
and 351-G (green) on switch side.
Continuity No continuity

(8) Faulty seat switch


(Faulty connector
contact)
Seat switch
(5) Check continuity between seat switch
harness 356-Y (yellow) and logic card
CN1-9Y (yellow), and between 351-G
(green) and CN1-22G (green).
Continuity No continuity

(6) Faulty logic card (7) Correct or replace wiring.

207719

4-50
TROUBLESHOOTING FOR CONTROL CIRCUITS

(2) Cause
Faulty right speed sensor, faulty right speed sensor wiring (wire breakage, shorting), faulty logic

card.

(3) Inspection

Check resistance between CN16-145Y (yellow) and CN16-146B (black) of right speed sensor.
Acceptable (1.8 - 2.2 kW) Unacceptable

(7) Replace right speed sensor.

(4) Remove logic card cover.

Check continuity between following


terminals and shorting to negative (-)
side.

CN16-145Y - CN11-145Y - Logic card


CN3-43Y (yellow)
CN16-146B - CN11-146B - Logic card

CN3-45B (black)
Continuity, no short to negative
No continuity, or
shorted to negative

Lift

207720

4-51
TROUBLESHOOTING FOR CONTROL CIRCUITS

(5) Faulty logic card


(6) Correct or replace wiring.

Problem: Left Vehicle Speed Sensor, Abnormality

Indication: “53” display. Faulty left speed sensor circuit. Drive and pump motors inopera-
ble. Normal Power Steering Operation.

(1) Situation
Indication: “53” display. Drive and pump motors inoperable.
(2) Cause

(4) Check tilt switch, wiring to logics, and


adjustment of switches.

(5) If faulty component cannot be located,


replace logic card.

Faulty left speed sensor, faulty left speed


sensor wiring (wire breakage, shorting),
faulty logic card.
(3) Inspection

Tilt

207721

4-52
TROUBLESHOOTING FOR CONTROL CIRCUITS

Check resistance between CN15-147L (blue) and CN15-148G (green) of left speed sensor.
Acceptable (1.8 - 2.2 kW) Unacceptable
(7) Replace left speed sensor.

(4) Remove logic card cover.


Check continuity between following terminals and shorting to negative (-) side.

CN15-147L - CN11-147L - Logic card CN3-47L (blue)


CN15-148G - CN11-148G - Logic card CN3-49G (green)
Continuity, no short to negative No continuity, or shorted to negative

Problem: Forward/reverse Lever and Accelerator, Faulty Setting

(4) Check AUX1 switch, wiring to logics,


and adjustments or switch.

(5) If faulty component cannot be located,


replace logic card.

Indication: “E” display. Vehicle travel-


ing operation disabled.

ATT1

207722

4-53
TROUBLESHOOTING FOR CONTROL CIRCUITS

(1) Situation
Indication: “E” display. Vehicle traveling operation disabled.

(2) Cause

Key switch turned on while forward/reverse lever was left either in forward or reverse
position. Key switch turned on while accelerator pedal was depressed. Faulty
forward/reverse lever switch, faulty accelerator, faulty logic card.

(3) Move forward/reverse lever to neutral, and release accelerator pedal.


Select direction of move again, and press accelerator.

No change Vehicle operates

(4) Check AUX2 switch, wiring to logics,


and adjustments or switch.

(5) If faulty component cannot be located,


replace logic card.

(4) Use self-diagnosis function to locate


faulty circuit or component.

(5) If faulty component cannot be located,

ATT2

207723

4-54
TROUBLESHOOTING FOR CONTROL CIRCUITS

replace logic card.

(6) Proper starting procedure requires that forward/reverse lever be in neutral position and accelerator
pedal be in OFF position when key switch is turned on.

Problem: Lift Lever, Faulty Setting

Indication: “H1” display. Hydraulic system operations disabled.


(1) Situation
Indication: “H1” display. Hydraulic system operations disabled.

(2) Cause
Key switch turned on while lift lever was in ON position. Faulty lift lever switch, faulty
logic card.
3) Set lift lever to OFF, then to ON again.

No change logics, and adjustment of switches.


Hydraulic system oper-
ates

(4) Check both lift switches, wiring to

Display

207724

4-55
TROUBLESHOOTING FOR CONTROL CIRCUITS

(5) If faulty component cannot be located, replace logic card.

(6) Proper starting procedure requires that lift lever be in OFF position when key switch is turned on.

Problem: Tilt Lever, Faulty Setting

Indication: “H2” display. Tilt operation disabled.

(1) Situation
Indication: “H2” display. Tilt operation disabled.

(2) Cause
Key switch turned on while tilt lever was in ON position. Faulty tilt lever switch, faulty logic
card.
(3) Set tilt lever to OFF, then to ON again.
No change Tilt function operates

tilt lever be in OFF position when key


(6) Proper starting procedure requires that switch is turned on.

4-56
TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Attach 1 Lever, Faulty Setting

Indication: “H3” display. AUX1 operation disabled.

(1) Situation
Indication: “H3” display. AUX1 operation disabled.

(2) Cause
Key switch turned on while AUX1 lever was in ON position. Faulty AUX1 lever switch,

faulty logic card.


(3) Set AUX1 lever to OFF, then to ON again.

No change
Aux1 function
operates

207725

4-57
TROUBLESHOOTING FOR CONTROL CIRCUITS

(6) Proper starting procedure requires that AUX1 lever be in OFF position when key switch is turned
on.
Problem: Attach 2 Lever, Faulty Setting

Indication: “H4” display. Aux2 operation disabled.

(1) Situation

Indication: “H4” display. Aux2 operation disabled.

(2) Cause
Key switch turned on while Aux2 lever was in ON position. Faulty Aux2 lever switch,

faulty logic card.


(3) Set AUX2 lever to OFF, then to ON again.
No change AUX2 function operates
(6) Proper starting procedure requires that AUX2 lever be in OFF position when key switch is

turned on. Problem: Data Communication,


Abnormality

207726

4-58
TROUBLESHOOTING FOR CONTROL CIRCUITS

Indication: “60” display. Vehicle (drive and pump motors) operate.

(1) Situation
Indication: “60” display. Vehicle operates.

(2) Cause
Faulty display, faulty wiring, faulty logic card.

(3) Inspection
Disconnect battery plug. Check continuity between display CN4-149W (white) and logic
card CN3-59W (white), and between CN4-150B (black) and CN3-61B (black).

Continuity No continuity

(4) Inspect display.


Acceptable Unacceptable

(5) Replace logic card.


(6) Replace display. Indication: “61” display. Vehicle
(7) Correct or replace wiring. operation disabled.

Problem: EEPROM, Abnormality

Line
contactor

207727

4-59
TROUBLESHOOTING FOR CONTROL CIRCUITS

(1) Situation
Indication: “61” display. Vehicles operation disabled.

(2) Cause
Faulty EEPROM.

(3) Inspection
Conduct initial adjustment of controller. (Perform default procedure on Page 3-22 Item #4)

“61” display remains Normal vehicle operation

(4) Replace logic card.

(4) Adjust battery discharge indicator (BDI) (5) Vehicle operates normally.
according to specification.
See Page 3-21 Item 12-2. Problem: Logic Card, Faulty Initial Setting
If BDI cannot be adjusted, replace logic
card.

Line
contactor

207727

4-60
POWER TRAIN

Procedures and Key Points for Removal and Installation .......................................................... 5 - 1


Removal .............................................................................................................................. 5 - 1
Installation .......................................................................................................................... 5 - 7

Service Data ................................................................................................................................ 5 - 9

5
POWER TRAIN

Procedures and Key Points for Removal and Installation


Removal
1. Remove the masts.
(Refer to Masts section.)
2. Removing batteries
(1) Disconnect the battery plug.
(2) Open the battery cover, and lock it in the
open position.
(3) Remove the side covers (L.H., R.H.) and
front covers (L.H., R.H.).

Lock / Unlock lever

102658

(4) Attach suspending ropes or adequate


lifting device to the batteries.

Battery weight EP16KT EP18KT, EP20KT


kg (lb) 1000 1225
(maximum) (2200) (2695)

(5) Remove the battery retaining plate and pin


and remove the batteries.
206918

3. Removing front wheels


(1) Place wheel stoppers at the rear wheels.
(2) Loosen the wheel nuts of the front wheels
by approximately one turn.
(3) Lift the vehicle with jacks or a crane so
wheels are off the ground. As a safety
measure, place wood blocks under the
frame on the front right and left sides, then
lower the jacks.
(4) Remove the front wheel nuts. 206919
(5) Remove the front wheels.

5-1
POWER TRAIN

Front wheels
1-ton class Solid Pneumatic tire Solid tire
18 ¥ 7.8
Tire size 2-ton class
200/50·10

206920

4. Removing steps and floor plate


(1) Steps (L.H., R.H.)
(3)
(2) Step plates (L.H., R.H.) Floor plate B
(3) Floor plate
(1)
Remove floor plate B.
(1) (2)
Disconnect the accelerator connector
mounted on the back side of the floor Floor plate A
plate, then remove floor plate A.

206921 (2)

5. Removing steering hoses


Disconnect the steering hoses and pipes at the
connectors.

206922

5-2
POWER TRAIN

6. Removing delivery pipe and traction motor


harness
(1) Remove the traction motor harness at the
Delivery pipe
connector.
Disconnect the harnesses of the brush
wear sensors and temperature sensors
located on the right and left sides. ·
(2) The harnesses are secured to the delivery
pipe with clamps. Loosen the clamps, and
remove the delivery pipe.
206880

7. Removing brake components

(ii) (i)

(iii)

(v)

(iv)

(vi)

206824

(1) Loosen the parking brake lever, and


remove parking brake cable assemblies (i)
(L.H.) and (ii) (R.H.).
Disconnect the parking brake cables at the
calipers, and keep the cables together on
the frame near the center brake.

5-3
POWER TRAIN

(2) Position an oil receiving pan, and disconnect


brake fluid tube (iii) at the master cylinder.
(3) Disconnect brake pipes (iv, v) (L.H., R.H.)
at the master cylinder. Disconnect the
branch brake hoses (L.H., R.H.) from the
brake pipes.
(4) Remove brake pedal assembly (vi).
8. Removing return hoses
Remove return hose (1) from the control valve, (1)
and return hose (2) from the lift cylinder.

(2)

206925

9. Remove cables of traction motors (L.H., R.H.).


Remove the generators (speed sensors) of the
transfers (L.H., R.H.).
10. Removing tension rods and brackets
Loosen right and left nuts (1) by approximately
6 mm (0.24 in.). (3)
(3)
Remove bolts (2), and take out bracket (3) and
tension bolt (4) together from each side of the (2)
(2)
vehicle. Right
Left transfer
transfer (4)

(1)
206926

5-4
POWER TRAIN

11. Removing transfer assemblies, traction motors


and calipers

Left Right
transfer transfer
(iii)
Gravity
center

(ii) (ii)

(i)
(i)

Frame

Frame (iv)

Gravity (iii)
(iv)
center
206927

Remove the transfer assemblies with the


traction motors and calipers mounted.
First, dismount the left transfer, lower it, then
pull it out from the front of the vehicle. Then, Cow hitch
dismount the right transfer, lower it, then pull
it out from the front.
(1) When suspending the assembly, position
the wire rope at the gravity center.
The suspending wire rope must be cow
hitched. 206928
When using a textile sling, make two
winds to prevent slipping.

5-5
POWER TRAIN

Total weight of transfer,


115 kg
traction motor and
(253.5 lb)
caliper

(2) Remove bolt (i) from the lower part of the


step and remove bolt (ii) from the front
wheel, then remove the assembly.
(3) Remove bolt (iii), and dismount the
caliper assembly.
(4) Remove bolt (iv) and dismount the
traction motor.
(See illustration No. 206927 on page 5-5.)

5-6
POWER TRAIN

Installation
Follow the removal sequence in reverse. For instal-
lation, follow the instructions below.

When mounting the transfer assembly on the


frame, do not insert a finger in a bolt hole to
check hole alignment.
1. Be sure to tighten bolts to the specified torque.

3 3

4 4

5
5
2
2

1
1 206785

Traction motor mounting bolt 1 A 108 ± 10 (11.0 ± 1.0) [79.5 ± 7.2]


Tightening
Transfer assembly mounting bolt 2 A 378 ± 38 (38.5 ± 3.9) [278.5 ± 28.2]
torque
N·m Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]
(kgf·m)
[lbf·ft] Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]
Hub nut 5 A 157 (16) [116]

2. Bleed the brake oil line.


(Refer to Brake System section.)

5-7
POWER TRAIN

3. After installing the parking brake cable, be


sure to adjust.
(Refer to Brake System section.)
4. Pour oil into the transfer cases:
Left transfer
Remove oil level plug (1).
Remove oil inlet plug (2). (2)
Pour appropriate oil in the oil inlet. Make sure
the oil level reaches the level plug location.
Left transfer Right transfer (1)

Oil quantity 1.09 1.86


l (U.S. gal) (0.29) (0.49)

Right transfer
(2)

(1)

206786

5. Bleeding hydraulic oil line and inspecting oil


level
Operate the tilt cylinders in the forward and
backward directions to bleed the tilt cylinders.
Operate the lift cylinders in the vertical
directions to fill the cylinders with oil.
Lower the lift cylinders to the lowest position,
and check the oil level gauge. If the oil level is
low, add oil to the specified level.
6. Checking steering oil line
Operate the steering wheel to make sure that it
operates smoothly.

5-8
POWER TRAIN

Service Data
A : Standard value
Allowable limit
Truck Models 1-ton class 2-ton class
Item
Traction motor mounting bolt 1 A 108 ± 10 (11.0 ± 1.0) [79.5 ± 7.2]
Tightening
Transfer assembly mounting bolt 2 A 378 ± 38 (38.5 ± 3.9) [278.5 ± 28.2]
torque
N·m Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]
(kgf·m)
[lbf·ft] Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]
Hub nut 5 A 157 (16) [116]

3 3

4 4

5 5

2
2
1
1

206785

5-9
MOTORS

Motor Installation Positions ...................................................................................................... 6 - 1

Specifications ............................................................................................................................ 6 - 1

Structures .................................................................................................................................. 6 - 2

Tightening of High-power Cable Terminals ............................................................................ 6 - 3

Inspection of Brushes for Wear and Brush Replacement ........................................................ 6 - 4

Procedures and Key Points for Removal and Installation ........................................................ 6 - 7

Procedures and Key Points for Disassembly and Assembly .................................................... 6 - 11

Troubleshooting ........................................................................................................................ 6 - 17
6
Service Data .............................................................................................................................. 6 - 18

Checks and Repairs .................................................................................................................. 6 -19


MOTORS

Motor Installation Positions

Electric power steering motor

Brake discs

Pump motor

Drive motor

Output shaft

206893

Specifications
Items Drive motor Pump motor EPS motor
Type DC separately excited DC series-wound DC permanent magnet type
self-ventilating type self-ventilating type
Voltage (V) 48 36 48 36 48 36
Output (kW) 4.5 4.5 11.5 — — —
Number of brushes 4
Weight kg (lb) 50 (110.2) 40 (88.2) 5 (11.0)

6-1
MOTORS
Structures
Drive motor

Key Bearing

Armature

Fan
Snap ring

Bearing bracket
Key Cover
Nut
Bearing
Bearing Washer
bracket
Brush
Brake disc
Brush wear sensor
Spring
Seal
Yoke
Snap ring Stud and nut
Connectors
Connectors
Brush holder
Field
Motor overheat sensor 206894

Pump motor

Nut
Washer
Screw
Plate Washer

Motor overheat
sensor Cable
Brush holder Armature
Cover
Key
Field
Retainer Brush Bearing bracket
Fan Bearing
Yoke Seal Screw
Bearing Washer
Spacer Bearing Retainer
bracket
Cover

Case

206895

6-2
MOTORS

Tightening of High-power Cable terminals


Drive motor (4 locations)

The high-power cable terminals of the


battery-operated vehicle are not tightened
properly, the increased contact resistance
causes excessive heat generation, and could
Pump motor (2 locations)
cause a fire in the worst case. To prevent
accidents and equipment problems, be sure to
regularly check the tightening torque of the
high-power cable terminals. Do not pull the
cables to check connections or during
adjustment. If the cable terminal sections are
moved, re-tighten the connections.

Terminals indicated by arrows : 6 locations


17.6 ± 1.9 N·m
Tightening torque (1.8 ± 0.2 kgf·m) 206897
[13 ± 1.4 lbf·ft]
Bolt size : M10

6-3
MOTORS

Inspection of Brushes for Wear and Brush


Replacement
Drive motors
(1) Park the vehicle over a pit.
(2) Disengage the catch, lift the battery cover, and
secure the cover in position by hooking the
lock/unlock lever.
Lock/unlock lever
NOTE
It is not necessary to remove the drive motor 102658
from the vehicle if the pit provides ample
space to work comfortably under the vehicle
for the inspection of the drive motor brushes.
But the batteries must be removed.

(3) Disconnect the battery plug, and remove the


batteries.
Disconnect the accelerator rod, and remove
the floor plate.
(4) Remove the front battery cover.
(5) Remove the drive motor cover.
(6) Disconnect wires. While pulling the curled
section of the spring by a hooked wire, remove 101895
each brush (eight in total) from the holder.

6-4
MOTORS

Replacement of pump motor brushes


(1) Disconnect the battery plug.
Remove the battery plate.

206994

(2) Disconnect wires from the terminals.


(3) Disconnect oil pump pipes.
On the suction side, loosen the hose clamp and
disconnect the hose from the pipe.
On the discharge side, disconnect the hose
from port P of the control valve.

206899

(4) Remove the mounting bolts of the motor


bracket.
(5) Remove the pump motor by using appropriate
lifting device.
(6) Remove the cover from the pump motor.
(7) Disconnect wires. While pulling the curled
section of the spring by a hooked wire, remove
each brush (eight in total) from the holder.
Replacement of EPS motor brushes
(1) Park the vehicle in a pit. 206002

6-5
MOTORS

(2) Disconnect the battery plug and accelerator


rod, then remove the floor plate.
(3) Remove the brush cover from the EPS motor.
(4) Disconnect wires. While pulling the curled
section of the spring by a hooked wire, remove
each brush (two in total) from the holder.

206994

6-6
MOTORS

Procedures and Key Points for Removal


and Installation
Drive motors
Removal
(1) Disconnect the battery plug.
(2) Using a crane, remove the head guard.

Head guard weight 1-ton class 70 kg


(154.3 lb) 206994
2-ton class

(3) Remove the battery retaining plate and pin,


and remove the batteries. Stopper pin
(4) Using a crane, remove the batteries.

101907
Stopper plate

(5) Disconnect the accelerator rod at the clip.


(6) Remove the floor plate.

101895

(7) Remove the battery adjustment plate and front


battery cover.

206900

6-7
MOTORS

(8) Disconnect the harnesses of the motor overheat


sensor and brush wear sensor.
(9) Disconnect the drive motor cables.
(10)Remove the brake caliper.
(11)Remove the bolt that secures the front axle on
the vehicle frame. With the drive motor still
mounted on the vehicle, remove the front axle
from the vehicle frame. Sensor
harnesses
Cable 206901

(12)Using a crane, lift the drive motor to suspend it.


NOTE
Position the hook above the gravitational
center of the drive motor.

206902

(13)Remove the bolts (4) that secure the drive


motor on the vehicle frame.
(14)Separate the transfer from the drive motor.

Installation
Follow the removal sequence in reverse.

6-8
MOTORS

Pump motor
Removal
(1) Disconnect the battery plug.

206994

(2) Remove the battery partition plate located


behind the batteries.

206903

(3) Disconnect motor cable 1 and the harnesses.

2 Motor overheat sensor harness


3 Brush wear sensor harness 3

206904

(4) Disconnect oil pump pipes.


(5) Remove the mounting bolts of pump motor
bracket.
(6) Remove the pump motor.

Installation
Follow the removal sequence in reverse.
206905

6-9
MOTORS

EPS motor
Removal
(1) Disconnect the battery plug.
(2) Remove the batteries.
(3) Disconnect the EPS motor harness at the
connector.
(4) Disconnect the piping (suction and delivery
pipes).
(5) Remove the EPS motor mounting bolts.
206994
NOTE
(a) The steering cylinder contains very soft
Grease GM grease No. 00
grease. If only the motor is removed,
grease flows out.
(b) If removal is difficult due to binding, use
a plastic hammer and tap the unit lightly.

Installation
Follow the removal sequence in reverse.
Before installing the EPS motor, replenish the
gear case with grease.

6-10
MOTORS

Procedures and Key Points for Disassembly and Assembly


Drive motor and pump motor
Disassembly
Drive motor 14
11

9 17
8 10 16
3

4
7
6 14
5

2
15

1 S2 (D2) A1

12
Output
side

S1 (D1) A2
Connected Connected
13 to motor to brush
overheat wear
indicator indicator

206909

1 Cover *7 Seal 14 Key


*2 Brush 8 Snap ring 15 Brake disc
3 Cover 9 Fan 16 Washer
4 Bearing bracket *10 Bearing 17 Nut
5 Snap ring 11 Armature
*6 Bearing 12 Support
13 Field
Preparation
(1) Before disassembly, prepare parts indicated by
an asterisk (*) above.
(2) Place a work table under the crane.
(3) Arrange the following tools.
Tester, spring scale, wires, eye bolt (for lifting
armature), wrenches (inch size), gear puller,
calipers, installer, sand paper (#600)

6-11
MOTORS

Pump motor

8
3
10

6 *5 9
*2

*7
4

S2 A1

Output side

Connected to motor overheat Connected to brush


indicator wear indicator
206910

1 Cover *5 Bearing 9 Support


*2 Brush 6 Fan 10 Field
3 Cover *7 Bearing
4 Bearing bracket 8 Armature

Preparation
(1) Before disassembly, prepare parts indicated by
an asterisk (*) above.
(2) Place a work table under the crane.
(3) Arrange the following tools.
Tester, spring scale, wires, eye bolt (for lifting
armature), wrenches (inch size), gear puller,
calipers, installer, sand paper (#600)

6-12
MOTORS
Disassembly sequence
(1) Measure insulation resistance between each
terminal and the motor unit.

Resistance limit 1 MW min.

If the measured values are less than the limit


value, there may be an internal short-circuit.
Check wires for short-circuiting during
disassembly. 206000

(2) Measure continuity between terminals.


Standard values are:

Measuring
terminals S1 (D1) - S2 (D2) 0 W
Drive motor
Measuring
terminals A1 - A2 0W

Measuring
Pump motor S2 - A1 0W
terminals
206001

If the measured values deviate from the


standard values, there may be a broken wire.
Check wires for breakage during disassembly.
(3) Loosen the cover clamp, and remove the cover.

206002

(4) Measure the brush spring tension. To measure


the tension, hook a spring scale to the curled
end of the brush spring.

9.8 to 19.6 N (1 to 2 kgf)


Brush spring tension
[2.2 to 4.4 lbf]

If the measured tension deviates from the


standard value, replace the yoke and spring.
(5) Disconnect wires. While pulling the curled 206003
section of the spring by a hooked wire, remove
each brush (eight in total) from the holder.

6-13
MOTORS

(6) Mount an eye bolt in the threaded hole of the


armature, and gently lift with a crane. Position
the motor upright with the support side on the
bottom.
(7) Remove the cover.
(8) Place alignment marks on the field and
bearing bracket, and the field and support. Alignment mark
(9) Remove the M10 bolt, and lift the motor unit
slightly. By lightly tapping the bearing bracket
with a plastic hammer, separate the bearing
bracket from the field. Remove the bearing
bracket and armature together as a set.

NOTE Field
When removing the armature, be careful not
Support 206004
to damage the field coil.

(10) Using a gear puller, remove the bearing Bearing


bracket from the armature. bracket

206005

(11)Remove the snap ring, and take out the bearing


using a special installer tool.

Snap ring

206006

6-14
MOTORS

(12) Remove the snap ring (for drive motors only),


and remove the fan and key (for drive motors
only).

