Ep16kt 20kt MC
Ep16kt 20kt MC
Ep16kt 20kt MC
Disassembly sequence
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
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
Vehicle Exterior.......................................................................................................................... 1 - 1
Models........................................................................................................................................ 1 - 1
1
Vehicle Number Stamping Positions ........................................................................................ 1 - 2
Technical Data............................................................................................................................ 1 - 5
GENERAL INFORMATION
Vehicle Exterior
102616
Models
This manual applies to EP16KT, EP18KT, and EP20KT.
1-1
GENERAL INFORMATION
206809
1-2
GENERAL INFORMATION
MEMO
1-3
GENERAL INFORMATION
External Specifications
B E F
206810
1-4
GENERAL INFORMATION
Technical Data
1-5
VEHICLE ELECTRICAL COMPONENTS
Accelerator Control.................................................................................................................... 2 - 6
Fuses .......................................................................................................................................... 2 - 8
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
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
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
206799
2-3
VEHICLE ELECTRICAL COMPONENTS
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
2-6
VEHICLE ELECTRICAL COMPONENTS
Combination
lamps Turn signal 2 Orange 25 W
(rear) lamps
Backup 2 Clear 10 W
lamps
205833
2-7
ES019-67110 2-11
ES019-67110 2-13
ES019-67110 2-15
ES019-67110 2-17
VEHICLE ELECTRICAL COMPONENTS
2-17
MAIN CONTROLLER
Outline ........................................................................................................................................ 3 - 1
Setting ........................................................................................................................................ 3 - 21
Printed Circuit Board Settings.............................................................................................. 3 - 21
Adjustment of Remaining Battery Level.............................................................................. 3 - 21
Setup Options ...................................................................................................................... 3 - 21
Self-diagnosis .............................................................................................................................. 3 - 22
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
Volume Microprocessor
206794
3-1
MAIN CONTROLLER
2 1
3 5 4 7 6
8
206795
3-2
MAIN CONTROLLER
5 3 4 2 8 6 1 7
206796
NOTE
IGBT stands for Insulated Gate Bipolar
Transistor.
3-3
MAIN CONTROLLER
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
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.
3-5
MAIN CONTROLLER
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
40
30
I [A] 20
10
0 0 2 4 6 8 10 12 14 16 18 20
v [Km/h]
207521
3-7
MAIN CONTROLLER
Powerful mode
Standard mode
Economy mode
Thermal & Low Battery mode
Brake Limit mode
207522
207523
3-8
MAIN CONTROLLER
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
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
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.
3-10
MAIN CONTROLLER
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 4 Range 5
207524
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
207525
3-11
MAIN CONTROLLER
250
200
I [A]
Range 1
150
100
50
0
0 2 4 6 8 10 12 14
Accelerator
Range 4 Range 5
207526
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
80
I [A]
60
Range 1
40
20
0
0 2 4 6 8 10 12 14 16 18 20
v [km/h]
Range 4 Range 5
207528
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]
207529
3-13
MAIN CONTROLLER
Range 4 Range 5
207530
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 4 Range 5
207531
3-14
MAIN CONTROLLER
100
I [%]
80
60
40
20
0
-90 -60 -30 0 30 60 90
Steering Angle [degrees]
Left Right
207532
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
207533
3-15
MAIN CONTROLLER
100
I [%]
80
60
40
20
0
-90 -60 -30 0 30 60 90
Steering Angle [degrees]
Left Right
207534
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
207535
3-16
MAIN CONTROLLER
100
I [