Snap ring

206008

(13) Remove the bearing from the support side


using a gear puller.

206009

(14) Remove dust and oil from the commutator of


the armature using compressed air, and wipe
with a dry cloth.
(15) Measure the outside diameter of the commutator
with calipers to obtain the amount of wear.
• Limit valve
1-ton class 96.8 mm (3.81 in.)
Drive motor
2-ton class 120.7 mm (4.75 in.) 206010
Pump motor 79.0 mm (3.11 in.)

If the measured value deviates from the above


limit values, replace the armature.
NOTE
If the commutator surface is irregular, smooth
the surface with sand paper (#600) and clean
with compressed air.
(16) Measure the undercut depth of the commutator. Undercut
Segment
Standard value 0.64 mm (0.025 in.)
206011
If the segments and mica are flush, undercut
the mice to the above standard value.

6-15
MOTORS

(17) Remove the bolt (5/16-16UNC). By lightly


tapping the support with a plastic hammer,
separate the support from the field.

NOTE
If no abnormality is found in the brush holder
or yoke, do not remove the field from the
support.

206012

Assembly
Sequence
(1) Install the support on the field.
(2) Install the support-side bearing fan on the
armature.
(3) Install new seal and bearing on the bearing
bracket.
(4) Lift the armature and place it in the field.
(5) Install the bearing bracket on the field.
(6) By pulling the spring, install each brush. Then,
connect wires.
(7) Install the covers (two in total).

NOTE
If any motors are defective, check the serial
Nos. of the faulty motors and notify the
dealer.

6-16
MOTORS

Troubleshooting
Low supply voltage Charge battery and improve
power supply condition.
Blown fuse Replace.
Excess load Reduce load.
Motor does not start. Faulty wire connection Repair, or re-tighten wire
connections.
Broken wire in control device Repair or replace.
Faulty brush connection Clean and adjust pressing tension.
Broken wire in field coil Repair or replace.
Broken wire in armature coil Repair or replace.
Motor starts but does Low supply voltage Charge battery and improve
not run at rated speed power supply condition.
Faulty connection of Repair connections.
armature circuit
Defective bearings Replace bearings.
Motor produces abnormal Loose mounting bolts Re-tighten bolts and nuts.
vibrations and noise. Contact between armature Repair or replace.
and field coil
Abnormal whistling sound Clean and adjust pressing tension.
Incorrect installation Correct installation condition.
Severe external vibration Remove the cause of vibration,
Bearing overheat. or take appropriate vibration-
insulating measures.
Defective bearings Replace.
Oil degradation or shortage Replace.
in bearings

Faulty brush contact surfaces Correct brush surfaces to ensure


full contact on commutator.
Faulty brush contact Clean commutator surface.
Brush malfunction Adjust brush pressing tension.
Faulty brush sliding Clean brush holder and ensure
free movement of brushes.
Incorrect brush dimension Replace.
or material
Dirtiness or damage Grind with sand paper or
Commutator stone, and wipe with clean cloth.
malfunction High mica Undercut mica.
High bar (commutator Grind with grinding stone or
surface irregularity) correct with lathe.
Short-circuit of commutator Remove conductive foreign
Armature malfunction materials from commutator
and commutator segments.
Broken wire or short-circuit Repair or replace.
in armature coil
Broken wire or short-circuit Repair or replace.
Field coil malfunction in field coil
Broken wire or short-circuit Correct by referring to wiring
in external circuit on field side diagram.
Excessive armature Excess load Reduce load.
current Short-circuit in external Correct short-circuit.
circuit on armature side
Insufficient ventilation due Clean.
to dust
Excess load Reduce load.
Coil overheat Short-circuit or broken wire Correct by referring to wiring
diagram.
Insulation degradation due Dry.
to moisture

6-17
MOTORS

Service Data
A : Standard value B : Correctable limit
Operable limit
Unit : mm (in.)
Truck Models 1-ton class 2-ton class
Item
Armature coil insulation resistance A 1 MW min. 1 MW min.
Drive motor B 96.8 (3.811) 120.7 (4.752)
Commutator outside diameter
Pump motor B 79.0 (3.11) 79.0 (3.11)
A 0.64 (0.025) 0.64 (0.025)
Undercut Undercut mice to above value when
B segments and mica become flush.
N 9.8 to 19.6 9.8 to 19.6
Brush pressing tension (kgf) A (1 to 2) (1 to 2)
[lbf] [2.2 to 4.4] [2.2 to 4.4]
S1 (D1) - S2 (D2) A 0 0
Terminal continuity Drive motor
A1-A2 A 0 0
(W)
Pump motor S2 - A1 A 0 0
N·m 17.6 ± 1.9 17.6 ± 1.9
Cable terminal tightening torque (kgf·m) 1.8 ± 0.2 1.8 ± 0.2
[lbf·ft] [13 ± 1.4] [13 ± 1.4]

Drive motor S2(D2)


A1 Pump motor S2 A1

S1(D1) A2
206916 205859

6-18
MOTORS
Checks and Repairs
Commutator Surfaces
GOOD CONDITION UNSATISFACTORY
LIGHT FILM CONDITION
Uniform coloring UNEVEN FILM
indicates satisfactory Patchy colors of varying
operation of machine and densities and shape. Due
brushes. Film color is to unclean operating
largely an effect of conditions or incorrect
thickness, therefore physical condition of
provided the film is commutator.
uniform it is perfectly
acceptable.

SATISFACTORY
CONDITION
UNSATISFACTORY
LIGHT AND DARK CONDITION
PATTERN
This is not a good condition FILM WITH DARK
but in our experience it is AREAS
known that machines having These areas can be isolated
this commutator pattern have or regular. Commutator out
operated with satisfactory of round. This can be
results for long periods of caused by vibration or
time. This condition can mechanical deficiencies in
appear in alternating bars as equipment operation,
shown or every 3rd or 4th bearings, couplings, etc.
bar, etc. This is related to the
winding design of the
armature. Difficulty caused
from split windings crossing
in the same slot.

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION
STREAKY FILM WITH EXAMPLE OF POOR
NO COMMUTATOR COMMUTATOR
WEAR MACHINING
Frequently due to under- Bars are low on entry and
loaded operation, machine leaving edges giving rise to
grossly over-brushed or the brushes riding on the
brush grade incorrect for middle of the bars.
particular machine
application. Atmosphere
and environmental
conditions can contribute.

6-19
MOTORS

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION
EXAMPLE OF POOR BRUSH CONTACT
COMMUTATOR MARK
MACHINING Storage of machines, for
Bars are low in the middle lengthy periods, with
giving rise to the brushes brushes in position.
riding on entry and This can also result from
leaving bar edges. operation of machine in
This and the previous prolonged stall conditions.
illustration indicate the
need for better
maintenance.

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION
STREAKY FILM WITH BAR EDGE BURNING
COMMUTATOR WEAR CAUSE HIGH MICA
This is a further Illustration shows high
development of the third mica in every slot. Same
example, previous page. effect can occur on one
Brush grade, machine bar only. Similar
applications and working conditions can be caused
environment all suspect. by a high or low bar.
Earlier corrective action
should have been taken.

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION
DOUBLE POLE PITCH SMALL BRIGHT SPOTS
Darkening of commutator Related to over-loaded
in sequences two pole machines and low brush
pitches apart is due to pressure. Due to sparking
armature fault, defective under brush which gives
coil, riser bars or equalizer rise to spots being of a
connections. random distribution. If not
corrected, will result in
scored commutator.

6-20
TRANSFER UNITS

Specifications ............................................................................................................................ 7 - 1

Structure and Functions ............................................................................................................ 7 - 2

Procedures and Key Points for Disassembly and Assembly .................................................... 7 - 4


Disassembly ........................................................................................................................ 7 - 4
Inspection after Disassembly .............................................................................................. 7 - 5
Assembly ............................................................................................................................ 7 - 6

Service Data .............................................................................................................................. 7 - 8

7
TRANSFER UNITS

Specifications
Truck Models 1-ton class 2-ton class
Item EP16KT, EP18KT EP20KT

Gear type Constant-mesh type, 3 stages (helical gears)

Reducing gear ratio 58 81 45


¥ ¥ = 17.478
24 18 28

7-1
TRANSFER UNITS

Structure and Functions (Part 1)

Front of vehicle

7 7

A A
8 8

6 6

1 3

5
5 4

206785

1 Transfer (left) 6 Wheel hub


2 Traction motor (left) 7 Front tire
3 Transfer (right) 8 Bracket
4 Traction motor (right) 9 Tension rod
5 Frame Section A: Mast support mounting section

Since two traction motors are installed in a limited Sections A support masts.
space, the traction motors are offset in position.
Tension rod 9 connects brackets 8, and includes a
turnbuckle to serve as a thrust rod for the left and
right transfer units.

7-2
TRANSFER UNITS

Structure and Functions (Part 2)

14 19
10 5
7 Left side
9
6

2
· 3

8
18
11
19
Front of vehicle
6 Right side
12 13 4 2
16
15
18 3
4
5
4 5
3 · 1

15

2
(View from left side)

206787 17 206786

1 Traction motor 8 Main case 15 Ball bearing


2 Input gear 9 Nut 16 Generator
3 Second gear 10 Plate 17 Plug
4 Third gear 11 Spacer 18 Oil level plug
5 Output shaft 12 Retainer 19 Air breather
6 Wheel hub 13 Taper roller bearing Bolts marked with ¥ :
7 Cover 14 Oil seal Bolts for mounting transfer
units to frame

The left and right transfer units are identical, and The generator detects rotating speed.
are mounted on the frame with bolts marked with Helical gears are used for reduced operating
¥ in the diagram. noise.
The left and right transfer units are installed with The output shaft is provided with two taper
traction motors. The motor shafts are jointed to the roller bearings to withstand heavy cargo.
involute splines of input gears.
Driving force is transmitted via the input gear,
second gear, third gear, then to the output shaft that
Transfer reducing gear ratio 17.478
rotates wheel hub.
7-3
TRANSFER UNITS

Procedures and Key Points for Disassembly and Assembly


Preparation
1. Remove power train consisting of transfer, 3. Remove traction motor and caliper.
traction motor and caliper. (Refer to Removal
and Installation of Power Train.)
2. Drain oil from transfer.
Disassembly

8
12
9 19
7

6
5
4
3 10

11
18

20

16
14
17 15
18 13
2 16
14

206788

Sequence
1 Bolt, spring washer 11 Taper roller bearing
Remove parts 2 to 12 as sub-assembly. 12 Oil seal
2 Cover 13 Input gear
3 Cap 14 Ball bearing
4 Nut 15 Second gear
5 Plate 16 Ball bearing
6 Spacer, O-ring 17 Third gear
7 Wheel hub, Hub bolt 18 Ball bearing
8 Taper roller bearing 19 Main case, Dwell pin
9 Retainer 20 Plug
10 Output shaft, O-ring

7-4
TRANSFER UNITS

Key points for disassembly


1. Removing nut 4
Nut 4 is secured to output shaft 10 by punching.
Use a chisel to scrape punched section carefully.
Do not scratch output shaft 10.
Nut 4 is not reusable.

206789

2. Cover 2
Outer laces of taper bearings 8 and 11 that are
press-fit into cover 2 do not have to be
disassembled if inspection finds no abnormality.
Remove oil seal 12, and use a new seal.

Inspection after Disassembly


1. Inspect the gear teeth and splines for wear and
damage.
2. Inspect the bearings for wear, damage, rotating
resistance and noise.
3. Inspect main case 19 and cover 2 for cracking
and damage.
4. Inspect the oil seal contact surface of retainer
9 for scratches and damage.

7-5
TRANSFER UNITS

Assembly

5 1
6 4
12
8

11

10

7 3 2 14
14
13
15
16

16
18
17

18
19

20 206790

Sequence
Assemble parts 1 to 4 prior to final assembly.
1 Cover 9 Plate
2 Taper roller bearing (outer) 10 Nut
3 Taper roller bearing (outer) 11 Cap
4 Oil seal 12 Main case
5 Output shaft, Inner lace of taper roller 13 Third gear
bearing 2, O-rings 14 Ball bearing
Assemble parts 6 and 7, and inner lace of taper 15 Second gear
roller bearing 3 prior to final assembly. 16 Ball bearing
6 Wheel hub, Hub bolt 17 Input gear
7 Retainer 18 Ball bearing
Install sub-assemblies 5 and 6 in cover 1. 19 Bolt, Spring washer
8 Spacer, O-ring 20 Plug

7-6
TRANSFER UNITS

Key points for assembly


1. Inspect the mounting surfaces of cover 1 and
main case 12 for dents and burrs, and clean the
surfaces. 3-f 16.5
2. To install oil seal 4, use a jig that presses the 2-f 18
oil seal evenly and pound on the jig.
Apply a thin coat of liquid gasket (Three Bond
#1104) on the oil seal mounting surface of
cover 1.
10
3. Tighten nut 10, and check the preload of taper
roller bearings 2 and 3.
When tightening the nut, insert vinyl tubes on
three symmetrical locations relative to the hub 207207
bolt and use a hub holding tool.
Hub holding tool: To be fabricated at service
location

NOTE
Cut a vinyl tube with an inside diameter of 14
mm (0.55 in.) into pieces of 25 mm (1 in.) in
length, and use these vinyl tube pieces to
protect the screw sections when using the
spring balance for measurement.

Preload 59 to 88 N
Tangential force (6 to 9 kgf)
on hub bolt [13.2 to 19.8 lbf]
206791

4. After checking preload, stake one side of nut


10 with a dull punch to secure the nut in place.
Make sure the groove is flattened completely
and the flattened area measures more than 4 mm
(0.16 in.) in diameter.

5. When installing cover 1 sub-assembly on main f4


(0.16)
case 12, apply a thin coat of liquid gasket
(Three bond #1104) on the mounting surfaces.
Bolt 19 must be tightened to the specified
torque. 206792

108 ± 10 N·m
Bolt tightening
(11.0 ± 1.0 kgf·m)
torque
[79.5 ± 7.2 lbf·ft]

7-7
TRANSFER UNITS

Service Data
A : Standard value
Unit : mm (in.)
Truck Models 1-ton class 2-ton class
Item
Input gear and second gear 1 A 0.09 to 0.21 (0.0035 to 0.0082)
Gear backlash Second gear and third gear 2 A 0.09 to 0.21 (0.0035 to 0.0082)
Third gear and output shaft 3 A 0.10 to 0.26 (0.0039 to 0.0102)
Preload of output shaft and taper roller bearing 4
Tangential force on hub bolt A 59 to 88 (6 to 9) [13.2 to 19.8]
N (kgf) [lbf]
Tightening torque of cover mounting bolt 5
A 108 ± 10 (11.0 ± 1.0) [79.5 ± 7.2]
N·m (kgf·m) [lbf·ft]

206790

7-8
REAR AXLE

Structure and Functions .............................................................................................................. 8 - 1

Procedures and Key Points for Removal and Installation .......................................................... 8 - 3


Rear Wheels ........................................................................................................................ 8 - 3
Rear Axle ............................................................................................................................ 8 - 4

Procedures and Key Points for Disassembly and Assembly ...................................................... 8 - 7


Disassembly ........................................................................................................................ 8 - 7
Assembly ............................................................................................................................ 8 - 8

Inspection and Adjustment ........................................................................................................ 8 - 14


Making sure of Minimum Turning Radius ........................................................................ 8 - 14

Service Data ................................................................................................................................ 8 - 15

8
REAR AXLE

Structure and Functions

2
3
4

19
18

11 8
9
12
10
13
14
15
16
17
16 206811

1 Housing 7 Taper roller bearing 13 Oil seal


2 Pinion gear 8 Oil seal 14 Taper roller bearing
3 Rack gear 9 Steering axle 15 Taper roller bearing
4 Piston 10 Wheel hub 16 Nut
5 Cap 11 Hub bolt 17 Lock washer
6 Taper roller bearing 12 Hub nut 18 Hydraulic oil inlet (left wheel)
19 Hydraulic oil inlet (right wheel)
The rear axle is coupled with pinion gear and rack The steering axle connected to the pinion gear
gear. The rack gear is mounted with pistons on is linked to two symmetrically arranged rear
both ends, and converting the reciprocal motion wheels. The steering axle and the taper roller
generated by oil pressure to the pinion gear to bearing of the pinion gear support the rear
rotational movement. The pinion gear serves as a wheel load.
steering device.
8-1
REAR AXLE

Rear Wheels

Solid Pneumatic Tire Solid Tire

114.3 mm (4.5 in.)


127 mm (5 in.)

2 3

206812

1 Steering axle 3 Wheel nut


2 Rear wheel 4 Rim

15 ¥ 4.5 - 8
Tire size
(15 ¥ 5 ¥ 11.5)

Dimensions in parentheses ( ) are for solid tires.

8-2
REAR AXLE

Procedures and Key Points for Removal and Installation


Rear Wheels
Removal
1 Wheel nut
2 Rear wheel

Removal sequence
1. Pull the hand brake lever, and place wheel
stoppers at the front wheels.
2. Turn the key switch ON, and turn the steering 1
wheel all the way to either right or left. 2
3. Locate the hub nut on one side of the vehicle
that is visible from the rear. Loosen the hub 206813
nut by turning it two or three rotations.
4. Turn the steering wheel to the opposite direction,
and loosen the hub nut on the opposite side by
turning it two or three rotations.
5. Turn the key switch OFF, and lift the rear side
of the vehicle (until the rear tires are off the
ground).
a. Place a jack at the rear center (under the
draw bar pin) of the counterweight, and
lift.
b. Attach a wire rope to the draw bar pin and
lift with a crane.
6. After the rear side of the vehicle is lifted, place
wood blocks under the frame on both sides at
the rear as a safety measure.
7. Turn the key switch ON, turn the steering
wheel, and remove the right and left tires.
8. Turn the key switch OFF.

206814
Installation
Follow the removal sequence in reverse.

NOTE
Tighten the wheel nuts evenly to the specified
torque.

Wheel nut 157 N·m


tightening torque (16 kgf·m)
[116 lbf·ft] 101212

8-3
REAR AXLE

Rear Axle
Removal (Part 1)

13
2

4 6
1
5
12
3
9

11
7

8
10

206815

Sequence
1 Battery cover, Gas spring, Seat 8 Hose (hydraulic suction)
2 Controller cover 9 Pipe (hydraulic delivery)
3 Battery 10 Motor, Hydraulic pump
4 Battery shield 11 Hose (hydraulic return)
5 Controller 12 Hose (rear axle return)
6 Bracket 13 Hydraulic tank
7 Hose (steering suction)
Preparation
1. Remove the rear wheels.
(Refer to Rear Wheel Removal procedure.)
2. Disconnect the battery plug located on the
right side of the foot area of the operator’s seat
to cut off power.

8-4
REAR AXLE

Key points for removal


The rear axle is mounted to the counterweight.
To remove the rear axle, it is necessary to
remove all the surrounding components such
as the motor, hydraulic pump, hydraulic tank
and controller.

Removing battery cover


Before removal, open the battery cover and
disconnect the seat switch terminal. Remove
the gas spring from the frame, and remove the
hinge bolts located on the counterweight. The
seat does not have to be removed.

Removing controller
Remove all cables connected to the controller.
During removal, record cable connecting
locations so that they can be reconnected to
the original positions. Disconnect all harness
connectors, and bind them to keep them out of
the way during rear axle removal.

Removing motor and hydraulic pump


Disconnect the cables and harness connectors
of the motor.
Arrange an oil pan to receive drained oil, and
remove hoses 7, 8 and pipe 9. Do not remove
the pipe on the suction side.

Removing hydraulic tank


Disconnect hoses 11, 12, then remove the
hydraulic tank. Since the tank contains oil,
keep the tank balanced during removal.

8-5
REAR AXLE

Removal (Part 2)

15

16

14

17

206816

Sequence
14 Connector 16 Steering hose
15 Overflow hose 17 Rear axle assembly and Steering axle
assembly

Key points for removal


A steering sensor is mounted on the top of the
rear axle. Be careful not to damage the sensor
when lifting the assembly.
Installation
Follow the removal sequence in reverse.
Key points for installation
Tighten the rear axle assembly mounting bolts
to the specified torque.

Bolt tightening torque 436 N·m (44.5 kgf·m) [322 lbf·ft]

8-6
REAR AXLE
Procedures and Key Points for Disassembly and Assembly
Steering axle
Disassembly

7
8

6
5
4
3
2

206817

Sequence
1 Cap 6 Wheel hub, Hub bolt
2 Nut 7 Oil seal
3 Lock washer 8 Taper roller bearing
4 Nut 9 Steering axle
5 Taper roller bearing

Key points for disassembly


1. Removing wheel hubs
Use a puller to remove the wheel hubs from
the steering axle.

206818

8-7
REAR AXLE
Assembly

1
2

8
7
4 6
3 5
206819

Sequence
1 Steering axle 6 Nut
2 Wheel hub 7 Lock washer
3 Taper roller bearing 8 Nut
4 Oil seal 9 Cap
5 Taper roller bearing
Key points for assembly
1. Assembling wheel hubs
(1) Insert the inner races of the taper roller
bearings using the bearing installer A
(special tool). A

Special tool needed


Bearing installer A 91268-01500

206820

8-8
REAR AXLE

(2) Filling insides of rear axle hubs with


grease
Supply grease into the rear axle hubs. See the
diagram for proper grease filling condition.
Supply grease to the roller holding devices.
Fill grease to approximately 80% of the
cavity. Do not supply grease to full level.
Filling grease to maximum level causes
excessive generation of heat and quickly
deteriorates the grease. When coating oil seal
lips with grease, be careful not to use too Refilling with grease
206821
much grease, since an excess amount of
grease can cause leaks.
2. Preload adjustment and lock nut
Adjust the inside nut first, then tighten the
outside nut (lock nut) to the specified torque.
Then, check the preload. To measure preload,
attach a spring balance to a hub bolt, then read
the force generated when the hub starts
rotating.
Use the following allowable ranges when
readjusting used bearings.
Outside nut
49 to 490 N·cm Inside nut 206821
Preload of hub bearing (5 to 50 kgf·cm)
[0.36 to 3.6 lbf·ft]
6.5 to 65 N
Tangential force on hub bolt (0.67 to 6.7 kgf)
[1.5 to 14.7 lbf]
157 N·m
Lock nut tightening torque (16 kgf·m)
[116 lbf·ft]

8-9
REAR AXLE

Rear Axle Assembly


Disassembly

14 2

17

Section A
4

10 11 12
9
7

8
A 1 3

15

16

6
207204
13 4

Sequence
1 Bolt 10 Bolt, washer
2 Plate 11 Piston assembly
3 Shim 12 Rack gear
4 Pinion gear 13 Oil seal
5 Taper roller bearing (inner) 14 Oil seal
6 Taper roller bearing (inner) 15 Taper roller bearing (outer)
7 Bolt, washer 16 Taper roller bearing (outer)
8 Cap 17 Housing
9 Seal, O-ring

8-10
REAR AXLE

Key points for disassembly


Press
1. Removal of the pinion gear
Remove bolt 1, plate 2 and shim 3. Position
housing 17 on a base, and use a press to 17
remove pinion gear 4.

2. Inspect taper roller bearing (inner) 6 which is


press-fit in pinion gear 4 and taper roller 4 207205
bearings 15, 16 which are press-fit in housing
17. If the roller bearings are in good condition,
they do not have to be removed.

Inspection after disassembly


1. Housing
Inspect the sliding surface of piston assembly
11 for damage.
If there are small scratches on the surface, use
sandpaper to remove the scratches.

2. Pinion gear and rack gear


Inspect the tooth surfaces for damage. Inspect
the steering axle mounting screw at the lower
pinion gear section for damage. Inspect the
contact section of the oil seal at the lower
pinion gear section for damage.

3. Taper roller bearing


Inspect the rolling contact surface of the
bearing.

4. Inspect the contact section of the oil seal of


plate 2 for damage.

5. Oil seal, O-ring and other parts


Replace oil seals 4, 5, other seals, O-ring 9,
and piston seal of piston assembly 11 with
new parts.

8-11
REAR AXLE
Assembly

4 16

Section A
12

8 7 6
9

11

10
A 17 15 B

14

13

5 12 207204

Sequence
1 Housing 10 Cap
2 Taper roller bearing (outer) 11 Bolt, washer
3 Taper roller bearing (outer) 12 Pinion gear
4 Oil seal 13 Taper roller bearing (inner)
5 Oil seal 14 Taper roller bearing (inner)
6 Rack gear 15 Shim
7 Piston assembly 16 Plate
8 Bolt, washer 17 Bolt
9 Seal, O-ring B Overflow port

For assembly, follow the disassembly sequence in


reverse.
Key points for assembly
1. When knocking oil seals 4, 5 into housing 1,
use a backing plate and strike the oil seals
uniformly to set the seals evenly into position.
8-12
REAR AXLE

2. Before installing piston assembly 7, apply


sealant 1E2200J on the periphery of the piston
and the sliding surface of housing 1.

3. When installing taper roller bearings (inner)


13, 14, coat them with hydraulic oil.

4. Coat the lips of oil seals 4, 5 with hydraulic oil


and install the seals.

5 To adjust the bearing end play after the


installation of taper roller bearings 13, 14, 14 Clearance
measure clearance between pinion gear 12
and taper roller bearing 14. Subtract a value
of 0.01 to 0.035 mm (0.0004 to 0.0014 in.)
from the measured value, and insert a shim
having the thickness of the calculated value,
then tighten plate 16.

12
Clearance – 0.01 to 0.035 mm= Shim thickness
(0.0004 to 0.0014 in.) 207206

6. Tighten bolt 17 to the specified torque.


Bolt tightening torque
N.m 45 ± 7
(kgf.m) (4.5 ± 0.7)
[lbf.ft] [99 ± 15]

7. After assembly, pour hydraulic oil into


overflow port B until the oil surface reaches
the overflow port. Cover the overflow port
with tape.

8-13
REAR AXLE

Inspection and Adjustment


1. Making sure of Minimum Turning Radius
(1) While operating the vehicle at low speed,
turn the steering wheel all the way to the
right, then to the left, and check the
diameter of the tire tracks in both turning
operations.
(2) Calculate minimum turning radius R by
dividing the turning diameter by two then
adding the distance between the center of
R
the outside rear wheel and the outside
edge of the counterweight.

206822

Unit : mm (in.)
Item
Minimum turning radius
Models
EP16KT 1517 (59.7)
EP18KT 1620 (63.8)
EP20KT 1645 (64.8)

8-14
REAR AXLE
Service Data
A: Standard value
Truck Models
EP16KT, EP18KT EP20KT
Item
Preload of hub bearing 1
A 49 to 490 (5 to 50) [0.36 to 3.6]
N·cm (kgf·cm) [lbf·ft]
Tangential force on hub bolt
A 6.5 to 65 (0.67 to 6.7) [1.5 to 14.7]
N (kgf) [lbf]
Lock nut 2 A 157 (16) [116]
Tightening
torque Rear axle tightening bolt 3 A 436 (44.5) [322]
N·m Steering axle tightening bolt 4 A 224 (22.9) [166]
(kgf·m) Wheel nut 5 A 157 (16) [116]
[lbf·ft]
Plat bolt 6 A 45 ± 7 (4.5 ± 0.7) [99 ± 15]

6
3

5
4

206823

8-15
BRAKE SYSTEM

Specifications .............................................................................................................................. 9 - 1

Structure and Functions .............................................................................................................. 9 - 2


Caliper Assembly ................................................................................................................ 9 - 3
Brake Pedal Assembly ........................................................................................................ 9 - 4
Master Cylinder .................................................................................................................. 9 - 5
Parking Brake Lever ............................................................................................................ 9 - 6

Procedures and Key Points for Disassembly and Assembly ...................................................... 9 - 7


Master Cylinder .................................................................................................................. 9 - 7

Inspection and Adjustment ........................................................................................................ 9 - 9


Pad Clearance Adjustment .................................................................................................. 9 - 9
Brake Pedal Adjustment ...................................................................................................... 9 - 9
Brake Switch Installation .................................................................................................... 9 - 10
Brake Fluid Line Bleeding .................................................................................................. 9 - 10
Parking Brake Adjustment .................................................................................................. 9 - 10

Troubleshooting .......................................................................................................................... 9 - 11 9

Service Data ................................................................................................................................ 9 - 12


BRAKE SYSTEM

Specifications

Truck Models 1-ton class 2-ton class


Item
EP16KT, EP18KT EP20KT
Type Hydraulic (mechanical) motor disc brake system
Brake disc effective diameter mm (in.) 162 (6.378)
Disc outside diameter mm (in.) 200 (7.874)
Disc thickness mm (in.) 10 (0.39)
Disc effective thickness mm (in.) 9 (0.35)
Pad area cm2 (in2.) 28.8 ¥ 2 (4.46 ¥ 2)
Pad thickness mm (in.) 6 (0.23)
Pad effective thickness mm (in.) 4 (0.16)
The minimum thickness of mm (in.) 0.4 (0.016)
disc and pads
Pad material NS 113
Wheel cylinder inside diameter mm (in.) 19.05 (0.75)
Wheel cylinder area cm (in .)
2 2 2.85 (0.44)

9-1
BRAKE SYSTEM

Structure and Function

8 1

5 7

4
206824

1 Caliper assembly 5 Reservoir tank


2 Brake disc 6 Parking lever assembly
3 Traction motor 7 Equalizer bracket
4 Brake pedal assembly 8 Lever D

The brake pads clamp the brake disc mounted on The brake pedal assembly is mounted on the
the traction motor to provide stopping force. left side of the frame.
The caliper assembles are installed on the rib The cable linked to the parking lever pulls lever
section of the traction motor. D of the caliper to provide stopping force.

9-2
BRAKE SYSTEM

Caliper Assembly

8 7 15 1
3
B 17

9
10
11
2
14 13 4
8 5 1
7 16
8

10

6
11
5

13 12
A 4
206825

1 Body assembly 8 Pin 15 Spring


2 Lever A 9 Spring 16 Bleeder screw
3 Lever B 10 Pad assembly 17 Brake disc
4 Pin, Split pin 11 Bolt, Washer A Brake fluid inlet
5 Lever C 12 Adjustment bolt B Parking brake cable
6 Lever D 13 Adjustment bolt mounting hole
7 Pin, Split pin 14 Lock nut, Washer

The brake pads clamp the brake disc mounted on causing the pad assembly to clamp the brake
the traction motor to provide stopping force. disc. When the parking brake cable connected to
The caliper assemblies are installed on the section B pulls the lever in the direction of the
traction motor. Brake fluid entering from section arrow, the pad assembly operates mechanically.
A under pressure pushes the piston in the Adjustment bolts 12, 13 and spring 15 maintain
cylinder of the body assembly. The piston then proper clearances between the brake disc and
presses pin 7, which then pushes levers C and D pads. The caliper assembly installed on the
to open position. Levers A and B move with pin opposite side of the vehicle is symmetrically
4 as the fulcrum and their link sides open, structured.

9-3
BRAKE SYSTEM

Brake Pedal Assembly

Brake fluid
6

3 7

4 1

206826

1 Pedal bracket 5 Master cylinder


2 Brake pedal 6 Adjustment bolt
3 Brake link 7 Brake switch
4 Return spring

The brake pedal assembly is mounted on the left Brake fluid is supplied to the master cylinder
side of the frame. from the reservoir tank located under the left
The adjustment bolt is used to set the brake pedal side of the dashboard.
height.
The installation length of the brake switch is pre-
adjusted. When the pedal is pressed, the switch
activates and controls the operating speed of the
traction motor.

9-4
BRAKE SYSTEM

Master Cylinder

Parts marked with an asterisk (*) are included in the repair kit.

13 14

1 4* 2* 9* 10 12 11
8* 7* 6* 5* 3*

206827

1 Cylinder body 8 Return spring


2 Stopper ring 9 Boot
3 Piston 10 Push rod
4 Secondary cup 11 Clevis
5 Cup spacer 12 Lock nut
6 Primary cup 13 Filler
7 Spring seat 14 Clamp

The inside diameter of the cylinder is 19.05 mm


(3/4 in.), and the maximum stroke is 28 mm
(1.1 in.).

9-5
BRAKE SYSTEM

Parking Brake Lever

Maximum stroke: 50°

1
3

8
2

206828

1 Lever body 5 Stopper


2 Gear 6 Spring
3 Notch 7 Hook
4 Grip 8 Pin

The parking brake lever is mounted on the left The maximum lever stroke is 50 degrees. There
side of the dashboard. are a total of 14 gear teeth. Adjust the parking
When the grip is pulled, the parking brake cable brake so that the brake activates and applies
activates the pad assembly of the caliper to force when the third or fourth tooth of gear 2
clamp the brake disc and apply stopping force. engages with the notch.
Notch 3 engages with gear 2 to retain the lever in
position. To release the parking brake, pull the Grip operating effort
294 (30) [66]
grip and press stopper 5. This disengages the N (kgf) [lbf]
gear from the notch, and the lever can be
returned to the original position.

9-6
BRAKE SYSTEM

Procedures and Key Points for Disassembly and Assembly


Master Cylinder
Disassembly

6 7

4
3
2

206829

Sequence
1 Clevis, Lock nut, Push rod 6 Return spring
2 Boot 7 Cylinder body
3 Stopper ring 8 Filler, Clamp
4 Secondary cup, Piston
5 Spring seat, Primary cup, Cup spacer

NOTE
Replacement parts marked with an asterisk
(*) are included in the repair kit.

9-7
BRAKE SYSTEM

Inspection after disassembly


1. Cylinder body
(1) Check the inner wall of the cylinder for
rust, corrosion and scuffing.
(2) Check the inlet port and relief port for
clogging, and the joint bolts and boot for
damage.
2. Piston Standard 0.020 to 0.105 mm
Check the piston for damage. Replace the Clearance between value (0.0008 to 0.0041 in.)
piston, if damaged. If the clearance between cylinder and piston Limit 0.2 mm
the piston and cylinder exceeds the limit value, value (0.0078 in.)
replace both cylinder and piston.
3. Return spring
Replace the return spring once a year.
4. Primary cup, Secondary cup and Valve
Inspect rubber parts for damage and expansion.
Replace the primary cup, secondary cup and
valve once a year.
Assembly
Follow the disassembly sequence in reverse.
Also follow the instructions below.
(1) Clean metal parts with a volatile cleaning
solution, and dry thoroughly using compressed
air.
(2) Apply a thin coat of brake rubber grease
or brake fluid on the inner surface of the
cylinder and the piston cup.

9-8
BRAKE SYSTEM

Inspection and Adjustment


1. Pad Clearance Adjustment Pad B
Use adjustment bolt A to adjust pad A
clearance. Turning adjustment bolt A causes
pad B to move. ·
Therefore, use adjustment bolt B to adjust pad ·
B clearance.
One rotation of adjustment bolt A moves pads Clearance
A and B a distance of approximately 1 mm (0.04
in.) to the right or left according to the direction Pad A
Adjustment bolt 206825
of the bolt rotation. One rotation of adjustment
bolt B moves pad B a distance of approximately
0.5 mm (0.02 in.) to the right or left according
to the direction of the bolt rotation. Adjustment bolt A
Adjust the clearance to a range of 0.4 to 0.55
mm (0.0157 to 0.0216 in.) on each side.
After adjustment, tighten the lock nut.

2.94 to 5.88 N·m


Lock nut
(30 to 60 kgf·cm)
tightening torque
[2.17 to 4.13 lbf·ft]
Adjustment bolt B
206825

2. Brake Pedal Adjustment


(1) Use the stopper bolt to adjust pedal height
C
A (distance between frame and the top of D
pedal pad).
(2) Set push rod length B to the specified
A’ A
dimension, and install the push rod into the
master cylinder. The clearance between the Stopper bolt
push rod and piston should be 0.5 to 1.5
mm (0.02 to 0.06 in.). The pedal play
should be 3 to 9 mm (0.12 to 0.35 in.).
(3) After adjustment, check to make sure that
pedal stroke C (brake activating point) is
as specified.
Unit : mm (in.)
Truck Models B 206830
1-ton class 2-ton class
Items
Pedal height A
167.5 (6.59)
from floor plate
Pedal height A’
168 (6.61)
from frame
Push rod length B 118.6 (4.67)
Free play C 3 to 9 (0.12 to 0.35)
Pedal stroke D
25 to 38 (1.0 to 1.5)
(brake activating point)

9-9
BRAKE SYSTEM

3. Brake Switch Installation


(1) Use the adjustment bolt to adjust the brake
pedal height, then tighten the lock nut. (ON/OFF point)
(2) By rotating the push rod of the brake 0.7 to 1.3 mm Brake switch
master cylinder, adjust the clearance (0.027 to 0.05 in.)
between the push rod and piston to a range
of 0.5 to 1.5 mm (0.019 to 0.059 in.).
When properly adjusted, the pedal should
travel a distance of 3 to 9 mm (0.12 to 0.35
in.) when pressed.
(3) Install the brake switch, and adjust so that Lock nut
205753
the switch activates when the brake pedal
is pressed 7 to 13 mm (0.27 to 0.51 in.).
Then, tighten the lock nut.
The brake switch should turn ON and OFF
with pedal movement of 0.7 to 1.3 mm
(0.027 to 0.051 in.).
4. Brake Fluid Line Bleeding
When part of the brake fluid system is
disassembled for a repair or when brake pedal
movement is spongy, it is necessary to bleed
the brake fluid line by following the procedure
below.
(1) To the bleeder screw of the right caliper
assembly which is located furthest from
the master cylinder, a clear vinyl tube over
bleeder screw. Place the other end of the
tube into a jar filled with brake fluid.
(2) Check the brake fluid level in the oil tank.
Add oil, if the level is low.
(3) Pump the brake pedal several times, then
keep the pedal pressed. While holding the
pedal pressed, loosen the bleeder screw.
While brake fluid is flowing inside the
vinyl tube, tighten the bleeder screw.
(4) Repeat the above procedure until there are
no air bubbles in the brake fluid.
Repeat the same procedure to bleed the
left caliper assembly.
After air bleeding is completed, add brake
fluid in the oil tank to the specified level.
5. Parking Brake Adjustment
When the pad clearances are adjusted to
approximately 1.1 mm (0.043 in.), the notch
should engage with the third or fourth tooth of
the gear when the parking brake lever is pulled.
If the pads are worn, tighten the adjustment bolts
of the calipers to adjust the clearances. To adjust 206833
the cable length, use the cable adjustment bolt.

9-10
BRAKE SYSTEM

Troubleshooting
*
Oil leak from master cylinder Inspect cylinder. If no abnormality
primary cup is found, replace piston cup.
Oil leak from caliper cylinder If piston cup is deformed, replace
cup cup and brake fluid (use genuine
Inadequate braking brake fluid).
force Oil leak from oil pipe joint Re-tighten, or replace pipe
and joint.
Worn lining Replace.
Oil adhesion on lining Clean with brake component
cleaner and repair or replace.
Air in hydraulic system Bleed master cylinder and
caliper cylinder.
Faulty master cylinder or Replace piston cup.
piston cup
Excessive pedal stroke Low oil level in master cylinder Add brake fluid.
Excessive clearance of master Adjust.
cylinder push rod
Brake fluid leak Refer to above section marked
with *.
Oil or grease adhesion on Clean with brake component cleaner
Imbalance in braking lining or disc and repair. If oil and grease cannot be
power removed from lining, replace lining.
Brake disc wobbling or loose Replace disc. If problem is caused
mounting by loose mounting, re-adjust and
re-tighten.
Lining surface too smooth Replace brake pad.
Worn lining
Brake squealing
Loose caliper tightening bolt Re-tighten.
Dirty disc Clean with brake component cleaner.
Inadequate clearance Adjust to standard clearance
Parking brake stroke between disc and lining value.
too short
Parking brake cable too short Adjust cable length using
adjustment bolt.
Abnormal noise from Inadequate clearance between Adjust to standard clearance
hand brake during brake pad and disc value.
driving Warped brake disc Repair brake disc according to
repair standard, or replace.
Parking brake cable too long Adjust cable length using
Parking brake not adjustment bolt.
producing stopping Brake lining worn beyond Replace brake pad.
force limit value
Excessive clearance between Adjust clearance between
brake pad and disc brake pad and disc.

9-11
BRAKE SYSTEM

Service Data
A : Standard value
Unit : mm (in.)
Truck Models
1-ton class 2-ton class
Item
Pedal height 1 A 167.5 (6.59)
(between upper pedal edge and floor)
Pedal stroke 2 (brake activating point) A 25 to 38 (1.0 to 1.5)
Free play 3 A 3 to 9 (0.12 to 0.35)
Push rod length 4 A 118.6 (4.67)
(standard assembly dimension)
Clearance between piston and push rod 5 A 0.5 to 1.5 (0.019 to 0.059)
Brake switch activating pedal stroke 6 A 7 to 13 (0.27 to 0.50)
Brake switch activating dimension 7 A 0.7 to 1.3 (0.027 to 0.05)

2 6
3

7
1

5 206831
4

9-12
BRAKE SYSTEM

A : Standard value B : Correctable limit


Operable limit
Unit : mm (in.)
Truck Models
1-ton class 2-ton class
Item
+0.052 +0.00205
Cylinder body inside diameter 1 A 19.05 0 (0.7500 0 )
-0.020 -0.0079
Piston outside diameter 2 A 19.05 -0.053 (0.7500 -0.00209 )
Clearance between cylinder and piston A 0.020 to 0.105 (0.00079 to 0.00413 )
B 0.2 (0.08)
0 0
Primary cup lip-side outside diameter 3 A 20 -0.3 (0.79 -0.012 )
B (Replace once a year.)
Secondary cup lip-side outside diameter 4 A 20.2 ± 0.2 (0.795 ± 0.008 )
B (Replace once a year.)
Return spring free-movement length 5 A 46.8 (1.843 )
B (Replace once a year.)

5 4

3 2 1 206827

9-13
BRAKE SYSTEM
A : Standard value B : Correctable limit
Operable limit
Unit : mm (in.)
Truck Models
1-ton class 2-ton class
Item
Tightening Pad assembly tightening
torque bolt 1 A 17.65 to 26.48 (180 to 270) [13.02 to 19.53]
N·m Adjustment bolt lock nut 2 A 2.94 to 5.88 (30 to 60) [2.17 to 4.34]
(kgf·cm)
[lbf·ft] Bleeder screw 3 A 6.86 to 11.77 (70 to 120) [5.06 to 8.68]
Pad lining thickness 4 A 6 (0.236)
B 2 (0.078)
Lever D pin hole stroke with 1.1 mm
(0.043 in.) of clearance between brake A 5 (0.196)
disc and pad 5
Lever D pin hole stroke with 5 mm
(0.196 in.) of pad thickness wear 6 A 26 (1.023)
Brake disc thickness 7 A 9 (0.354)

·
5

1
2

206832

9-14
STEERING SYSTEM

Specifications .............................................................................................................................. 10 - 1

Structure and Functions .............................................................................................................. 10 - 1


General ................................................................................................................................ 10 - 2
Steering Control Valve ........................................................................................................ 10 - 3

Procedures and Key Points for Removal and Installation ........................................................ 10 - 4


Steering Column Assembly ................................................................................................ 10 - 4

Steering Control Valve ................................................................................................................ 10 - 6


Disassembly ........................................................................................................................ 10 - 6
Inspection ............................................................................................................................ 10 - 8
Assembly ............................................................................................................................ 10 - 9

Hydraulic Circuit ...................................................................................................................... 10 - 13

Troubleshooting .......................................................................................................................... 10 - 14

Service Data ................................................................................................................................ 10 - 15

10
STEERING SYSTEM

Specifications
Truck Models
Items EP16KT, EP18KT EP20KT
Type All hydraulic power steering
Diameter of steering wheel, mm (in.) 328 (12.9)
Manufacture Sumitomo Eaton
Steering
control Flow rate
valve 5.2 to 7.8 (317.3 to 476)
liter (cu in.) /min

10-1
STEERING SYSTEM

Structure and Functions


General

E 7
F
D

A 1

F E

H
B

J
6 3 2 C
206834

1 Hydraulic tank 5 Steering wheel


2 Hydraulic pump 6 Rear axle assembly
3 Steering pump 7 Hydraulic control valve
4 Steering control valve

The steering system is an open-center type, and Overflow oil at the pinion gear of the rear axle
uses a dedicated steering pump to feed oil. returns to the hydraulic tank.
The steering pump has a built-in relief valve to Oil from the hydraulic pump enters the hydraulic
protect the steering control valve and rear axle control valve for loading operation.
assembly. In the steering system, oil flows as follows:
Oil enters the steering control valve to provide AÆCÆDÆ[E]ÆGÆH
directional control of the rear axle. When the F
steering wheel is not operated, oil returns to the
hydraulic tank via the hydraulic control valve.

10-2
STEERING SYSTEM

Steering Control Valve

13

T L RP

5 6 7 8 1 9 10 2 11 3 12 4
200786

1 Long housing 8 Drive shaft P Pump port


2 Spacer plate 9 Control sleeve T Tank port
3 “Gerotor” set 10 Control spool L Cylinder port (left)
4 End cap 11 Spacer R Cylinder port (right)
5 Thrust needle 12 Spacer
6 Centering spring 13 Check valve
7 Pin

10-3
STEERING SYSTEM

Procedures and Key Points for Removal and Installation


Steering Column Assembly
Removal

1
3

4
8
5 4

B
2
9
B
6
8
A 68
9
10
20 A

35

Sequence
1 Steering wheel, Cap, Nut, Washer 7 Hose, Pipe, Hose clamp, Connector,
2 Console box (front panel) O-ring
3 Central vehicle monitor panel 8 Tilt steering lock lever, Spacer, Shaft,
4 Forward/reverse lever, Turn signal switch Bolt, Split pin
5 Console box (rear panel) 9 Pin, Washer, Split pin
6 Floor plate 10 Steering column assembly

10-4
STEERING SYSTEM

Suggestion for removal


Steering wheel removal Wheel puller
Use the Wheel puller (special tool).
Special tool needed

Wheel puller 91268-10600

205770

Inspection
(1) Steering wheel free play
Check the free play with the key switch in the
ON position.
(2) Steering effort
(a) Set the parking brake with the key switch
in the ON position, operate the lift lever to
raise and lower the lift bracket until the
hydraulic oil temperature increases to 40 to
60°C (104 to 140°F).
(b) Hook a spring scale to the rim of the steering
wheel. Pull the scale in the tangential
direction and look at the reading on the scale
just when the wheel begins to turn to find the 206836
free play.

Steering effort 9.8 N·m (1 kgf·m) [7.2 lbf·ft]


Spring scale
58.8 N (6 kgf) [13.2 lbf]
reading

10-5
STEERING SYSTEM

Steering Control Valve


Disassembly

6
11
5

12

10

201515

Sequence
1 End cap, Bolts, O-ring and Spacers 7 Control sleeve
2 “Gerotor” set, O-ring 8 Control spool
3 Drive shaft, Spacer plate and O-ring 9 Pin
4 Retaining ring 10 Centering springs
5 Seal gland bushing, O-ring, Oil seal and 11 Check valve, Check ball retainer, Ball,
Dust seal O-ring, Check seat and Screw
6 Thrust needle, Race bearing 12 Long housing

10-6
STEERING SYSTEM
Suggestions for disassembly
(1) Retaining ring removal
Remove the ring from the housing by prying
its end out of the groove.

200665

(2) Seal gland bushing removal


Position the control spool and control sleeve
assembly so that the pin is even with the center
of the assembly. Remove the bushing.

200666

(3) Control spool and sleeve removal


Remove the control spool and sleeve assembly
from the housing by pulling it toward the end
of the housing opposite to the flange. Remove
the pin from the assembly.
NOTE
When removing the assembly, slowly turn it
in the housing in both directions while pulling
out to prevent damage to the housing.
200667

(4) Control spool and sleeve disassembly


Pull the control spool from the sleeve enough
to permit removal of the centering springs.
Remove the centering springs. Remove the
spool from the sleeve by pulling it toward the
rear end of the sleeve while turning slowly.
NOTE
Before removing the spool from the sleeve,
put a mark across the spool and sleeve so that 200668
the spool can be installed in the same position.

10-7
STEERING SYSTEM

Inspection
Spool movement in housing and sleeve
(a) Check the spool in sub-assembly condition
for free movement.
(b) If the spool is sticky or otherwise erratic in
its movement, disassemble the steering
control valve, and check its sliding surfaces
for abnormal condition. If the sliding
surfaces are found in bad condition, replace
the whole control valve assembly.

10-8
STEERING SYSTEM

Assembly

10

2
9
7

·
12

4 5 3 6 1
11
200787

Sequence
1 Long housing 7 Thrust needle, Race bearings
2 Check valve, Check ball retainer, Ball, 8 Seal gland bushing, Oil seal, Dust seal
O-ring, Check seat and Set screw and O-ring
3 Control sleeve 9 Retaining ring
4 Control spool 10 Drive shaft, Spacer plate and O-ring
5 Centering springs 11 “Gerotor” set, O-ring
6 Pin 12 End cap, O-ring, Spacer and Bolts

Start by :
a) Replace worn or defective parts
b) Wash all metal parts and blow dry
c) Replace O-rings and seals
d) Apply grease to O-rings and other sealing
parts

10-9
STEERING SYSTEM

Suggestions for assembly


(1) Check valve assembling
Put the retainer in position on the housing. Put
the seat in position in the housing with the
hole at the bottom. Apply Loctite 271 to the
threads of the set screw and tighten the screw
to the specified torque.

Tightening torque
11.3 N.m (1.2 kgf.m) [8.3 lbt.ft] 200669
for set screw

(2) Control spool and sleeve assembling


Put the spool in the sleeve with the spring Spring groove
groove in alignment with the spring groove in
the sleeve. Make sure the marks put during Spring groove
disassembly are in alignment.

NOTE
Make sure the spool rotates freely in the sleeve. Matching marks

200670

(3) Centering spring installation


Hold two sets of three springs back to back.
Using Spring Inserting Tool, put these sets of
the springs in the groove with the bevel ends at
the bottom.

Special tool needed

Spring inserting tool 97157-00100


200671

(4) Control spool and sleeve assembly installation


to housing
Put the pin in the holes in the spool and sleeve.
Put the control spool and sleeve assembly in
the housing from the rear side while rotating it
in both directions with the pin kept level with
center of the spool.
NOTE
Make sure the rear end of the spool and sleeve
assembly is even with the rear end of the housing. 200672

10-10
STEERING SYSTEM

(5) Seal installation


Put the dust seal in position on the seal gland Dust seal
bushing with the flat side down. Also, put the
oil seal in position on the bushing. Seal gland bushing

Quad ring seal

207184

(6) Reassembling the seal gland bushing


• Install the dust seal in the bushing with the
flat side facing towards the bushing.
• Install the quad ring seal in the bushing by
smoothing it into place with your finger.
• Install the bushing assembly over the
spool end with a twisting motion. Tap it
into place with a soft head mallet. Make
sure the bushing is flush against the
bearing race. 200673

• Install the retaining ring in the housing Screwdriver


and pry it with a screwdriver around the Dust seal
entire circumference to ensure a good Retaining ring
Seal gland bushing
sitting.
Quad ring seal
O-ring

207195

(7) Reassembling the wear plate


• Clamp the housing in a vise, equipped
with soft jaws or softened with rag. Clamp
lightly over the edges of the mounting
area. Do not overtighten the vise jaws.

NOTE

Check that the spool and sleeve are flush with


or slightly below the surface of the housing. 207196

10-11
STEERING SYSTEM

• Install the O-ring in the housing. Place the


wear plate on the housing and align the
bolt holes with the tapped holes in the
housing.

207169

(8) Reassembling the driver


• Make a mark across the splined end of the Port surface
drive to indicate the direction of the slot at Drive
the opposite end of the drive.
• Rotate the spool and sleeve assembly until
the pin is parallel with the port surface.
Pin parallel
Install the drive and make sure that it
with port surface
engages the pin. The mark should be
parallel to the port surface. Pin
200675

(9) Reassembling the gerotor set


• Install O-ring in the gerotor set.
• With the O-ring side of the gerotor set
Gerotor set star valley
towards the wear plate, align the star
valleys A with the mark on the drive B.
Noting the parallelism of reference lines
A, B, C, and D, align the bolt holes
without disengaging the gerotor set from
the drive. Drive (marked)

Port surface
Pin 207199

10-12
STEERING SYSTEM

(10) Reassembling the end cap


End cap
• Install the drive spacer in the gerotor set.
Install the O-ring in the end cap. Install the Cap screw
end cap in the gerotor set and align the
holes

O-ring
Drive spacer
207200

• Tighten all screws snug, then tighten them


progressively to the specified torque in the
sequence as shown.

14.7 N·m
Initial torque for screws (1.5 kgf·m)
[10.8 lbf·ft]
23.5 N·m
Finishing torque for screws (2.4 kgf·m)
[17.3 lbf·ft] 200677

After installing the end cap, install the steering


wheel to the spool and make sure the spool rotates
smoothly.

10-13
STEERING SYSTEM

10-14
STEERING SYSTEM

Troubleshooting

Clogged metering section Disassemble and clean.


Control valve malfunction Faulty spool operation Disassemble and clean.
Faulty bearing Disassemble and replace.
Rear axle cylinder
Faulty piston seal Replace.
malfunction
Others Flattened pipe, mixing of Clean or replace oil line.
foreign particles

Sticking of spool or sleeve Replace.


Control valve malfunction
Damaged centering spring Replace.
Flattened pipe, mixing of Clean or replace oil line.
Others foreign particles
Faulty piston seal in rear Replace.
axle cylinder

10-15
STEERING SYSTEM

Service Data
A = Assembly standard
Truck Models 1-ton class 2-ton class
Items
Steering effort (at steering wheel rim),
N·m (kgf·m) [lbf·ft]
(Standard value measured with key switch ON, A 9.8 (1) [2.2]
steering wheel turning speed of 1 revolution/
sec, and stationary swing operation)
Turning Inside wheel A 76°16’
angle, deg Outside wheel A 49°41’
Number of lock-to lock turns A 4.56
Tightening
torque, Steering wheel nut A 54 to 59 (5.5 to 6.0) [40 to 43]
N·m
(kgf·m) Steering bracket bolts A 29.4 (3) [21.7]
[lbf·ft]
Displacement, cc (cu in.)/rev. A 168 (10.2)
Rated flow rate, liter (cu in.)/min. A 22.7 (1385)
Maximum operating pressure,
A 17162 (175) [2489]
kPa (kgf/cm2) [psi]
Tightening
torque, End cap bolts 1 A 28.4 (2.9) [21]
N·m
(kgf·m) Check valve set screw 2 A 11.8 (1.2) [8.7]
[lbf·ft]

1
2

200786

10-16
HYDRAULIC SYSTEM

Specifications .............................................................................................................................. 11-1

Structure and Functions .............................................................................................................. 11-2


Hydraulic Line .................................................................................................................... 11-2
Gear Pump .......................................................................................................................... 11-3
Control Valve ...................................................................................................................... 11-4
Lift and Tilt Cylinders ........................................................................................................ 11-7
Flow Regulator Valve .......................................................................................................... 11-8
Down Safety Valve .............................................................................................................. 11-8

Gear Pump .................................................................................................................................. 11-9


Procedures and Key Points for Removal and Installation .................................................. 11-9
Procedures and Key Points for Disassembly and Assembly .............................................. 11-11

Control Valve .............................................................................................................................. 11-13


Procedures and Key Points for Removal and Installation .................................................. 11-13
Procedures and Key Points for Disassembly and Assembly .............................................. 11-14

Lift Cylinders .............................................................................................................................. 11-17


Procedures and Key Points for Removal and Installation
Dual-stage Panoramic Mast (Simplex Mast) ................................................................ 11-17
Procedures and Key Points for Removal and Installation
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................................ 11-20
Procedures and Key Points for Disassembly and Assembly
(Simplex Mast, Triplex Mast Second Cylinders) ........................................................ 11-23
Procedures and Key Points for Disassembly and Assembly
11
(Duplex Mast, Triplex Mast First Cylinder) ................................................................ 11-25
Procedures and Key Points for Disassembly and Assembly
(Duplex Mast Second Cylinders).................................................................................. 11-27

Tilt Cylinders .............................................................................................................................. 11-29


Procedures and Key Points for Removal and Installation .................................................. 11-29
Procedures and Key Points for Disassembly and Assembly .............................................. 11-30
Flow Regulator Valve ................................................................................................................ 11-33
Procedures and Key Points for Disassembly and Assembly .............................................. 11-33

Suction Strainer and Return Filter .............................................................................................. 11-34


Procedures and Key Points for Removal and Installation .................................................. 11-34

Inspection and Adjustment ........................................................................................................ 11-35


Hydraulic Tank .................................................................................................................... 11-35
Control Valve ...................................................................................................................... 11-36
Lift Cylinders and Tilt Cylinders ........................................................................................ 11-38
Test ...................................................................................................................................... 11-39
Adjustment Values of Microswitches.................................................................................. 11-40
Procedures for Adjusting Microswitches ............................................................................ 11-41

Hydraulic Circuit Diagram ........................................................................................................ 11-42

Troubleshooting .......................................................................................................................... 11-43

Service Data ................................................................................................................................ 11-45


HYDRAULIC SYSTEM

Specifications
Truck Models
EP16KT, EP18KT, EP20KT
Items
Type Gear pump
Model type 15X230J7J2B1B1-210-LA
-AUIHIB
Rated discharge volume 23 (1.40)
cc/rev. (cu.in./rev.)
Drive system Direct connection with
pump motor
Type KVS (equipped with
microswitches)
Main relief pressure 18142 (185) [2631]
kpa (kgf/cm2) [psi]
Type Variable type
Control flowrate 50 (13.2)
l/min (U.S.gal./min)
Inside diameter 45 (1.77)
mm (in.)
Stroke mm (in.) 1645 (64.76)
Inside diameter 70 (2.75)
mm (in.)
Stroke mm (in.) 850 (33.46)
Inside diameter 45 (1.77)
mm (in.)
Stroke mm (in.) 1595 (62.80)
Inside diameter 45 (1.77)
mm (in.)
Stroke mm (in.) 1525 (60.00)
Inside diameter 63 (2.48)
mm (in.)
Stroke mm (in.) 82 (3.23)
Operating oil volume N level : 14.7 (3.88)
L (US.gal) H level : 16.8 (4.44)

11-1
HYDRAULIC SYSTEM

Structure and Functions


Hydraulic Line

View from operator’s seat

6 8
6

5
7
7

1
2
S
R 207772

1 Hydraulic tank 6 Lift cylinder


2 Gear pump 7 Tilt cylinder
3 Control valve S To steering pump
4 Flow regulator valve R From rear axle
5 Down safety valve 8 First lift cylinder (three-stage and two-
stage full-free panorama mast system)
When the lift lever or tilt lever is operated, the the steering function. Although the steering
microswitches located in the spool of the control system shares the hydraulic oil with the
valve send signals to the logic card in the main hydraulic system, it uses its own oil pump
controller. Based on received signals, the logic with a built-in relief valve to provide drive
card drives the pump motor and operates the oil power.
pump. Refer to Steering System section.
The oil flows from the oil pump to the hydraulic
system in the same way as in engine-powered
models.
The steering pump line is a dedicated oil line for
11-2
HYDRAULIC SYSTEM

Gear Pump

Driven gear
Driven gear

· ·

· ·

Rear drive gear


Front drive gear
206875

Operation
Driven gear
Essentially the pump consists of two gears – drive
gear and driven gear – smoothly fitted in the
housing. The oil is carried around the periphery of
the revolving gears from the suction to discharge
side. The teeth are meshing between the two gears
and thus prevent return of oil from the discharge
to the suction side.

Drive gear 203585

Pressure loading mechanism


End clearance
The oil leak in pump decreases the pump efficiency.
The pressure loading mechanism, where the high
discharge pressure is applied to the bush back faces,
reduces this leak by minimizing the clearance
between pump gears and bushes.
Even when sliding faces of gear or brushes are
worn, this mechanism keeps the clearance between
gears and bushes, and maintains the good pump
efficiency.

Outlet 200333

11-3
HYDRAULIC SYSTEM

Control Valve

11 12 13 14
8

10

9
10

6 7

4
2 3

207773

1 Inlet cover 8 Main relief valve


2 Lift valve assembly 9 Tie-bolt
3 Tilt valve assembly 10 Nut
4 Attachment valve assembly 11 Lift switch 1 (Microswitch)
5 End cover 12 Lift switch 2 (Microswitch)
6 Pump port 13 Tilt switch (Microswitch)
7 To tank 14 Attachment switch (Microswitch)

The control valve structure is shown above. The valve turn ON and OFF according to the spool
parts are joined together by three tie-bolts. movement, and send lift and tilt signals to the
Since a lapping process is used for the coupling of logic card.
the body and spool, the body and spool The lift valve is equipped with two micro-
combination cannot be changed. switches for two-step lift speed selection.
The inlet cover contains the main relief valve. The
lift valve assembly contains the load check valve.
The tilt valve spool contains the tilt lock valve.
The microswitches located on top of the control

11-4
HYDRAULIC SYSTEM

Lift valve assembly

15 13 14 13 12 11 10 1 12 13

8
6

3 5 4 2
206992

1 Body 6 Cap 11 Spring


2 Spool 7 Seats 12 Plugs
3 Plates 8 Screw 13 O-rings
4 O-rings 9 Spring 14 Orifice
5 Wipers 10 Poppet 15 Connector

Tilt valve assembly

17 16 15 1 11 10 12 13 2

8
6
9
14 3 5 4 203489

1 Body 7 Seats 13 Screws


2 Spool 8 Screw 14 Bolts
3 Plates 9 Spring 15 Tilt lock valve
4 O-rings 10 Poppet 16 Spring
5 Wipers 11 Spring 17 O-ring
6 Cap 12 O-ring

11-5
HYDRAULIC SYSTEM

Attachment valve assembly

4 3 2 1
5
10

6 12

8 9 11
207776

1 Spring 5 Spring 9 O-rings


2 Poppet 6 Cap 10 Wipers
3 O-ring 7 Screw 11 Plates
4 Bolts 8 Seats 12 Screws
Main relief valve

13 10 11 12 14

3 4 9 5 6 8 1 2 7
203490

1 Cap 6 Pilot poppet 11 Backup ring


2 Plug 7 Lock nut 12 O-ring
3 Sleeve 8 Pilot spring 13 O-ring
4 Main poppet 9 Spring 14 O-ring
5 Pilot seat 10 O-ring

11-6
HYDRAULIC SYSTEM

Lift and Tilt Cylinders


Lift cylinder (Simplex mast)
(Triplex mast second cylinder)

207765
(Duplex and triplex mast first cylinder)

1 2 3
207766
(Duplex mast second cylinder)

207605
Tilt cylinder

202771

The lift cylinders, left and right, are of single- The tilt cylinders, left and right, are of double-
acting type. Air and oil remaining inside air acting type. The piston rod carries a screw-on
chamber 1 of the rod and inside rod chamber 2 socket. This socket is to be repositioned by
between the tubes open check valve 3 when turning, as necessary, when the cylinder is
compressed, thus the air and oil flow out of the connected to the outer mast. The right and left
cylinder. cylinders are hydraulically connected to each
Only the second cylinders of the Duplex Mast other. The tilt angle can be increased or
are provided with bleeding valves. decreased by means of spacer and shim of each
cylinder.

11-7
HYDRAULIC SYSTEM

Flow Regulator Valve

From control valve To control valve

To lift cylinder From lift cylinder


203558

The flow regulator valve is located between loaded forks are lowered to keep a constant safe
each lift cylinder and control valve. It limits the lowering speed regardless of load.
flow of oil forced out of the cylinder when the

Down Safety Valve

Normal

Burst

When hose burst


204971

The down safety valve is located at the bottom side


of right-hand lift cylinder. This valve provides a
means of preventing the load from lowering,
unsafely, rapidly, when the hose bursts.

11-8
HYDRAULIC SYSTEM
Gear Pump
Procedures and Key Points for Removal and
Installation
1. Gear pump
The gear pump is mounted on the counter-
weight.
The rear axle is also connected to the counter-
weight, and the rear axle must be removed
after other components are dismounted. For
the removal of the motor and gear pump, refer
to the procedures for rear axle removal and
installation.
After the parts are removed from the counter-
weight, disconnect the suction pipe from the
gear pump, then remove the gear pump from
the motor.
NOTE
Do not remove the rear wheel during
preparation work.

2. Steering pump

5
5

10
10
2 7 9
8

206917

Removal sequence
1 Batteries 6 Suction hose
2 Step (R.H.) 7 Delivery pipe
3 Step plate 8 Motor, Steering pump
4 Floor plate (A, B) 9 Connector, Suction pipe, O-ring
5 Cord (positive and negative wires) 10 Connector, Delivery pipe, O-ring
11-9
HYDRAULIC SYSTEM

Key points for removal


1. Before removing the batteries, disconnect the
battery plug located at the right side of the
operator’s foot area to cut off the power
supply.

206994

2. Remove the floor plate, and remove floor plate


B.
Disconnect the accelerator connector from the
back side of the floor plate, then remove the
two bolts to take off floor plate A.
3. When disconnecting the suction hose and
delivery pipe, place a drip pan to catch drained
oil.

11-10
HYDRAULIC SYSTEM

Procedures and Key Points for Disassembly and Assembly


Disassembly

* : Parts contained in seal kit 7

*
9

4 6 *
10 8
*

5
*
1
3
*
* * 11
2 3
* 206878

Sequence
1 Cover, Bolt 7 Bushing, Backing ring
2 Mounting flange, Snap ring, Oil seal 8 Rear drive gear
3 Body seal, Bushing seal 9 Driven gear
4 Bushing, Backing ring 10 Center bushing
5 Front drive gear 11 Body
6 Driven gear
Preparation
(1) Before disassembly, obtain the repair kit
containing the parts marked with an aster-
isk (*).
(2) Place disassembled parts on clean paper or
cloth.
(3) Clean the exterior of the pump with clean
hydraulic oil.
Key points for disassembly
(1) Hold the body with a vice for disassembly.
(2) Do not strike the body, gears or bushings
with a hammer to remove them.
(3) Arrange removed parts in the order of dis-
assembly. Pay special attention to the rel-
ative positions of the gears and bushings.
NOTE
Do not remove the oil seal unless it must be
replaced due to an oil leak or other damage.
205873

11-11
HYDRAULIC SYSTEM

Inspection after disassembly


1. Abnormality of oil seal
If the lip section is worn or damaged, replace
the oil seal.
2. Abnormalities requiring replacement of
gear and bushing as a set
(1) The gear and bushing must be replaced
as a set when the gear teeth have cracks
or the teeth surfaces show excessive
wear. Suction Discharge
(2) The gear and bushing must be replaced side side
as a set when heat seizure or abnormal
wear is observed on the bushing. Scuffing
NOTE 205876
Bushing damage is often caused by dirty oil.
When the bushing is replaced, flush the entire
hydraulic circuit and add new oil. Bushing
damage is also caused by a malfunction or
overload of the relief valve.
(3) If the body has scuffing on more than
half of the periphery on the surface
caused by contacting the tips of the gear
teeth, replace the pump assembly.
Key points for reassembly
(1) Before assembly, visually check to see
that all parts are clean. Coat the inside
surface of the body with hydraulic oil.
(2) Apply a thin coat of grease on the lip
sections of seals and oil seals.
(3) Be sure to install the four bushings in
their original positions.
(4) Be sure to align the flat surfaces of the
bushings that face each other.
(5) Cover the shafts of the drive gears with
tape to prevent damaging the oil seal lips
during drive gear installation.
(6) Tighten the cover bolts. Do not tighten
them in single operations, but move
diagonally from bolt to bolt to ensure
uniformity of the tightening force.
46 to 48 N·m
Cover mounting bolt
(4.7 to 4.9 kgf·m)
tightening torque
[34 to 35.4 lbf·ft]
(7) The pump shaft should be easily turned
by hand using a pipe wrench.

11-12
HYDRAULIC SYSTEM

Control Valve
Procedures and Key Points for Removal and
Installation
Removal
(1) Remove the floor plate.
(2) Remove the clevis pin from the control
lever rod, and disconnect the rod from the
control valve spool.
(3) Disconnect the microswitches at connec-
tor 1. 1

207775

(4) Remove the pipes.


2 Tilt pipe
3 Delivery hose
4 Tilt pipe 2
5 Lift pipe
6 Return hose
3

6 207774
4 5

(5) Remove the bolts and nuts that mount the


control valve to the dashboard, and
remove the control valve.

Installation
Follow the removal procedure in reverse.
During installation, conduct the following
inspection.
Check the hydraulic oil level. If the oil level is
low, add oil to the specified level. 206881

11-13
HYDRAULIC SYSTEM

Procedures and Key Points for Disassembly and Assembly


Disassembly
1

24
1
25
2 26

28

31 29

32

17
27
23
30 16 19

20
21 11

15
13
18 6
12
22 8

9
5
14

7
4
10 3
206993

11-14
HYDRAULIC SYSTEM
Disassembly sequence 17 Cap, Bolt
1 Tie-bolt, Nut 18 Spool
2 End cover 19 Screw, O-ring, Seat, Spring
3 Main relief valve, O-ring 20 Plate, Wiper, O-ring
4 Inlet cover, O-ring 21 Tilt lock valve, Spring
5 O-ring 22 Plate, Wiper, O-ring, Screw
6 Cap, Bolt 23 Tilt valve body
7 Spool 24 O-ring
8 Screw, Seat, Spring 25 Spring, Poppet
9 Plate, Wiper, O-ring 26 Cap, Bolt
10 Plate, Wiper, O-ring, Screw 27 Spool
11 Connector, O-ring 28 Screw, Seat, Spring
12 Plug, O-ring 29 Plate, Wiper, O-ring
13 Plug, O-ring, Spring, Poppet 30 Plate, Wiper, O-ring, Screw
14 Lift valve body 31 Shut-off valve assembly
15 O-ring 32 Attachment valve body
16 Spring, Poppet

Key points for disassembly


1. Main relief valve
Do not disassemble main relief valve 3 unless Plug section
it has an abnormality. Also, do not disassem-
ble shut-off valve assembly 31 (option)
mounted on the attachment valve if it has no
abnormalities.

NOTE Lock nut

When the lock nut is loosened, the relief set


pressure changes. Therefore, be sure to turn the
plug section. If the lock nut is accidentally
loosened, reset the pressure using a pressure 205878
gauge.

2. Removing spool
When removing spool 7 from the valve body,
pull out the spool together with screw 8, plate
9 and other parts.
Remove spools 18 and 27 in the same way.
3. Removing screw
Hold the spool in a vice using protective plates
(hard wood pieces or aluminum plates), and use a
hexagon wrench to remove the screw. Carefully
remove the screw since the internal spring force
can eject the screw when it is loosened. 205028

NOTE
Do not remove the orifice from the lift body
valve if there is no abnormality.

11-15
HYDRAULIC SYSTEM

Inspection after disassembly


Valve, spool and return spring
(1) Check for cracks in the valve body, dam-
age on the sliding surfaces, and wear of
the check valve seat surface.
(2) Check the spool for damage, seizure, bend
and operating force.
(3) Check the tilt lock valve for damage and
seizure.
203517

Assembly
Follow the disassembly procedure in reverse.
(1) Clean removed parts with cleaning oil and
dry with compressed air to remove foreign
particles.
(2) Coat parts with hydraulic oil.
(3) Replace O-rings with new parts.
(4) Tighten the tie-bolt to the specified torque.
Tie-bolt tightening 41.2 N·m (4.2 kgf·m)
torque [30.4 lbf·ft]
(5) Make sure the spool moves smoothly.

11-16
HYDRAULIC SYSTEM

Lift Cylinders
Procedures and Key Points for Removal and Installation
Dual-stage Panoramic Mast (Simplex Mast)

6
7
8

8
5
1 4

2
207768
Sequence
1 Nuts 4 Hose guard 7 Cylinder clamp,
2 Fork, Lift bracket 5 High-pressure hose Cushion, Collar, Shims
3 Return (low-pressure) 6 Set bolt, Shims 8 Lift cylinder, Bracket
hose

Suggestions
1. Lift bracket removal
(1) Tilt the mast forward, and lower the inner mast
to the bottom. Slacken the lift chains, and
remove the nuts from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise
the inner mast until the lift bracket becomes
free. Then, back the truck away from the lift
bracket and fork assembly.

204873A

11-17
HYDRAULIC SYSTEM

2. Removing return hose


Connector
Lift the mast to the maximum lift position, and From right lift cylinder
turn the key switch off. Disconnect the return
hose from the right and left lift cylinders at the
connectors.
Removing hose guard To tank
With the masts at the maximum lift position,
remove the hose guard from the front side.
Lowering masts From left lift cylinder 204932
Operate the lift lever gradually to lower the
masts.

3. Disconnecting high-pressure hoses


Disconnect the high-pressure hoses at the Left-hand cylinder
Right-hand cylinder
joints indicated by arrows. Use a drip pan to
catch oil flowing out of the hoses.

204933

4. Removing set bolts


(1) Remove the set bolt at the top of each lift cylin-
der. Lift the inner mast to separate the cylinder
rod ends. To lift the inner mast, hitch a sling
around the mast with protective rag.

NOTE
The rod end of either lift cylinder is shim
adjusted to eliminate the difference in stroke
between the cylinders. Before removing the
set bolts, make a record of the amount of
shims and cylinders to which the shims are fit- 204934
ted.

(2) Tie wood blocks under the inner mast and


detach the sling. Use blocks strong enough to
support the mast.
Make sure the right and left wood blocks are
the same in height.

202983

11-18
HYDRAULIC SYSTEM

5. Removing lift cylinders


Hitch a sling to the lift cylinder from the rear side
of the mast, and remove the cylinder. Hitch the
sling before removing the cylinder clamp.

204935

Installation
To install, follow the reverse of removal sequence,
and do the following steps:
1. Extend and retract the lift cylinders several
times under no load condition to bleed air out
of the cylinder circuits and to make sure that
the cylinders move smoothly.
2. Check the oil level in the hydraulic tank with
an oil level gauge. (Make reference to
Hydraulic Tank section, Inspection and
Adjustment.)
3. Check to make sure that the lift height is
correct.
4. After the lift cylinders or piston rods have
been replaced, check for difference in stroke
between the two cylinders. (Make reference to
Group 12 MAST AND FORK.)

11-19
HYDRAULIC SYSTEM

Procedures and Key Points for Removal and Installation


The following describes the procedures for removing and installing the mast assembly. Note that
the triple-stage full free panoramic mast (Triplex Mast) is used as an example.

Triple-stage Full Free Panoramic Mast (Triplex Mast)

3
1

207612

Sequence

3 First lift cylinder


1 Nuts 4 Chain wheel support assembly
2 Lift bracket assembly 5 Second lift cylinder

Suggestions

1. Removing lift bracket assembly 2

(1) Lower lift bracket assembly 2, and place wood


blocks under the assembly. Tilt the mast 1
forward, lower the inner mast to the bottom,
then remove nuts 1 from the anchor bolts of
the first lift chains. 207613

11-20
HYDRAULIC SYSTEM

(2) Position the mast upright. Raise the inner mast


until main rollers 6 of lift bracket assembly 2
become free. Then, slowly move the vehicle in
reverse to separate from lift bracket 2.
6

207762

2. Removing first lift cylinder 3

(1) Hitch a sling to first lift cylinder 3, and sus-


pend the cylinder with a hoist. Wind the sling
securely to prevent slipping.

(2) Remove the lift cylinder connecting and


mounting bolts, and gently dismount first lift
cylinder 3.

207616

3. Removing second lift cylinders 5

(1) Disconnect hoses from second lift cylinders 5.

(2) Remove stopper bolts at the upper sections of


second lift cylinders 5, and lift the inner mast
[dual-stage full free panoramic mast] or mid-
dle mast [triple-stage full free panoramic
mast] approximately 550 mm (21.67 in.) using
5
slings.

207617

11-21
HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast [dual-


stage full free panoramic mast] or middle mast
[triple-stage full free panoramic mast].
Make sure the right and left wood blocks are
the same in height.

202983

(4) Hitch a sling to second lift cylinder 5 behind


the mast, remove cylinder clamp retaining
bolts, and gently remove second lift cylinder
5.
Hitch the sling securely to the cylinder. The
cylinder cannot be lifted straight up since the
mast cross-member is located above the cylin-
der. Tilt the cylinder and move it away from
the cross-member to remove. Be careful not
have the hands caught between the cylinder
and mast.
5

207618

Installation

To reinstall, follow the removal sequence in


reverse, and service as follows.

(1) Install chain wheel support assembly 4 paral-


lel to a line connecting the centers of chain
anchor bolt holes on first lift cylinder 3 to pre-
vent chains from twisting.

(2) Adjust the chain tensions.


(See the section on inspection and adjust- Good Bad
ment.)
207638
(3) Extend and retract the lift cylinders several
times under no load condition to bleed air out
of the cylinder circuits and to make sure that
the cylinders move smoothly.

(4) After proper operation is confirmed, check the


oil level.

11-22
HYDRAULIC SYSTEM

Procedures and Key Points for Disassembly and Assembly


(Simplex Mast, Triplex Mast Second Cylinders)
* : Parts contained in seal kit

2*
5

207769

Sequence
1 Bearing 4 Piston rod, Piston seal, Piston guide ring
2 Wiper ring, O-ring, Rod guide rings, Seal 5 Cylinder tube
3 Spacer

11-23
HYDRAULIC SYSTEM

Reassembly

* : Parts contained in seal kit

10 6 7 8 9 1 5 4 2 3
*
* * * * *

207765

Sequence
1 Piston rod 6 Bearing
2 Piston guide ring Install 7 through 10 to 6, and screw into 5.
3 Piston seal 7 Seal
4 Spacer 8 Rod guide rings
5 Cylinder tube 9 O-ring
10 Wiper ring

Suggestions

1. Use all parts in the seal kit to replace removed


parts.

2. After installing seal kit parts, apply hydraulic


oil before installing to the cylinder tube or pis-
ton rod.
3. Tighten the bearing to the specified torque.

200 to 230 N·m


Bearing tightening (20.4 to 23.5 kgf·m)
torque [148 to 170 lbf·ft]

11-24
HYDRAULIC SYSTEM

Procedures and Key Points for Disassembly and Assembly


(Duplex Mast, Triplex Mast First Cylinder)

* : Parts contained in seal kit

* 4

1
* 3
7 * 2

*
5

207767

Disassembly sequence

1 Cylinder head assembly 4 Ring assembly


2 O-rings, U-ring, Wiper ring 5 Snap ring, O-ring, Check valve
Remove parts 3 through 6 as sub-assembly 6 Piston rod, Piston
from part 8. 7 Plug, Gasket
3 Slide 8 Cylinder tube

11-25
HYDRAULIC SYSTEM

Reassembly

* : Parts contained in seal kit

10 11 9 8 11 12
1 7
* * * * 5 6 4
2
* *

*
3

207766

Sequence
1 Piston rod, Piston 7 Cylinder tube
Install parts 2 through 6 to part 1. 8 Cylinder head assembly
2 Check valve Install parts 9 through 11 to part 8.
3 O-ring 9 U-ring
4 Snap ring 10 Wiper ring
5 Ring assembly 11 O-rings
6 Slide ring 12 Plug, Gasket

Suggestions

1. Use all parts in the seal kit to replace 4. Tighten the cylinder head to the specified
removed parts. torque.

2. After installing seal kit parts, apply 382 ± 87.3 N·m


Cylinder head
hydraulic oil before installing to the cylinder (39 ± 8 kgf·m)
tightening torque
tube or piston rod. [282 ± 57.9 lbf·ft]
3. Fill the space between the cylinder tube and
piston rod with the specified amount of 5. Tighten the plug to specified torque.
hydraulic oil before installing the cylinder
head. 3.92 N·m
Plug tightening
(0.4 kgf·m)
Amount of hydraulic 75 to 85 cc torque
[2.9 lbf·ft]
oil (4.75 to 5.19 cu. in.)

11-26
HYDRAULIC SYSTEM

Procedures and Key Points for Disassembly and Assembly


(Duplex Mast Second Cylinders)

*: Parts contained in seal kit

6
5
4

1
*2

7 3

207641

Disassembly sequence
1 Holder 5 Spacer, Snap ring
2 Wiper ring, O-ring, U-ring, Backup ring 6 Piston rod
3 Cylinder head, Bushing 7 Cylinder tube, Set screw, Steel ball
Remove parts 4 through 6
as sub-assembly from part 7.
4 Slide ring, Set screw, Piston

NOTE
Spacer is installed in cylinders with lifting
height of 3.7 m (146 in.) or more.

11-27
HYDRAULIC SYSTEM

Reassembly

*: Parts contained in seal kit


10 8 9 16 15 3

* 2
* * * 7 1 5 6 4 207605
14 11 12 13

Sequence
1 Piston rod 6 Snap ring 11 Backup ring
Install parts 2 through 6 7 Cylinder tube 12 U-ring
to part 1. 8 Cylinder head 13 O-ring
2 Piston 9 Bushing 14 Wiper ring
3 Set screw 10 Holder 15 Steel ball
4 Slide ring Install parts 11 through 16 Set screw
5 Spacer 14 to part 10.

Suggestions
1. Use all parts in the seal kit to replace
removed parts.
2. Apply hydraulic oil to the sliding sections
on the cylinder tube inner surface and pis-
ton rod outer surface before installation.
3. Tighten the piston and holder to the speci-
fied torque.
Unit: N·m (kgf·m) [lbf·ft]
196 ± 35
Piston tightening torque (20 ± 3.6)
[145 ± 26]
206 ± 39.2
Holder tightening torque (21 ± 4)
[152 ± 29]

4. Tighten the set screws (2 locations) to the


specified torque.
Unit: N·m (kgf·m) [lbf·ft]

3.92 ± 0.98 (0.4 ± 0.1)


Set screw tightening torque
[2.9 ± 0.72]

11-28
HYDRAULIC SYSTEM

Tilt Cylinders
Procedures and Key Points for Removal and
Installation 1
1 Rubber hose 4
2 Tilt socket pin, Bolt, Washer
3 Tilt cylinder pin, Bolt, Washer
4 Tilt cylinder

3
2 206883

Start by:
(1) Lower the forks to the bottom, and tilt the
mast fully forward.
(2) Hitch lifting slings to the top crossmember
of outer mast by using eye-bolts, and sup-
port the weight of the mast with hoist.

205740

11-29
HYDRAULIC SYSTEM

Procedures and Key Points for Disassembly and Assembly


*: Parts contained in seal kit 2
*
*
*
* 4

3
*

207770

Disassembly sequence
1 Tilt socket, Bolt, Washer, Nut, Spherical 3 Piston rod assembly, Piston seal
bearing, Grease nipple 4 Cylinder tube, Bushing
2 Guide bushing, O-ring, Dust seal,
Packing, Buffer ring

NOTE
Do not remove the tilt socket bearing and
cylinder tube bushing unless they are defec-
tive.

11-30
HYDRAULIC SYSTEM

Suggestions
Removing bushing
Wrap the cylinder with a rag, and clamp it in
a vise. Using a wrench, remove the guide
bushing from the cylinder.

Inspection after disassembly 200351


1. Cylinder tube
(1) Check the bore wall for wear, grooving,
scratch marks and rusting.
(2) Check the welds for cracks.

2. Piston rod
(1) Check for deflection as shown.
(2) Check for surface flaws such as groov-
ing, scratch marks, rusting and wear.
The rod must be replaced if its threads
show a sign of stripping or any other
damage.

3. Packings and rings


Replace all parts contained in the seal kit,
once disturbed. 200319

11-31
HYDRAULIC SYSTEM
Reassembly
*: Parts contained in seal kit

8 7 6
12 9
10 * * * *

13 1 5
11 4
* 3
2
202771

Sequence
1 Piston rod assembly 8 Dust seal
2 Piston seal 9 O-ring
3 Bushing 10 Tilt socket
4 Cylinder tube 11 Spherical bushing
5 Guide bushing 12 Grease nipple
6 Butter ring 13 Bolt, Washer, Nut
7 Packing
Suggestions 4. Mount the tilt cylinder to the vehicle
1. Use all parts in the seal kit to replace body and check the front-and-back tilt-
removed parts. ing angle of the mast, then tighten the
bolt and nut on the tilt socket to the spec-
2. After installing seal kit parts, apply ified torque.
hydraulic oil before installing to the
cylinder tube or piston rod. 127 to 152 N·m
Bolt and nut on the tilt
(13 to 15 kgf·m)
3. Tighten the guide bushing to the speci- socket
[94 to 109 lbf·ft]
fied torque.
5. The piston rod does not normally have to
be disassembled. If the piston is
265 ± 29 N·m
Guide bushing replaced, however, install a new self-
(27 ± 3 kgf·m)
tightening torque locking nut and tighten to the specified
[195 ± 21.7 lbf·ft]
torque.

127 ± 9.8 N·m


Self-locking nut
(13 ± 1.0 kgf·m)
tightening torque
[94 ± 7.2 lbf·ft]

11-32
HYDRAULIC SYSTEM

Flow Regulator Valve


Procedures and Key Points for Disassembly and Assembly

5
3

203559

Disassembly sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims

Inspection after disassembly


1. Check spring fatigue.
2. Check seat and sliding faces of valve and
piston.
3. Check the sliding surfaces of the piston
and valve body for damage.

NOTE
Replace the flow regulator valve an assembly
if any part is defective.

11-33
HYDRAULIC SYSTEM

Suction Strainer and Return Filter


Procedures and Key Points for Removal and
Installation
1. Removal
The hydraulic tank is mounted on the counter- 1
weight.
Before dismounting the hydraulic tank, 2
remove other parts such as the motor, gear 6
4
pump and controller. Regarding the removal
sequence, refer to Removal (Part 1) in Rear 5
Axle section. 3 6 7
Sequence
1 Hose (rear axle return), Clamp
2 Hose (suction), Clamp
3 Hose (return), Clamp
4 Cap, Oil level gauge
5 Clamp
6 Return pipe, Return filter, O-ring
7 Suction pipe, Suction strainer, Packing, 8 206885
Plate
8 Hydraulic tank

2. Inspection
Clean the parts. Replace parts that are clogged
or damaged.

3. Installation
Follow the removal procedure in reverse.
Observe the following instructions during
installation.
(1) When replacing the strainer or filter,
observe the specified tightening torque
during installation to the pipe.
Tightening torque 49 ± 9.8 N·m 206886
for strainer and filter (5 ± 1 kgf·m)
(installation to pipes) [36 ± 7.2 lbf·ft]
(2) Replace the packings and O-ring with new
parts.

11-34
HYDRAULIC SYSTEM

Inspection and Adjustment


Hydraulic Tank
Oil
Oil level, contamination, clouding (mixing
of air or oil)
Tank capacities and mast types Unit : l (U.S.gal)
Truck Models
Mast 1-ton class 2-ton class

Lift
Two-stage panorama masts N level 14.7 (3.88)
2.0 to 5.0 m
(Simplex mast) H level 16.8 (4.44)
(79 to 197 in.)
Lift
Two-stage full-free masts 3.0 to 4.0 m N level 14.7 (3.88)
(Duplex mast) (118 to 157 in.) H level 16.8 (4.44)

Lift
3.7 to 4.33 m N level 14.7 (3.88)
(146 to 170 in.) H level 16.8 (4.44)
Three-stage full-free masts
(Triplex mast) Lift
4.78 to 6.0 m N level 14.7 (3.88)
(188 to 236 in.) H level 16.8 (4.44)

NOTE
In all models and mast and attachment
combinations, the oil level in the tank should
not exceed the H level when the masts are
lowered.

Suction strainer
Damage, clogging
Return filter
Damage, clogging

11-35
HYDRAULIC SYSTEM
Control Valve
(1) External oil leaks
(a) Oil leaks from O-rings between housings
(b) Oil leaks from scraper O-ring
(c) Oil leaks from bolt sections
(2) Oil leaks
3° to 4°
Since it is difficult to measure the amount of
oil leaks from the dismounted control valve,
inspect oil leaks with the control valve con-
nected to the cylinder by following steps (a)
through (c).
Measured amounts of oil leakage refer to the
total amount of oil leakage from the lift spool, Approx. 1 m
tilt spool, tilt lock valve and check valves. (3.3 ft)
(Oil temperature for oil leak measurement:
Approx. 50°C (122°F)) 207764
(a) Place rated cargo load on the forks and lift
to a height of approximately 1 m (3.3 ft).
Tilt the masts approximately 3 or 4
degrees forward from the upright position,
then turn the key switch off.
(b) Remove the oil return hose, and collect the
drained oil.
Standard volume of oil 20 cc
drained in 15 minutes (1.22 cu.in.) max.
(c) When the gravitational-pull lowering dis-
tance and forward tilt distance are large,
check the amount of oil leakage from each
cylinder even if the amount of oil drained
in 15 minutes is less than 20 cc (1.22
cu.in.). (Measured amount of oil leakage
is a standard value; it does not denote the
allowable limit.) 206888

(3) Adjustment of main relief valve


(a) Mount an oil pressure gauge with a mea-
suring range of 24.5 MPa (250 kgf/cm2)
[3,555 psi] on the delivery pipe.
Special tool needed
64309-17733
Connector (R (PT) 1/8 thread)
Hose 64309-17722
64309-17731
Connector (for gauge mounting) 206887
64309-17712 24.5 MPa
Gauge (250 kgf/cm2) [3,555 psi]

NOTE
The above parts are included in the 64309-
17701 kit.
11-36
HYDRAULIC SYSTEM
(b) Operate the tilt lever and tilt the masts
backward to the maximum position. When
the tilt cylinder reaches the limit in its
backward tilt movement, check the oil
pressure gauge. If the gauge indicates
18,142 kPa (185 kgf/cm2) [2,631 psi], it is
normal.
(c) If the relief pressure is not normal, loosen
the lock nut of the relief valve, and while
observing the gauge indication, adjust the
pressure using the adjusting screw.
(d) While pressing the adjusting screw,
tighten the lock nut to secure.
(e) After tightening the lock nut, check the set
pressure of the relief valve again.

18142 + 490
0 kPa
Main relief valve (185+ 50 kgf/cm2)
setting pressure [2631+ 71
0 psi]

(4) Adjustment of optional overload relief valve


(a) Mount an oil pressure gauge in the same
way as for the main relief valve
adjustment.
(b) Move the attachment lever forward or
backward. When the actuator oil pressure
reaches the limit, check the oil pressure
gauge. If the gauge indicates the specified
oil pressure, it is normal.
(c) If the relief pressure is not as specified,
loosen the relief valve lock nut, and while
observing the gauge indication, adjust the
pressure using the adjusting screw.
(d) While pressing the adjusting screw,
tighten the lock nut to secure. kPa (kgf/cm2) [psi]
(e) After tightening the lock nut, check the
relief set pressure again. 4903 50 711
6865 70 995
NOTE 9806 100 1422
There are six relief set pressure values for the 11770 120 1706
overload relief valve. 13730 140 1991
15690 160 2275

11-37
HYDRAULIC SYSTEM

Lift Cylinders and Tilt Cylinders


(1) Adjustment of mast tilt angle
(a) Adjust the air pressure of the tires, and
place the vehicle on level ground.
(b) Tilt the masts backward to the maximum
position.
(c) Measure the backward tilt angles of both
right and left tilt cylinders.
(d) To adjust, loosen the socket tightening
bolt, turn the tilt cylinder rod and adjust
the cylinder stroke until the right and left Bolt Hexagonal
tilt cylinders are tilted at the same angle. section
206890
NOTE
The forward tilt angle of the masts is
automatically set when the backward tilt
angle is adjusted.

Forward tilt - Backward tilt 6° - 7°


(STD)

(2) Adjustment of right and left lift cylinder strokes


(a) Gently raise the inner masts, and observe
the right and left piston rod stopping con-
ditions when they reach the maximum lift
position.
(b) If the upper parts of the inner masts shake
at the moment they stop moving, make
adjustment with shims.
Improper adjustment causes the inner
masts to be slightly lopsided when they 204698
stop, and causes the lift cylinder with a
longer cylinder stroke to shake when the
lift cylinders stop moving.

[Adjustment method]
(1) Raise the inner masts, and place wood blocks
under the inner masts. Lower the masts until
the inner masts contact the wood blocks.

202983

11-38
HYDRAULIC SYSTEM
(2) Loosen the stopper bolt located at the upper
part of the lift cylinder that stopped first.
Lower the piston rod, and insert a shim at the Shim
upper piston rod end.
NOTE
When lowering the piston rod, operate the lift
lever to lower the masts and release oil from
the cylinder.
200365
(3) Raise the piston rod, then tighten the lift cylin-
der stopper bolt. Remove the wood blocks
from under the inner masts.
(4) Lower the inner masts gently, and check to see
if the piston rods move smoothly until the
inner masts reach the lowest position.

Test
(1) Gravitational-pull lowering test
(a) Set the masts upright with rated cargo
load, raise the masts approximately 1 to
1.5 m (3.3 to 4.9 ft), then turn the key
switch off.
(b) Draw a reference line on a mast, and mea-
sure the distance of fork lowering after 15
minutes.
206891

Unit: mm/15 min (in./15 min)


Gravitational-pull lowering
50 (1.97) max.
distance (with load)

(2) Gravitational-pull forward tilt test


(a) Set the masts upright with rated cargo load,
raise the forks approximately 500 mm
(19.7 in.), then turn the key switch off.
(b) Measure the amount of the tilt cylinder
extension after 15 minutes.

Unit: mm/15 min (in./15 min)


Truck Models 206892
Item 1-ton class 2-ton class

Gravitational-pull
forward tilt distance 22 (0.87) 20 (0.79)
(with load)

Inspection of Piping
(1) Check the piping for oil leaks.
(2) Check the rubber hoses for damage, twisting
and sagging.

11-39
HYDRAULIC SYSTEM
Adjustment Values of Microswitches
(1) The ON timings of the lift and tilt microswitches
are indicated in the following table.
(2) In the control valve dismounted from the
vehicle, check the amount of spool travel. In
the control valve mounted on the vehicle,
check the operating stroke of the control lever
knob section.

• Lever operating distances for microswitch


activation
Unit: mm (in.)
Pulling of lever Pushing of lever
18.9 to 25.3
Lift switch 1 (0.744 to 1.0)
56.7 to 63.0
Lift switch 2 (2.23 to 2.48) Pushing of lever
11.9 to 19.8 11.9 to 19.8
Tilt switch (0.47 to 0.78) (0.47 to 0.78)
11.9 to 19.8 11.9 to 19.8
3-stage switch (0.47 to 0.78) (0.47 to 0.78) Pulling of lever
11.9 to 19.8 11.9 to 19.8
4-stage switch (0.47 to 0.78) (0.47 to 0.78)

• Spool travel distances for microswitch


activation
Unit: mm (in.)
Pulling of lever Pushing of lever
1.5 to 2.0
Lift switch 1 (0.06 to 0.078) Pulling of lever
4.5 to 5.0
Lift switch 2 (0.177 to 0.197)
1.0 to 1.5 1.0 to 1.5
Tilt switch (0.04 to 0.06) (0.04 to 0.06)
1.0 to 1.5 1.0 to 1.5 Pushing of lever
3-stage switch (0.04 to 0.06) 206242
(0.04 to 0.06)
1.0 to 1.5 1.0 to 1.5
4-stage switch (0.04 to 0.06) (0.04 to 0.06)

(3) If the measured values deviate from the


standard values listed in the table, make
adjustments by following the procedures on
the following page.

WARNING
If the switch ON timing is too late relative
to the spool movement, the masts move
suddenly, disallowing precious control.
Adjust the switch ON timing accurately
especially for the forward tilt operation,
since improper adjustment can cause
accidents.
11-40
HYDRAULIC SYSTEM

Procedures for Adjusting Microswitches


(Nut A for roller extension adjustment, nut B for Nut B
securing switch in position) Nut A
(1) Adjustment of roller extension
As shown in the diagram, turn nut A to adjust Spool
the amount of roller extension. Temporarily
tighten nut B when the roller contacts the
spool lightly.

NOTE
If the roller is pressed hard against the spool,
loosen nut A and readjust. Set switch upright Slight contact (Moving
roller by hand should
create a small gap)
206243

(2) Adjustment of roller position (height)


Adjustment of lift switch height
Adjustment in dismounted control valve
Loosen nut B slightly. With the roller con- Proper position
tacting the tapered section of the spool, after
move the roller back a distance equaling adjustment
the specified spool travel distance, and Spool
secure it in place. travel
During the above procedure, the attach- distance Contact
position of
ment microswitch roller should be posi-
roller and
tioned at a midpoint of the tapered section spool
of the spool. Spool Contact point
206244

Adjustment in mounted control valve


Adjustment of tilt and attachment switch height
After checking the roller extension as
described in above (1), operate the lever to
check the ON timing. To check the ON
timing, listen to the switching sound when
the test area is quiet, or use the lift speed
check of the I/O self-diagnosis function
when the test area is noisy (motor rotation Midpoint of
may be used as a means of operation con- spool
firmation). 206245
To adjust, loosen nut B slightly and move
the switch.

NOTE
When the lever is in the neutral position, the
switch roller should not contact the spool.

11-41
HYDRAULIC SYSTEM
Hydraulic Circuit Diagram

11-42
HYDRAULIC SYSTEM

Troubleshooting

Improper oil viscosity of oil


Excessive workload caused by severe work condition
Sectional heating caused by large resistance due to
clogged line
Hydraulic tank heats
Improper adjustment of relief valve
extremely
Low set pressure resulting from spring fatigue or dam-
age
Worn gear pump
Flattened discharge line or clogged line

Pump produces loud Insufficient pump suction


abnormal noise Cavitation

Damage in pump case, drive Applied pressure exceeded rating.


gear or pump port flange Deformation or damage caused by external force

Oil leaks from oil seal


Oil leaks from pump Oil leaks from sliding surface of drive shaft
Loose pump tightening bolt
Deteriorated seal inside pump

Low relief set pressure


Masts rise slowly or do not Sticking of relief valve piston
rise Damaged outer O-ring of relief valve body
Insufficient spool stroke due to loose operating lever
Large gravitational-pull
lowering or forward tilt Leaks inside control valve spool
distance

Oil leaks from spool ring cap


Oil leaks Loose plug
Damaged O-ring

11-43
HYDRAULIC SYSTEM
Insufficient oil in hydraulic tank
Masts do not rise or tilt in Relief valve malfunction
either forward or backward (1) Sticking of main valve
direction (2) Broken valve spring
Oil pump malfunction

Relief valve malfunction


(1) Low relief set pressure
Rated cargo load cannot be (2) Faulty plunger or poppet seat
lifted (3) Spring fatigue
(4) Damaged valve case O-ring
Oil pump malfunction
Worn or damaged piston seal
Insufficient oil (due to natural oil consumption)
Oil leaks from oil line or due to damaged seal
Cylinders operate very Oil viscosity higher than specified
slowly No oil suction by gear pump
Oil leaks from hydraulic circuit
Abnormal oil temperature rise
Slow engine rotation
Rising speed is very slow Insufficient spool stroke due to loose operation lever
Clogged tank strainer
Insufficient gear pump discharge volume

Lift cylinder lowering Sticking of flow regulator valve piston


speed is very slow Clogged flow regulator valve, bent hydraulic hose, or
large resistance in hydraulic circuit due to sectional clogging
Bent piston rod
Cylinders shake during
Air mixed in hydraulic piping
operation
Insufficient operating oil in tank
Leaks inside control valve spool
Scratches on sliding surface of cylinder tube that are
Large gravitational-pull
deep enough to be detected by finger nails
lowering distance in lift
Large scratches on sliding surface of cylinder tube
cylinders
Damage or deformation of piston seal
Oil leaks from hydraulic piping
Leaks inside control valve spool
Large gravitational-pull Lodging of foreign particles on packing
forward tilt distance in tilt Damaged piston seal
cylinder Scratches on piston seal
Abnormal shape deformation or leaks from hydraulic
piping
Lift cylinders or tilt cylin- Large sectional scratches or rusting on inner surface of
der drop or tilt forward nat- cylinder
urally at certain position Deformed cylinder
Lodging of foreign particles on seal
Oil leaks from bushing Scratches on oil seal or periphery of dust seal
Damaged O-ring
Abnormal shape deformation
11-44
HYDRAULIC SYSTEM

Service Data

A : Assembly standard
Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT

EP16KT
Lift speed (rated load) 420 (82.7) EP20KT
A EP18KT 400 (78.74)
mm/sec (fpm) 410 (80.7)
[simplex mast]

Lowering speed (rated load)


mm/sec (fpm) A 520 (102.4)
(simplex mast)

Forward tilt angle A 6°


Backward tilt angle A 7°

Lift cylinder rod drift (rated load)


mm (in.)/15 min. A 50 (1.97), max
[Oil temperature 45 °C (113 °F)]

Tilt cylinder rod drift (forward) (rated load)


mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max
[Oil temperature 45 °C (113 °F)]
Main relief valve setting
kPa (kgf/cm2) [psi] A 18142 +490 +5 +71
+0 (185 +0) [2631 +0 ]

Power steering relief valve setting


kPa (kgf/cm2) [psi] A 9336 (95.2) [1354]

Capacity A 23 (1.40)
cc (cu. in.)/rev

Mounting bolts 46 to 48
N·m (kgf·m) [lbf·ft] A (4.7 to 4.9)
[34 to 35.4]

Tie bolts (1/2 in.) A 46 (4.7) [34]


Tightening torque
N·m (kgf·m) [lbf·ft]
Tie bolts (3/8 in.) A 19 (1.9) [14]

11-45
HYDRAULIC SYSTEM

A : Assembly standard
Unit: mm (in.)
Truck Models EP16KT
EP20KT
Items EP18KT

Lift speed (rated load/no load)


A — —

mm/sec (fpm)
[duplex mast]

Lowering speed (rated load)


mm/sec (fpm) A — —
[duplex mast]

Forward tilt angle A 6°


Backward tilt angle A 7°
No. 1
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A —
[Oil temperature 45 °C (113 °F)]
No. 2
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max
[Oil temperature 45 °C (113 °F)]

Lift speed (rated load/no load)


A — —

mm/sec (fpm)
[triplex mast]

Lowering speed (rated load)


mm/sec (fpm) A — —
[triplex mast]

Forward tilt angle A 6°


Backward tilt angle A 7°
No. 1
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A —
[Oil temperature 45 °C (113 °F)]
No. 2
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max
[Oil temperature 45 °C (113 °F)]

11-46
HYDRAULIC SYSTEM

A : Assembly standard
Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT

[piston] 45
A
Inside diameter of cylinder tube 1 (1.77)

Diameter of piston rod 2 A 35 (1.38)

Bearing thread diameter 3 A M48 ¥ 1.5

200 to 230
Tightening torque for bearing 3
A (20.4 to 23.5)
N·m (kgf·m) [lbf·ft]
[148 to 170]

3 2 1

207765

Tightening torque
A 49 ± 9.8 (5 ± 1) [36 ± 7.2]
N·m (kgf·m) [lbf·ft]

Flow rate (no load)


liter (U.S. gal)/min A 50 (13.2)

Tightening torque of elbow and connector


(for mounting on flow regulator valve) A 63.7 (6.5) [47]
N·m (kgf·m) [lbf·ft]

11-47
HYDRAULIC SYSTEM

A : Assembly standard
Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT
[piston] 70
Inside diameter of cylinder A (2.76)
tube 1
Diameter of piston rod 2 A 55 (2.16)
Cylinder head thread M75 ¥ 2
A
diameter 3
Tightening torque for 382 ± 87.3
cylinder head 3 A (39 ± 8)
N·m (kgf·m) [lbf·ft] [282 ± 57.9]
Tightening torque for plug 4 A 3.92 (0.4) [2.9]
Amount of hydraulic oil 5 75 to 85
A
cc (cu.in.) (4.75 to 5.19)

4 1

3
5

207766

11-48
HYDRAULIC SYSTEM

A: Assembly standard
Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT
[piston] 45
Inside diameter of cylinder A (1.77)
tube 1

Diameter of piston rod 2 A 32


(1.26)
Tightening torque for 206 ± 39.2
holder 3 A (21 ± 4)
N·m (kgf·m) [lbf·ft] [152 ± 29]

Holder thread diameter 3 A M52 ¥ 2

Piston tightening torque 4 196 ± 35


N·m (kgf·m) [lbf·ft] A (20 ± 3.6)
[145 ± 26]
Set screw tightening 3.92 ± 0.98
torque 5 A (0.4 ± 0.1)
N·m (kgf·m) [lbf·ft] [2.9 ± 0.72]

5 1 2 5

3
4
207605

11-49
HYDRAULIC SYSTEM

A : Standard value
Unit : mm (in.)
Truck Models EP16KT
EP20KT
Item EP18KT
63
Inside diameter of cylinder tube 1 A
(2.48)
[Guide bushing] 25
A
Diameter of piston rod 2 (0.98)
0
(2.48) 35 –0.012
Inside diameter of tilt socket bushing (fitted) 3 A 0
(1.38 –0.0005 )
32 +0.085
0
Inside diameter of cylinder tube head bushing (fitted) 4 A
(1.26 +0.003
0 )
[Guide bushing] A M68 ¥ 2
Thread diameter 5 A 265 ± 29 (27 ± 3) [195 ± 21.7]

[Guide bushing] A M68 ¥ 2


Tightening torque 5 A 265 ± 29 (27 ± 3) [195 ± 21.7]
N·m (kgf·m) [lbf·ft]
[Tilt Socket]
A M24 ¥ 1.5
Thread diameter 6
Tilt socket bolt 7 A 127 to 152 (13 to 15.5) [94 to 109]
Tightening torque
127 ± 9.8 (13 ± 1.0)
N·m (kgf·m) [lbf·ft] Self-locking nut 8 A
[94 ± 7.2]

6 5 8
3 4

2
7 1

202771

11-50
MAST AND FORK

Mast Systems ............................................................................................................................ 12 - 1


Mast Type Code Stamping Position .................................................................................... 12 - 1
Explanation of Mast Type Code.......................................................................................... 12 - 1
Mast Types .......................................................................................................................... 12 - 1

Description ................................................................................................................................ 12 - 2
Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... 12 - 2
Dual-stage Full Free Panoramic Mast (Duplex Mast) ........................................................ 12 - 3
Triple-stage Full Free Panoramic Mast (Triplex Mast) ...................................................... 12 - 4
Operation of Dual-stage Full Free Panoramic Mast .......................................................... 12 - 5
Operation of Triple-stage Full Free Panoramic Mast.......................................................... 12 - 5

Removal and Installation............................................................................................................ 12 - 6


Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... 12 - 6
Triple-stage Full Free Panoramic Mast (Triplex Mast) ...................................................... 12 - 9

Disassembly and Reassembly .................................................................................................... 12 -12


Dual-stage Panoramic Mast (Simplex Mast) ...................................................................... 12 -12
Dual-stage Full Free Panoramic Mast (Duplex Mast) ........................................................ 12 -16
Triple-stage Full Free Panoramic Mast (Triplex Mast) ...................................................... 12 -20

Inspection and Adjustment ........................................................................................................ 12 -24


Forks .................................................................................................................................... 12 -24
Chain Tension Adjustment .................................................................................................. 12 -25
Tightening Torque .............................................................................................................. 12 -25
Clearance Adjustment on Lift Bracket................................................................................ 12 - 28
Mast Clearance Adjustment ................................................................................................ 12 - 30
Main Roller Shim Replacement (Simplex Mast) ................................................................ 12 - 32
Mast Strip Adjustment ........................................................................................................ 12 - 36
Tilt Angle Adjustment ........................................................................................................ 12 - 36
Lift Cylinder Stroke Adjustment ........................................................................................ 12 - 37

Troubleshooting.......................................................................................................................... 12 - 38

Service Data .............................................................................................................................. 12 - 39 12


Simplex Mast ...................................................................................................................... 12 - 39
Duplex Mast ........................................................................................................................ 12 - 39
Triplex Mast ........................................................................................................................ 12 - 41
MAST AND FORK

Mast Systems
This manual applies to the following vehicle models (names).

Mast types Two-stage Two-stage full-free Three-stage full-free


Model panorama mast system panorama mast system panorama mast system
EP16KT
2G15A 2H15A 2J15A
EP18KT
EP20KT 1G20A 1H20A 1J20A

NOTE : Maximum fork lift height (30 : 3,000 mm) [118 in.]

Mast Type Code Stamping Position Mast Types

Code Mast type


G Two-stage panorama mast
Simplex mast
H Two-stage full-free panorama mast
Duplex mast
J Three-stage full-free panorama mast
Triplex mast

2G 15A 30

206837

Explanation of Mast Type Code


Example: 2 G 15 A 30

Maximum fork lift height (30 : 3,000 mm) [118 in.]


Revision code (A Æ B Æ C ··· Z)
Representative model (not allowable load)
Mast type
Major revision record (2 to 9)

12-1
MAST AND FORK

Description
Dual-stage Panoramic Mast (Simplex Mast)

G
1
Ø Forward Ø Forward
A

Detail of A Detail of F
2
3

Ø Forward Ø Forward

Detail of B, C Detail of D
D

C Ø Forward
E

4 Detail of E Detail of G 207082


F
Unit: mm (in.)
Diam of
1 ton models 2 ton models
5 main roller
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
207760
L 101 (3.98) 116 (4.54)
LL 102 (4.02) 117 (4.60)

1 Inner mast A Main roller F Main roller


2 Outer mast B Main roller G Mast strip
3 Lift chain C Main roller
4 Lift bracket D Side roller
5 Mast-support bearing cap E Main roller

The Panoramic mast features two lift cylinders Mast strips are fitted to the top end of outer
placed behind the mast columns, right and left, mast. These strips are for backing up the inner
to provide maximum visibility. mast when the mast is tilted backward.

12-2
MAST AND FORK

Dual-stage Full Free Panoramic Mast (Duplex Mast)

Ø
Front

8
Cross section of mast Cross section of mast
upper main roller strip
7

9
1
Ø
Front
3
6
Cross section of
Cross section of lift
chain wheel
4 bracket upper main
2 roller

5
10 Ø
Ø
Front Front

Cross section of mast Cross section of lift


lower main roller bracket side roller

207608

1 Lift chain 4 Inner mast 7 Chain wheel


2 First lift cylinder 5 Outer mast 8 Lift bracket main roller
3 Second lift cylinder 6 Lift bracket 9 Mast upper main roller
10 Mast lower main roller

The duplex mast provides a free lift amount When the first lift cylinder rod extends fully,
until the top of lift bracket reaches the mast the second lift cylinders raise the assembly
height. consisting of the lift bracket, first lift cylinder
The mast assembly consists of the inner mast, and inner mast.
outer mast, lift bracket, first lift cylinder and The shoulder sections of the mast main rollers
second lift cylinders. contact the mast rails. The rollers are installed
The first lift cylinder raises the lift bracket, perpendicular to the sliding surfaces.
while the second cylinders operate the inner The main rollers used in the 1-ton and 2-ton
mast and lift bracket. models are the same as those in dual-stage
For lifting operation, oil is first sent to the first panoramic mast.
lift cylinder which raises the forks until the
cylinder rod reaches its stroke end.

12-3
MAST AND FORK
Triple-stage Full Free Panoramic Mast (Triplex Mast)

10 Ø
Front

8 Cross section of mast Cross section of


upper main roller mast strip
1

Ø Ø
11 Front Front
9

3 Cross section of lift Cross section of


bracket upper main hose pulley
4 roller

5
Ø Ø
Front Front
2
6

Cross section of Cross section of sec-


7 side roller ond chain wheel
12

Ø
Front

Cross section of mast Cross section of


lower main roller first chain wheel
207609 207610

1 First lift chain 5 Inner mast 9 Second chain wheel


2 First lift cylinder 6 Middle mast 10 Lift bracket main roller
3 Second lift chain 7 Outer mast 11 Mast upper main roller
4 Second lift cylinder 8 Lift bracket 12 Mast lower main roller
The triplex mast provides a free lift amount When the first lift cylinder rod extends fully,
until the top of lift bracket reaches the mast the second lift cylinders raise the assembly
height. consisting of the lift bracket, first lift cylinder,
The mast assembly consists of the inner mast, inner mast and middle mast.
middle mast, outer mast, lift bracket, first lift The shoulder sections of the mast main rollers
cylinder and second lift cylinders. contact the mast rails. The rollers are installed
The first lift cylinder raises the lift bracket, perpendicular to the sliding surfaces.
while the second cylinder operates the three- The main rollers used in the 1-ton and 2-ton
stage telescopic mechanism and lift bracket. models are the same as those in dual-stage
Two pairs of lift chains are installed. The panoramic mast.
cylinders and lift chains are designed for
smooth and effective operation.
For lifting operation, oil is first sent to the first
lift cylinder which raises the forks until the
cylinder rod reaches its stroke end.
12-4
MAST AND FORK

Operation of Dual-stage Full Free Panoramic Mast

Inner mast

First lift cylinder

Second lift cylinder

Free-lift
height Outer mast

Forks on the ground Maximum free lift Maximum lift 203598

Operation of Triple-stage Full Free Panoramic Mast

First lift chain

Inner mast
First lift cylinder
Middle mast

Second lift chain

Second lift cylinder

Free-lift Outer mast


height

Forks on the ground Maximum free lift Maximum lift 203600

12-5
MAST AND FORK
Removal and Installation
Mast and lift bracket assembly
Dual-stage Panoramic Mast (Simplex Mast)

1 5 6 4

2
207761

Sequence

1 Nuts 5 Low-pressure hose


2 Forks, Lift bracket 6 High-pressure hose for lift cylinders
3 Tilt socket pins 7 Mast-support bearing cap and Bushing
4 Tilt cylinders

Suggestions

1. Lift bracket removal


(1) Tilt the mast forward, and lower the inner
mast to the bottom. Slacken the lift chains, and
remove the nuts from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise
the inner mast until the lift bracket becomes
free. Then, back the truck away, from the
lift bracket and fork assembly.

207084

12-6
MAST AND FORK

2. Removing lift cylinder high pressure hoses


Place the mast in the bottom position, disconnect
the hoses at the flow regulator valve.

3. Removing tilt cylinders


(1) Hitch a sling to the mast. Using two eye-bolts
and a sling as shown and support the mast with
a hoist.

Be sure to use a hoist having a capacity


enough to support the mast assembly.

204845

(2) Remove the tilt socket pins, and separate the


masts from the tilt cylinders.
(3) Start the engine, and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Stop the engine and disconnect the high-pres-
sure hose for lift cylinders.

Tilt socket
pin

207086

4. Removing mast support bearing caps


(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast
assembly. Lay it down flat on a level floor.

NOTE
Marks
Lay the mast assembly on a floor large enough
to disassemble the parts.

207087

12-7
MAST AND FORK

Installation

To install, follow the removal sequence in


reverse, and service as follows. Mast cap
Bushing
1. Procedure for mounting mast support bush-
ings and caps.
(1) Apply grease to the inner surfaces of caps
and mast support bushings.
(2) Install mast support bushings and caps,
making sure that the sides with larger Apply grease
chamfered area face toward the center of Chamfered faces
the vehicle. 203712
(3) Be sure to tighten the support tightening
bolts securely.
1.0 ton 2.0 ton
model model
Bolt tightening
torque 74 (7.5) [54] 178 (18.2) [132]
N·m (kgf·m)
[lbf·ft]

2. Adjust the chain tensions.


(Refer to the Inspection and Adjustment sec-
tion.) Anchor bolt
Tighten the nuts to the specified torque.
2Upper nut
Tightening torque
Unit: N·m (kgf·m) [lbf·ft]

Upper nut 2 57 (5.8) [42.0] 3Double nut (upper)


Double nut 1Double nut (lower)
(lower) 1 98 (10.0) [72.3]
102709

3. Air bleeding of lift cylinders


Due to internal drain type cylinder, the lift
cylinders do not require air bleeding.

4. After proper operation is confirmed, check


the oil level.

12-8
MAST AND FORK

Removal and Installation

Mast and lift bracket assembly

The following describes the procedures for removing and reinstalling the mast assembly. Note that the
triple-stage full free panoramic mast (Triplex Mast) is used as an example.

Triple-stage Full Free Panoramic Mast (Triplex Mast)

5
2 7 6 4 207777

Sequence

1 Nut 5 Low-pressure hose


2 Fork, lift bracket assembly 6 Mast support cap
3 Tilt socket pin 7 Mast support bushing
4 High-pressure hose for lift cylinders
Suggestions

1. Removing lift bracket assembly 2


(1) Lower lift bracket assembly 2, and place wood
blocks under the assembly. Tilt the mast for-
ward, lower the inner mast to the bottom, then
remove nuts 1 from the anchor bolts of the first
lift chains.
1

207613
12-9
MAST AND FORK

(2) Position the mast upright. Raise the inner mast


until main rollers 7 of the lift bracket become
free. Then, slowly move the vehicle in reverse
to separate from lift bracket 2.
7
2

207762

2. Separating mast and tilt cylinders


(1) Lower the inner mast. Hitch a sling to the
upper cross-member of the outer mast. For
sling attachment, install eye-bolts in the holes
on the right and left sides. Use a crane and lift.

Be sure to use a hoist having a capacity


enough to support the mast assembly.

207614

(2) Place wood blocks under the tilt cylinder


mounting sections, and remove pins
(3) Start the engine, and pull back the tilt lever to
contract the tilt cylinder rods.
(4) Disconnect high-pressure hose 4 for lift cylin-
ders.

Tilt socket
pin

207086

3. Removing mast support caps 5


(1) Mark caps 5 to ensure the caps are reinstalled
in original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the
mast assembly from vehicle in the suspended
condition. With the lift bracket side facing up,
place the mast assembly horizontally on
wooden blocks on the level ground.

207615

12-10
MAST AND FORK

Installation
6
To install, follow the removal sequence in reverse, 7
and service as follows.

1. Procedure for installing mast support bushings


7 and caps 6
(1) Apply grease to the inner surfaces of caps and
mast support bushings. Apply grease
(2) Install mast support bushings 7 and caps 6, Chamfered faces
making sure that the sides with larger cham- 203712
fered area face toward the center of the vehi-
cle.
(3) Be sure to tighten the support tightening bolts
securely.

1.0 ton 2 ton


model model
Bolt tightening
torque N·m 74 (7.5) [54] 178 (18.2) [132]
(kgf·m) [lbf·ft]

2. Adjust the chain tensions.


(Refer to the Inspection and Adjustment section.)
Tighten the nuts to the specified torque.

Tightening torque Anchor bolt

Unit: N·m (kgf·m) [lbf·ft]


2Upper nut
Upper nut 2 57 (5.8) [42.0]
Double nut
(lower) 1 98 (10.0) [72.3]

3. Bleeding lift cylinders. 3Double nut (upper)


In the dual-stage full free panoramic mast, only the 1Double nut (lower)
second lift cylinders are provided with air bleeding 102709
valves.
The other lift cylinder does not require air bleeding
since it is an internal drain type cylinder.

4. After proper operation is confirmed, check the


oil level.

12-11
MAST AND FORK

Disassembly and Reassembly


Dual-stage Panoramic Mast (Simplex Mast)
Disassembly

13 11
16
3

12
11

14
10
2
18
9

8
17
6
8

6 15
1
4
5 207763

Sequence

1 Nuts 10 Snap ring, Chain wheel


2 Forks, Lift bracket 11 Cylinder clamps, Seats, Shims, Cushion,
3 Backrest Collar, Bolts
4 Main roller, Shims 12 Bolt, Shims
5 Main roller, Shims 13 Mast strip, Shims
6 Side roller, Brackets, Shims 14 Main roller, Shims
7 Hose guard 15 Main roller, Shims
8 Lift hose (high pressure) 16 Inner mast
[Rubber hose, T-joint, Down safety valve] 17 Lift cylinders
9 Low-pressure hose 18 Outer mast
Suggestions

1. Removing mast strips and main rollers


Remove bolts 11, 12 to free lift cylinder 17.
Displace the tops of the two lift cylinders from
inner mast 16. Slide inner mast 16 toward the bot-
tom of outer mast 18, and remove main rollers 14,
15 and mast strips 13.
12-12
MAST AND FORK

2. Inner mast removal


After removing the main rollers, hitch a sling to
the inner mast crossmember and slide the inner
mast to the upper side of the outer mast to clear the
outer mast roller shafts. Hitch a sling to the inner
mast again and remove it from the outer mast.

207089

Inspection after disassembly

1. Mast
(1) Check each roller for wear, binding or other
defects.
(2) Check each roller on rolling surface for pitting
or other defects.
(3) Check the mast member and the welded joints
of cross members, shafts and supports for
cracks.
(4) Check the mast support bushings for wear or 207090
other defects.

2. Lift bracket
(1) Check the main rollers and side rollers for
smooth rotation. Inspect each roller for wear
and cracks.
(2) Check the welded portions of the bracket for
cracks.
(3) Check the finger bar for bend or distortion.
A = Assembly standard
5 mm (0.2 in.)
Distortion of finger bar A
maximum
207091

12-13
MAST AND FORK

3. Lift chains, chain wheels and chain wheel sup-


ports
(1) Measure the length of each chain to make sure
that two chains are equal in length. Also check
the chains for wear, indication of breakage,
link binding and twist.
(2) Check each chain anchor bolt for cracks or
defects on thread.
(3) Check each chain wheel support and chain
wheel for crack or wear. Check that the wheels
rotate smoothly.
Length of lift chain (per 20 links)

A = Assembly standard
B = Repair or service limit Unit: mm (in.)
1 ton 2 ton
models models
A 318 (12.52) 381 (15.00)
B 327 (12.87) 392 (15.43)

4. Mast strips
Check the mast strips for damage, wear or distor-
tion.
Reassembly

To reassemble, follow the reverse of disassembly


procedure, and service as follows:
1. Longitudinal clearance adjustment between
Clearance
mast and lift bracket
Rollers for mast and lift bracket are available in
three sizes (diameters) for selective use. Select the
size that will provide a longitudinal clearance of 1
mm (0.04 in.) or less. Clearance

Roller sizes
Unit: mm (in.)
Diam of 1 ton 2 ton Lower roller Upper/middle roller
main roller models models 207096
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.60)

12-14
MAST AND FORK

2. Cylinder clamps
Install each lift cylinder in place (in vertical posi-
tion) by fitting to the support, and see if there is
any clearance between the outer mast and cylinder.
Reduce the clearance, if any, to zero by shimming.

Shims

207093

3. Mast supports
(1) Apply grease to the inside surfaces and
grooves of the caps. Mast cap
(2) Install mast support bushings and caps placing Bushing
the chamfered faces inward.
Place wood blocks under mast to apply grease
easily.

Apply grease
Chamfered faces
203712

4. Precautions for installing chain anchor kit


Be careful not to install the center plate in the posi-
tion for link plate.
2
3

4 Stamped mark
207094

1 Link plate (stamped mark on surface)


2 Center plate (no stamped mark)
3 Link
4 Split pin

12-15
MAST AND FORK

Disassembly and Reassembly


Dual-stage Full Free Panoramic Mast (Duplex Mast)
Disassembly

17

10

16
15 8
14

1 15
11
6
5

6 8
12
A
A
1
4 A 12
2
9 1
3
2
13 13 19

18

7 207607

Sequence

1 High-pressure hose for first cylinder, 10 Bolt, Washer, Shims


Clamp 11 Mast strip, Shims
2 Bolt, Washer, Shims 12 Main roller, Shims
3 First lift cylinder 13 Stopper cushion, Cushion plate, Shims,
4 Chain guard Bolt, Washer
5 Chain wheel support, Pin 14 Inner mast
6 Chain wheel, Snap ring 15 Second lift cylinder
7 Cylinder guard, Bolt, Washer 16 Cylinder bracket
8 High-pressure hose 17 O-ring, Plug
9 Cushion, Collar, Shims, Bolt, Washer, 18 Mast cap, Bolt, Washer
Clamp 19 Outer mast, Grease nipple

NOTE
The lift bracket disassembly procedure is
the same as for the dual-stage panoramic
mast.

12-16
MAST AND FORK

Preparation

With the lift bracket side facing up, place the mast
horizontally on wood blocks. Place a wood block 3
as a wedge to prevent the inner and middle masts
from sliding.

Suggestions

1. Removing first lift cylinder 3.


(1) Remove retaining bolts from the first lift cylin-
der.
(2) Hitch slings on first lift cylinder 3, and gently 207619
remove the cylinder.
Use two slings. Wind or tie slings securely to
prevent slipping.

2. Removing main rollers 12 and mast strips 11


(1) Remove clamp bolts from the second lift
cylinders.
12
(2) Remove bolts from the upper rod sections of
the second lift cylinders, and place the cylin- 11
ders on the outer mast.
(3) Check the number of shims and the shim
thickness at the rod end sections.
(4) Move the inner mast down, then remove main
rollers 12, mast strips and shims 11.

3. Removing inner mast 14 12 207620


Using slings, lift and remove inner mast 14, steer-
ing it clear of the roller shaft sections of outer mast
19.

Inspection after disassembly

Follow the same inspection procedure as for the


dual-stage panoramic mast. 19

14 207621

12-17
MAST AND FORK

Reassembly

To reinstall, follow the removal sequence in 12


reverse, and service as follows.

1. Main rollers
(1) Adjust the right and left clearances by increas-
ing or decreasing the thickness of shims 12.

207622

(2) When replacing lift bracket main rollers, make


sure clearance A between each roller and mast
surface is 1 mm or less. A

207623

(3) To install main rollers on shafts, use a driving


tool. Be careful not to accidentally strike the
outer roller surface with the driving tool.
The side of the roller with larger chamfered
area must face toward the outside.

202263

2. Installing second lift cylinders


When installing second lift cylinders 15, make
sure the cylinders are parallel to the mast to pre-
vent torsional stress on the lift cylinders when the
mast is positioned at the bottom. Adjust the instal- 9
lation positions of lift cylinder brackets 16 with 15
shims 9.

16 207632

12-18
MAST AND FORK

3. Installing first lift cylinder


The first lift cylinder must be installed parallel to
the mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 2, adjust the backward inclination so that
clearance at section B is 0 to + 0.5 mm (0 to + 0.02
2
in.) larger than clearance at section A.

201752

4. Precaution for installation of chain anchor kit


Do not use center plate in place of link plate. 2
3

1
4
Stamped mark
200383

1 Link plate (stamped mark on surface)


2 Center plate (no stamped mark)
3 Link
4 Split pin

12-19
MAST AND FORK

Disassembly and Reassembly


Triple-stage Full Free Panoramic Mast (Triplex Mast)
Disassembly
15
17

9 16
1
15
1
23 19
26
10
28
22 20

24 19
25

12 21
7
6 8
19
8 19
7

27 14
30

5 19
13 29
3
4
2
11 18 207606
Sequence

1 Hose for first lift cylinder, Clamp, Bolt, 16 Snap ring, Chain wheel
Washer 17 Snap ring, Hose pulley, Shaft,
2 Bolt, Washer Snap ring, Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose, clamp, Bolt, Washer
5 Chain guard 20 Joint, Connector, Bolt, Washer
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut (chain for second lift cylinder) 23 Bolt, Washer, Shims
9 Mast strip, Shims 24 Second lift cylinder
10 Main roller, Shims 25 Mast strip, Shims
11 Main roller, Shims 26 Main roller, Shims
12 Inner mast 27 Main roller, Shims
13 Nuts 28 Middle mast
14 Lift chain (for second lift cylinder) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple

12-20
MAST AND FORK

NOTE
The lift bracket disassembly procedure is the
same as for the dual-stage panoramic mast.

Preparation

With the lift bracket side facing up, place the mast
horizontally on wood blocks. Place a wood block
as a wedge to prevent the inner and middle masts
from sliding.

Suggestions

1. Removing first lift cylinder 4.


(1) Remove retaining bolts from the first lift cylin- 4
der.
(2) Hitch slings on lift cylinder 4, and gently
remove the cylinder.
Use two slings. Wind or tie slings securely to
prevent slipping.

207624

2. Removing inner mast and main rollers 12


Lower inner mast 12 until the main rollers can be
removed. Remove main rollers 10, 11 and mast 11
strips 9. 9

10 207625

3. Removing inner mast


Using slings, lift and remove the inner mast, steer-
ing it clear of the roller shaft sections of the mid-
dle mast.

12 207626

12-21
MAST AND FORK

4. Removing main rollers 26, 27 from middle 28


mast 28 and outer mast 30
Remove the bolts that are holding second lift 24 27
cylinders 24. Place the cylinder rod ends on the
outer mast. Lower middle mast 28 until main
rollers 26, 27 can be removed. Then, remove the
main rollers.

30

26 207627

Inspection after disassembly

Follow the same inspection procedure as for the


dual-stage panoramic mast.

Reassembly

To reinstall, follow the removal sequence in


reverse, and service as follows.
Shims
1. Main rollers Main
(1) Adjust the right and left clearances by increas- roller
ing or decreasing the thickness of shims.

207630

(2) When replacing lift bracket main rollers, make Outer mast
Middle mast
sure clearance A between each roller and mast Inner mast
surface is 1 mm (0.04 in.) or less.
A

Lift bracket 207629

12-22
MAST AND FORK

(3) To install main rollers on shafts, use a driving


tool. Be careful not to accidentally strike the
outer roller surface with the driving tool.
The side of the roller with larger chamfered
area must face toward the outside.

202263

2. Installing second lift cylinders 24


When installing second lift cylinders 24, make
sure the cylinders are parallel to the mast to pre-
vent torsional stress on the lift cylinders when the
mast is positioned at the bottom. Adjust the instal- 22
lation positions of lift cylinder brackets with shims
24
22.

207631

3. Installing first lift cylinders


The first lift cylinder must be installed parallel to
the mast when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using
shims 3, adjust the backward inclination so that
clearance at section B is 0 to + 0.5 mm (0 to +
3
0.02 in.) larger than clearance at section A.

A 201752

4. Precautions for installation of chain anchor kit


Do not use center plate in place of link plate. 2
3
1 Link plate (stamped mark on surface)
2 Center plate (no stamped mark)
3 Link
4 Split pin

1
4 Stamped mark
200383

12-23
MAST AND FORK

Inspection and Adjustment


Forks
1. Carefully inspect the forks for cracks. Special
attention should be given to the heel section A,
all weld areas and mounting brackets B.
Forks with cracks should be removed from
service. B
Magnetic particle inspection is generally pre- A
ferred due to its sensitivity and the ease of
interpreting the results.

101628

2. Check the difference in height of one fork tip


to the other when mounted on the fork carrier.
A difference in fork tip height can result in
uneven support of the load and cause problems
when loaded.
The maximum allowable difference in fork tip C
elevation C is 5 mm (0.20 in.) for pallet forks.
Replace one or both forks when the difference
in fork tip height exceeds the maximum allow-
able difference. 101629

3. Check the fork blade D. The fork should be


withdrawn from service if the thickness is
reduced to less than the allowable thickness.
Fork blade length may also be reduced by
wear, especially on tapered forks and platens.
Withdraw the forks from service when the D
blade length is no longer adequate for the load
size.
Unit: mm (in.)
101630
Tolerant thickness Standard Limit
EP16KT 35 ± 2 (1.4 ± 0.8) —
EP18KT 35 ± 2 (1.4 ± 0.8) —
+3 +0.1
EP20KT 35 0 (1.8 0 ) 33 (1.3)

12-24
MAST AND FORK

Chain Tension Adjustment


Two-stage panoramic mast
(Simplex Mast)

NOTE
Follow the same chain tightening procedure
for all masts except for the Simplex Mast
chains on the lift bracket side.

WARNING
Personal injury can be caused by sudden
movement of the mast and lift bracket. Use
blocks to fix the mast and lift bracket from
any movement while the adjustments are Anchor bolt
made. Keep hands and feet clear of any parts
that can move.
2Upper nut

1. Have the truck on a level floor, with the mast


vertical and the fork lowered to the bottom.
Check that the lift cylinders are fully retracted.
2. Loosen the double nut 1 (lower) and 2 3Double nut (upper)
(upper). 1Double nut (lower)
3. Set the anchor bolts with double nut (upper) 3. 102709
4. Raise the forks slightly and push the chains
inward midway between the chain wheel and
anchor alternately to check the tension. When
adjusting the chains by means of the double
nut (upper) 3, tilt the mast forward to slacken
the chains to facilitate adjustment.
5. Turn double nut (upper) 3 to adjust the chain
tension. Then, hold the anchor bolt in place
with a wrench and tighten upper nut 2 to the
specified torque.
6. Hold double nut (upper) 3 in place with a
wrench, and tighten double nut (lower) 1 to
the specified torque.
102708
Tightening Torque
Unit: N·m (kgf·m) [lbf·ft]
57
Upper nut 2 (5.8)
[42.0]
98
Double nut
(10)
(lower) 1
[72.3]

7. With the lift cylinder rods fully contracted, make


sure the amount of protrusion of each lift bracket
main roller is 40% of the roller diameter or less.
40% or less
8. Make sure that the chain tension is correct
207634
with the mast in vertical (0°) position.
12-25
MAST AND FORK

Dual-stage full free panoramic mast


(Duplex Mast)

1. On the level ground, position the mast at a


right angle to the ground surface, lower the
forks to the ground, and make sure the lift
cylinder rods are contracted fully.
2. Secure the anchor bolts on the lift bracket side
by tightening the upper nuts and double nuts.

207633

3. Adjust the chain tensions by turning the dou-


ble nuts (upper) on the lift cylinder side. With
the mast standing perpendicular to the ground,
lift the forks slightly, then press the chains
alternately at a midpoint between the chain
wheel and the secured end of the chain to make
sure the tension is the same in both chains.

NOTE
Tilting the mast slightly forward causes the
chains to sag, thus making it easier to adjust 102708
the chain tensions with the double nuts (upper).

4. Tighten the upper nuts and double nuts on the


cylinder side to the specified torque.
5. With the lift cylinder rods fully contracted,
make sure the amount of protrusion of each lift
bracket main roller is 40% of the roller diam-
eter or less.
6. Conduct final adjustment with the mast posi-
tioned perpendicular to the ground.

40% or less
207634

12-26
MAST AND FORK

Triple-stage full free panoramic mast


(Triplex Mast)

Adjust each of the first and second chains (total of


four).

1. On the level ground, position the mast perpen-


dicular to the ground surface, lower the forks
to the ground, and make sure the lift cylinder
rods are contracted fully.
2. Secure the anchor bolts on the lift bracket
(first chains) side and the lower inner mast
section (second chains) by tightening the
upper nuts and double nuts.

NOTE
207635
When installing the second chains (between
inner mast and outer mast) in the triple-stage
full free panoramic mast, adjust the chain ten-
sions slightly tighter. If the chains are loose,
damage can occur to the hose pulley.

3. Adjust the chain tensions by turning the dou-


ble nuts (upper) on the lift cylinder side. With
the mast standing perpendicular to the ground,
lift the forks slightly, then press the chains
alternately at a midpoint between the chain
wheel and the secured end of the chain to
make sure the tension is the same in both
chains.

NOTE
Tilting the mast slightly forward causes the
102708
chains to sag, thus making it easier to adjust the
chain tensions with the double nuts (upper).

4. Tighten the upper nuts and double nuts on the


cylinder side to the specified torque.
5. With the lift cylinder rods fully contracted,
make sure the amount of protrusion of each lift
bracket main roller is 40% of the roller diame-
ter or less.
6. Conduct final adjustment with the mast posi-
tioned perpendicular to the ground.

40% or less
207636

12-27
MAST AND FORK
Clearance Adjustment on Lift Bracket

NOTE
The adjustment procedure for the lift bracket
is the same for the Simplex Mast, Duplex
Mast and Triplex Mast.

1. Longitudinal clearance adjustment on lift


bracket main rollers F
(1) Raise the forks a little from the floor.
(2) Insert a bar between the upper part of lift
bracket and the inner mast, and push the inner
mast to one side. Using feeler gauges, measure
the clearance F between the main roller and
inner mast on the opposite side.
0.1 to 1.0 mm
Clearance F F 207095
(0.004 to 0.039 in.)

(3) If the clearance F is out of specification, use


oversize rollers. F
Roller sizes
Unit: mm (in.)
Diam. of 1 ton 2 ton
main roller models models
F
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57) Lower roller Upper/middle roller
207096
LL 102 (4.02) 117 (4.60)

(4) Lift bracket main rollers (upper and center rollers)


The upper rollers should be the same in size or
1-rank larger than the center rollers.
2. Lateral clearance adjustment on lift bracket
main rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its con-
tact point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and
push the lift bracket to one side with a bar. Set 203818
the indicator to zero.
(4) Insert a bar between the inner mast and lift 1 1
bracket on the indicator side, and push the lift
bracket to the opposite side. G1
(5) Read the indicator. 2 2
0.1 to 0.5 mm
Clearance G1
(0.004 to 0.020 in.)

(6) Adjust clearance G1 between the center main


roller and weld plate 2 at the maximum lift
position by increasing or decreasing the thick- 202276
ness of the shim.
Do not install a shim at upper main roller 1.
12-28
MAST AND FORK

For the lift bracket upper main roller or center


main roller, to extend 0.5 mm (0.02 in.), insert Inner mast
a 0.5 mm (0.02 in.) shim (a) on the inside and
remove the 0.5 mm (0.02 in.) shim (b) from
Shims (b)
the lower stopper, then tighten the bolts.

Shims (a)

207156

(7) Lower the lift bracket slightly from the top,


then adjust clearance G2 between the side
roller and mast by increasing or decreasing the G2
thickness of the shims. • •

Clearance G2 01 to 0.5 mm
(0.004 to 0.020 in.) Side roller
Side roller

202277

Adjust the side roller clearance by adding


shims between the roller bracket and lift
bracket.

Shims
Roller

Bracket
207098

(8) With the lift bracket at the top, adjust clear-


ance G3 with shims.

Clearance G3 01 to 0.5 mm
(0.004 to 0.020 in.)

G3
207158

12-29
MAST AND FORK

Mast Clearance Adjustment

NOTE
Adjust mast clearances at the locations indi-
cated below.
1. Simplex Mast and Duplex Mast: Main
rollers between the outer mast and inner Shims
mast
2. Triplex Mast: Main rollers between the
outer mast and middle mast, and main
207157
rollers between the middle mast and inner
mast.

1. Longitudinal clearance adjustment on mast


main rollers
(1) Tilt the mast fully backward.
H
(2) Using feeler gauges, measure the clearance H
between the inner mast lower roller and outer
mast.
0.1 to 1.0 mm
Clearance H
(0.004 to 0.039 in.)

(3) If the clearance H is out of the specification, 207099


use oversize rollers.
Roller sizes
Unit: mm (in.)
Diam. of 1 ton 2 ton
main roller models models
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.60)

2. Lateral clearance adjustment on inner mast


main rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inside of the outer
mast with its contact point rested on the inner
mast.
(3) Go over to the opposite side of the mast, and
push the inner mast against the outer mast. Set
the indicator to zero.
J
204886

12-30
MAST AND FORK

(4) Insert a bar between the outer and inner masts


on the indicator side, and push the inner mast
to the opposite side.
(5) Read the indicator.
0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)

J
207101

(6) If the clearance J is out of specification, adjust


by shims.

NOTE
Refer to Main Roller Shim Replacement.
Shims

207102

3. Lateral clearance adjustment on outer mast


main rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the outer mast with its
contact point rested on the inner mast.
K
(3) Go over to the opposite side of the mast, and
push the outer mast against the inner mast with
a bar. Set the indicator to zero.
(4) Insert a bar between the outer and inner mast,
and push the inner mast to the opposite side. 204889
(5) Read the indicator.
0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.) K

207103

12-31
MAST AND FORK

(6) If the clearance K is out of specification,


adjust it by shims.

NOTE
Refer to Main Roller Shim Replacement.

Shims

207104

Procedure for replacing main roller shims


[Simplex Mast]

1. Remove the lift bracket from the mast.

NOTE
Refer to Removal and Installation,
1. Lift bracket removal.

2. Lower the inner mast below the outer mast as


follows:
(1) Raise the front end of the truck, and support
that end with block or the like.
(2) Remove the upper set bolts from the lift cylin-
ders, and lift the inner mast with a hoist.
Remove the hose guard.
(3) Remove the clamps from the lift cylinders.
Pull the bottom ends of the cylinders from the
outer mast, tilt the cylinders to the center of
the mast, and tie them to the crossmember of
outer mast with rope.
(4) Slowly lower the inner mast until it comes in
contact with the lift cylinders.
(5) Now the main rollers can be removed from the 202961
inner and outer masts. Remove the mast strips
and shims in advance because they are apt to
come off under this condition.

12-32
MAST AND FORK

Procedure for replacing main roller shims


[Dual-stage full free panoramic mast (Duplex
Mast)]

1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" in the
Hydraulic System section.

2. Removing first lift cylinder


(1) Hitch a sling on the first lift cylinder, and sus-
pend it with a hoist. Wind the sling securely to
prevent slipping.
(2) Remove lift cylinder connecting bolts and
mounting bolts, and gently remove the first lift
cylinder.

NOTE
Subsequent removal procedure is the same as
the removal procedure for the Simplex Mast
(see "Procedure for replacing main roller
shims").

207616
3. Position the inner mast lower than the outer
mast by following operations.
(1) Lift the front side of the vehicle with a rigid
rack or other equipment.
(2) Remove set bolts from the upper sections of
the lift cylinders, then lift the inner mast.
(3) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the
lower outer mast section. Tilt the cylinders by
moving the top sections towards the center of
the vehicle, then secure the cylinders to the
cross-member of the outer mast with a rope.
202961
(4) Lower the inner mast until it contacts the lift
cylinders.
(5) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.

12-33
MAST AND FORK

Procedure for replacing main roller shims


[Triple-stage full free panoramic mast (Triplex
Mast)]

1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" section in
the Hydraulic System section.

2. Removing first lift cylinder


(1) Hitch a sling on the first lift cylinder, and sus-
pend it with a hoist. Wind the sling securely to
prevent slipping.
(2) Remove lift cylinder connecting bolts and
mounting bolts, and gently remove the first lift
cylinder.

3. Position the inner mast lower than the middle


mast by following operations. 207616
(1) Lift the front side of the vehicle with a rigid
rack or other equipment.
(2) Hitch slings to the upper cross-member of the
inner mast, and suspend with a hoist.
(3) Remove the chain guards for the second lift
chain wheels.
(4) Dismount the second lift chains on the outer
mast side, and place them in front of the inner
mast.
(5) Lower the inner mast until main rollers can be
removed.
(6) Place wood blocks under the inner mast for 207639
support.
(7) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.

NOTE
In this condition, second lift cylinders cannot
be dismounted.

12-34
MAST AND FORK

4. Position the middle mast lower than the outer


mast by following operations.
(1) Lift the inner mast to the height of the middle
mast, then place wood blocks for support.
(2) Hitch slings to both middle mast and inner
mast, and suspend with a hoist.
(3) Remove set bolts from the upper sections of
the middle mast lift cylinders, then lift the
middle mast and inner mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the
lower outer mast section. Tilt the cylinders by
moving the top sections towards the center of
the vehicle, then secure the cylinders to the
cross-member of the outer mast with a rope.
(5) Lower the middle mast and inner mast until
main rollers can be removed.
(6) Place wood blocks under the middle mast and
inner mast for support.
(7) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.

207640

12-35
MAST AND FORK

Mast Strip Adjustment

1. Check the clearance L with the clearance


between the outer mast rollers and inner mast L
set to zero (0) in maximum lift position.
0.l to 0.5 mm
Clearance L
(0.004 to 0.020 in.)

200391

2. If the clearance L is out of specification, adjust


it by shims. Shims

NOTE
Refer to Main Roller Shim Replacement.

3. After adjusting the all clearance, move the


mast and lift bracket slowly to make sure that
they move smoothly through their full stroke.

200392

Tilt Angle Adjustment

1. Adjust the tire pressure correctly and park the


truck on a level floor.
2. Tilt the mast fully backward and stop the
engine.
3. Measure the backward tilt angle of the mast at
both sides.
4. To adjust the tilt angle, loosen the bolt of tilt
cylinder socket, and adjust the rod length by Bolt
turning the rod. Adjust cylinders so that there
is no difference in tilt angle between the cylin-
ders, left and right. 207105

NOTE
It is not necessary to adjust the forward tilt angle
if the backward tilt angle is properly adjusted.

Forward - backward tilt angle 6° - 7° (standard)

12-36
MAST AND FORK

5. After adjusting the tilt angle, tighten the sock-


et bolts to the specified torque.
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 127 to 152
for tilt cylinder (13 to 15.5)
socket bolt [94 to 112]

Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast, and observe how


the piston rods, left and right, stop at the
moment the inner mast reaches its maximum
height.
2. If the top of the inner mast rolls at that
moment, make a shim adjustment. Abnormal
condition can be detected by a little time lag in
stopping between the piston rods, left and
right, and rolling of the rod with a longer 204698
cylinder stroke.

3. Adjusting method
(1) Raise the inner mast, place blocks under the
left and right sides of the inner mast, and lower
the mast until its rests on the blocks.
(2) Remove the set bolt at the top of lift cylinder
which stopped first, retract the piston rod, and
insert shims at the top of piston rod end.
(3) Extend the piston rod, and tighten the cylinder
set bolt. Remove the blocks from under the
inner mast.
(4) Slowly lower the inner mast to the bottom to 202983
ensure the piston rods move smoothly and that
the left and right lift cylinders come to the end
of stroke simultaneously.
Bleeding lift cylinders
Set bolt
When air and oil remaining inside the air Shims
chamber of the rod and inside the rod chamber
between the tubes are compressed, they open
the check valve and flow out of the cylinder.
Therefore, there is no need to bleed the lift
cylinders.

200365

12-37
MAST AND FORK

Troubleshooting
Faulty rotation of rollers Supply grease or replace
Lift bracket, inner masts rollers.
and middle masts do not
Improper mast strip clearance Adjust with shims.
rise or lower smoothly
Improper main roller or side Adjust front-to-back and
roller clearance right-to-left clearances.
Uneven chain tension between Adjust chain tension.
right and left chains
Excessive side roller clearance Adjust by adding shims.
Lift bracket or inner masts Uneven adjustment of shims Adjust by removing shims.
are lopsided between right and left lift
cylinders
(at maximum lift position)
Lift bracket retaining stopper Adjust chain tension.
in contact

Abnormal noise is generated Faulty rotation of rollers Supply grease or replace


by masts. rollers.
Defective hose pulley bearing Replace.
[for three-stage full-free
panorama mast system only]

Lift cylinders descent by Damaged gaskets in lift Replace.


leaks. cylinders
Internal leak of control valve Replace.
Entire masts shake Worn mast support bushings Re-tighten, or replace
and caps bushings and caps.
Masts are deformed in
shape. Uneven cargo load or Replace assembly.
overload
Bent finger bars Repair or replace.
Uneven fork end heights Bent forks Replace.
Mast deformation due to Repair or replace.
uneven cargo load
Low oil temperature Increase oil temperature by
Second lift cylinders move raising and lowering lift bracket.
when first lift cylinder oper-
ates. [three-stage full-free No clearance for lift bracket Readjust rollers.
panorama mast system] roller surfaces
Clogged pipes Inspect and clean hydraulic
line.
Mushy operation of fall-
prevention function when Improper air bleeding Bleed hydraulic system.
lifting operation is stopped. Improper air bleeding Bleed hydraulic system.

12-38
MAST AND FORK

Service Data
Simplex Mast A: Assembly standard B: Repair or service limit
Duplex Mast Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT
Difference in height between fork tips A 5 (0.20)

+3
920 ¥ 100 ¥ 35 ± 2 920 ¥ 100 ¥ 35 0
A (36.2 ¥ 3.94 ¥ 1.38 ± 0.079) (36.2 ¥ 3.94 ¥ 1.38 +0.118 )
0

Thickness of forks (width ¥ thickness)


EP16KT
— 920 ¥ 100 ¥ 33
B
EP18KT (36.2 ¥ 3.94 ¥ 1.3)

A 318 (12.52) 381 (15.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43)
S A 99 (3.90) 113.8 (4.48)
M A 100 (3.94) 115 (4.53)
Diameter of main roller L A 101 (3.98) 116 (4.57)
LL A 102 (4.02) 117 (4.60)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
(inside to inside) A A 523 (20.59) 575 (22.64)
Distance between middle mast main rollers
(outside to outside) B A 581 (22.87) 639 (25.16)
Distance between lift bracket main rollers
(outside to outside) C1 A 396 (15.60) 437 (17.22)
Distance between lift bracket main rollers
(outside to outside) C2 A 396 (15.60) 437 (17.22)
Distance between lift bracket main rollers
(outside to outside) D A 401 (15.80) 439 (17.30)
Distance between lift bracket side rollers
(outside to outside) E A 406 (16.00) 446 (17.57)
Longitudinal clearance of lift bracket middle
rollers (with forks slightly lifted) F A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of lift bracket middle
main rollers (fully raised) G1 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket side rollers
(fully raised) G2 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket lower main
rollers (fully raised) G3 A 0.1 to 0.5 (0.004 to 0.020)
Longitudinal clearance of mast main rollers
(in the whole lift range) H A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of middle mast, inner mast
main rollers (fully raised) J A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of outer mast, middle mast
main rollers (fully raised) K A 0.1 to 0.5 (0.004 to 0.020)
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)

12-39
MAST AND FORK

Simplex Mast A: Assembly standard


Duplex Mast Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT

F
L
G1

G3

G2
B
F
Inner mast
Lift bracket
A C1
K

H E

J C2

D
Outer mast

207106
Mastsupport bolts A 74 (7.5) [54] 178 (18.2) [132]
Tightening torque
Upper nut 2 57 (5.8) [42.0]
N·m (kgf·m) [Ibf·ft] A
Double nut (lower) 1 98 (10) [72.3]
Distortion of finger bar A 5 (0.2)

Anchor bolt

2 Upper nut

3 Double nut (upper)

1 Double nut (lower)


102709

12-40
MAST AND FORK

Triplex Mast A: Assembly standard B: Repair or service limit


Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT
Difference in height between fork tips A 5 (0.20)

920 ¥ 100 ¥ 35 ± 2 920 ¥ 100 ¥ 35+30


A (36.2 ¥ 3.94 ¥ 1.38 ± 0.079) (36.2 ¥ 3.94 ¥ 1.38+0.118 )
0

Thickness of forks (width ¥ thickness)


EP16KT
— 920 ¥ 100 ¥ 33
B
EP18KT (36.2 ¥ 3.94 ¥ 1.3)

A 318 (12.52) 381 (15.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43)
S A 99 (3.90) 113.8 (4.48)
M A 100 (3.94) 115 (4.53)
Diameter of main roller
L A 101 (3.98) 116 (4.57)
LL A 102 (4.02) 117 (4.60)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
(inside to inside) A A 523 (20.59) 575 (22.64)
Distance between middle mast main rollers
(outside to outside) B A 581 (22.87) 639 (25.16)
Distance between lift bracket main rollers
(outside to outside) C1 A 396 (15.59) 437 (17.20)
Distance between lift bracket main rollers
(outside to outside) C2 A 396 (15.59) 437 (17.20)
Distance between lift bracket main rollers
(outside to outside) D A 401 (15.79) 439 (17.28)
Distance between lift bracket side rollers
(outside to outside) E A 406 (15.98) 446 (17.56)
Longitudinal clearance of lift bracket middle
rollers (with forks slightly lifted) F A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of lift bracket middle
main rollers (fully raised) G1 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket side rollers
(fully raised) G2 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket lower main
rollers (fully raised) G3 A 0.1 to 0.5 (0.004 to 0.020)
Longitudinal clearance of mast main rollers
(in the whole lift range) H A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of middle and inner mast
main rollers (fully raised) J A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of outer and middle mast
main rollers (fully raised) K A 0.1 to 0.5 (0.004 to 0.020)
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)
Distance between middle mast main rollers M A 433 (17.05) 475 (18.70)
Distance between inner mast main rollers N A 491 (19.33) 539 (21.22)

12-41
MAST AND FORK

Triplex Mast A: Assembly standard


Unit: mm (in.)
Truck Models EP16KT
Items EP18KT EP20KT

F
L
G1

G3
Middle mast
G2
F B
N Lift bracket
Inner mast

K C1

Outer mast E
A
H M J C2
Middle mast K

207644
Mastsupport bolts A 74 (7.5) [54] 178 (18.2) [132]
Tightening torque
Upper nut 2 57 (5.8) [42.0]
N·m (kgf·m) [Ibf·ft] A
Double nut (lower) 1 98 (10) [72.3]
Distortion of finger bar A 5 (0.2)

Anchor bolt

2 Upper nut

3 Double nut (upper)

1 Double nut (lower)


102709

12-42
SERVICE DATA

Inspection Standards .................................................................................................................. 13 - 1

Periodic Replacement of Parts .................................................................................................... 13 - 7


Critical Safety Parts ............................................................................................................ 13 - 7

Lubricating Standards ................................................................................................................ 13 - 8


Lubrication Chart ................................................................................................................ 13 - 8
Lubricant Quantities ............................................................................................................ 13 - 9

Main Component Weights .......................................................................................................... 13 - 10

Tightening Torques for Standard Bolts and Nuts ...................................................................... 13 - 11

Special Tool Table ...................................................................................................................... 13 - 13

13
SERVICE DATA

Inspection Standards
■ Inspect and conduct maintenance according to the specified hourme- : Inspect or clean
ter indication or the number of calendar days, whichever comes first. : Replace or adjust

Periodic inspection
interval

Remarks

Inspection/maintenance location and item

Service standard

Electrical system
Abnormal noise during rotation
Traction motors Brush thickness limit:
Brush wear and Pump motor 19 mm (0.75 in.)
rotating smoothness
Brush thickness limit:
Steering motor
13 mm (0.51 in.)
Brush spring fatigue

Motors Brush contact wear pattern and side


working face amount
Commutator contamination, streaks
and wear irregularities
Looseness of connections
Grease replacement in motors, shafts
and couplings
Insulation resistance
Electrolyte levels Inspection: Every week or 50 hours
Specific gravity of electrolyte after Inspection: Every week or 50 hours
charging Specific gravity: 1.28
Voltage of each cell 48 V
Batteries Terminal corrosion, damage,
contamination and looseness
Case damage and contamination, and
fluid leaks
Insulation resistance
Charge level
Contactors Contact looseness, damage and wear

13-1
SERVICE DATA

Periodic inspection
interval

Remarks

Inspection/maintenance location and item

Service standard

Control valve microswitch operating


condition
Damage and mounting looseness
Micro Foot brake switch operating condition
switches
Damage, mounting looseness
Hand brake switch operating condition
Damage and mounting looseness
Controller operating condition
(1) Seat switch
(2) Forward/reverse selector switch
(3) Control valve switch
(4) Brake switch
(5) Accelerator switch
Main (6) Line contactors
controller (7) Forward
(8) Reverse
(9) Regeneration bypass
Internal contamination and damage
Over-current limit value

Fuses Fuse mounting looseness


Fuse capacity
Wire harness damage and clamp
looseness

Wiring Terminal connection looseness and


taping condition
Battery connector contacts and bolt
looseness

13-2
SERVICE DATA

Periodic inspection
interval

Remarks

Inspection/maintenance location and item

Service standard

Power transmitting system


L.H. 1.09 l (0.29 U.S. gal)
Transfer oil level and contamination
R.H. 1.86 l (0.49 U.S. gal)
Transfers Oil leaks
Bolt looseness
Drive system
Tire cracking and damage
Tire tread depth
Tires Abnormal tire wear
Metal pieces, rocks, other foreign
materials on tires
Hub bolts Damage and looseness
Rims and
Damage
wheeldiscs
Wheel bearing rattle
Wheel
bearings Abnormal noise in wheel bearings
Grease replacement
Steering system
Play, looseness, rattling and operating
Play : 15 to 30 mm (0.6 to 1.2 in.)
Steering condition
wheel
Gear box mounting looseness
Deformation, cracking and damage
Rear axle Oil leaks
Bolt looseness

13-3
SERVICE DATA

Periodic inspection
interval

Remarks

Inspection/maintenance location and item

Service standard

Braking system
Free play 3 to 9 mm (0.12 to 0.35 in.)
Distance between depressed brake
pedal and floor board
Air trapped in fluid
Brakes
Braking performance
Uneven braking performance between
right and left
Reservoir tank level and oil leaks 99 cc (6.04 CU. in.)
Parking Lock condition
brake Braking performance 3rd or 4th notch engagement
Rods and Operating condition
cables Looseness of links and clamps
Damage, leaks and contact with other
Hoses and parts
pipes
Looseness of links and clamps
Clearance between brake disc and pad 0.4 to 1.1 mm (0.016 to 0.043 in.)
Brake disc mounting looseness
Brake discs Brake pad wear Service limit : 2 mm (0.078 in.)
and pads Brake pad operating condition
Rusting of pins
Return spring fatigue and damage
Brake disc wear and damage Service limit : 9 mm (0.354 in.)

13-4
SERVICE DATA
Periodic inspection
interval

Remarks

Inspection/maintenance location and item

Service standard

Lift system
Fork and stopper pin damage
Allowed fork thickness wear limit
Forks Forks—wear and distortion EP16KT
EP18KT
EP20KT
Cracking and wear in fork base and
tooth weld
Cracking in cross-member welds of
outer and inner masts
Cracking in welds of tilt cylinders
and masts
Cracking in welds of outer masts and
Masts cylinder support
and lift
Cracking in lift bracket welds
bracket
Roller bearing rattle
Wear and damage of mast support metal
Cracking and damage in rollers, roller
pins and welds
Mast operating condition and mounting
looseness
Allowed lift chain stretch
Length of lift chains (20 links) 1-ton class : 327 mm (12.87 in.)
2-ton class : 392 mm (15.43 in.)
Chains and Chain deformation, damage, lubrication
chain and rusting
wheels Chain bushing coupling, bolt
deformation and damage
Chain wheel deformation and damage
Chain wheel bearing rattle
Attachment abnormality and mounting
Attachments
conditions
Hydraulic system
Looseness, deformation and damage of
rods, rod bolts and rod ends
Cylinder operating condition Drift lowering distance
Drift lowering and forward 50 mm (1.97 in.)/15 min
Drift forward tilting distance
Cylinders tilting distances 1-ton class: 22 mm (0.87 in.)/15 min
Cylinder oil leaks and damage 2-ton class: 20 mm (0.79 in.)/15 min
Wear and damage of piston and cylinder
shaft bearings
13-5
SERVICE DATA

Periodic inspection
interval

Remarks

Inspection/maintenance location and item

Service standard

Oil leaks, abnormal noise, wear in drive


Oil pump
unit, and mounting looseness
N level : 14.7 l (3.88 U.S.gal)
Oil level and contamination
Hydraulic H level : 16.8 l (4.44 U.S.gal)
tank
Filter clogging
Linkage looseness
Operation
levers Lever functions
Oil leaks
Control Safety valves
valves +490 +5 +71
Release pressure measurement 18142 0 kPa (185 0 kgf/cm2) [2631 0 psi]
Safety devices and others
Head guard Mounting looseness
and
backrest Deformation, cracking and damage
Turn signal operation and mounting
condition
Alarm device operation and mounting
condition
Safety Lamp operation and mounting condition
devices Backup warning device operation and
mounting condition
Rear-view mirror dirtiness and damage
Rear-view mirror image and condition
Proper function of seat belt and hip restraint
Instruments Instrument operations
Seat Looseness and damage
Vehicle Damage and cracking in frame and
body cross-members
Inspection of chassis lubricating
Oil and conditions after cleaning
grease
replacement Confirmation of oil replacement
intervals

13-6
SERVICE DATA

Periodic Replacement of Parts


Replace the following critical safety-related parts and elements according to the specified intervals.
Replacement interval

Parts for periodic replacement Method

1 * Rubber parts in brake master cylinder Replace


2 * Rubber parts in brake caliper cylinders Replace
3 * High-pressure hoses for lift system Replace
4 * Lift chains Replace
Hydraulic tank return oil filter Replace
NOTE: “ * ” mark indicates critical safety parts.

Critical Safety Parts

3
1

206929

13-7
SERVICE DATA

Lubricating Standards
Lubrication Chart

*
Lift chain HO
*
MPG Mast support

Roller surface *
MPG
Mast strip *
* MPG Tilt socket
Lift bracket side roller MPG

Brake fluid BF
*
MPG Tilt cylinder

*
Transfer HO HO

Hydraulic oil HO

Every week or 50 hours

Every month or 200 hours

Every 6 months or 1,200 hours

Every 12 months or 2,400 hours


Inspection, replenishment

Replacement BF Brake fluid

* Parts located on both sides of vehicle HO Hydraulic oil

MGP Multipurpose grease Main Component Weights


206930

13-8
SERVICE DATA

Lubricant Quantities
Truck Models
Items EP16KT EP18KT EP20KT
Transfer oil capacity l (U.S.gal) L.H. 1.09 (0.29) R.H. 1.86 (0.49)
N level : 14.7 (3.88)
Hydraulic system oil capacity l (U.S.gal) H level : 16.8 (4.44)
Brake fluid capacity cc (cu. in.) 99 (6.04)

Lubricant Tables
Greases Brake fluids
NLGI No. 1 NLGI No. 2
Consistency 310 to 340 Consistency 265 to 295 SAE J1703f
Mobil Grease JL 77 No. 1 Mobil Grease JL 77 No. 2 Mobil Super Heavy Duty Brake Fluid
Retinax A No. 1 Retinax A No. 2 Shell Brake Fluid 250
Ronex MP Brake Fluid DOT-3
Castrol LM Grease Castrol Spheerol API Castrol Brake Fluid Crimson

Hydraulic, transfer and rear axle oils


Viscosity
Manufacturer SAE 5W SAE 10W
Mobil — Hydraulic Oil 28 LP
Shell Tellus Oil 22 Tellus Oil T-32
Exxon Nuto H32
Castrol Castrol Hyspin AWS32 Castrol Hyspin AWS68

■ Brands of oils are subject to change without notice.

Lubricant Quantities
Truck Models
Items EP16KT EP18KT EP20KT
Transfer oil capacity L (U.S.gal) L.H. 1.09 (0.29) R.H. 1.86 (0.49)
N level : 14.7 (3.88)
Hydraulic system oil capacity
L (U.S.gal) H level : 16.8 (4.44)
Brake fluid capacity cc (cu. in.) 99 (6.04)

13-9
SERVICE DATA

Unit : kg (lb)
Truck Models
Items EP16KT EP18KT EP20KT
780 800 950
Counterweight
(1720) (1764) (2094)
Power line
72.4 72.4 72.4
Transfer
(159.6) (159.6) (159.6)
40 40 40
Traction motor
(88.2) (88.2) (88.2)
70 70 70
Head guard
(154.3) (154.3) (154.3)
20 20 20
Rear axle
(44.1) (44.1) (44.1)
Mast (3.3 m (130 in.), Simplex)

Outer mast 164.84 (363.4) 164.84 (363.4) 164.84 (363.4)

Inner mast 136.73 (301.4) 136.73 (301.4) 136.73 (301.4)

Lift bracket (including backrest) 93.34 (205.8) 93.34 (205.8) 108.22 (238.6)

Forks (set of two) 70.8 (156) 70.8 (156) 70.8 (156)

Lift cylinders, etc. 78.47 (173) 78.47 (173) 78.47 (173)

Mast (3.3 m (130 in.), Duplex) 550 (1210) 690 (1520)

Mast (4.8 m (189 in.), Triplex) 720 (1585) 955 (2105)

13-10
SERVICE DATA

Tightening Torques for Standard Bolts and Nuts

With spring washer 101656


Nominal size Pitch

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft

Without spring washer 101656


Nominal size Pitch

Remarks : 1. The tolerance on these torques is ±10%.


2. These torques are for “dry” condition.

13-11
SERVICE DATA

With spring washer 101656


Nominal size Pitch

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft

Without spring washer 101656


Nominal size Pitch

Remarks : 1. The tolerance on these torques is ±10%.


2. These torques are for “dry” condition.

13-12
SERVICE DATA

Special Tool Table

Truck Models
1-ton 2-ton
Part No. Name class class
Application

1 64309-17701 Gauge kit Measurement of hydraulic pressure

2 91268-01500 Installer Installation of rear axle inner bearing and inner race

3 91268-01400 Installer Installation of rear axle outer bearing and inner race

Steering
4 91268-10600 Removal of steering wheel
wheel puller

5 91268-03200 Puller Removal of steering column and needle roller bearing

6 91268-01600 Installer Installation of tilt cylinder tube bushing

7 09305-00680 Hook wrench Removal and installation of tilt cylinder guide bushing

09305-00520 Hook wrench Removal and installation of lift cylinder guide bushing

09305-00750 Hook wrench Removal and installation of first lift cylinder guide bushing

Spring
8 97157-00100 Install centering spring in steering gear
installer

13-13
SERVICE DATA

Gauge Kit Puller

1 203544 5 203552

Installer Installer

30 45
10
80
2 200447 6 200448

Installer Hook wrench

30
40 Flame-hardened Hv 500
30 depth 2 mm (0.08 in.)
3 200446 7 203556

Steering wheel puller Spring installer


1.25

M8 ¥ 1.25

55
M12 ¥

4 203551 8 206997

13-14
TECHNICAL PUBLICATIONS FEEDBACK

(Please Print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:

The following discrepancy or omission has been discovered in:

❏ Operation & Maintenance Manual ❏ Option Bulletin

❏ Part List/Manual ❏ Special Instruction

❏ Service Manual ❏ Service Data manual

❏ Electronic Manual ❏ Other:


Publication # Engine model #
Truck model # Issue date #
Truck serial # Page #

(Please print)
Explanation of discrepancy or omission:

Please fax or mail completed form to:

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2011 W. Sam Houston Parkway N. P.O. Box 30171
Houston, Texas 77043-2421 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.


Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-861-9277
Copyright © 2000 by MCFA. All Rights Reserved. Printed in
99719 - 67110 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. the U.S.A.

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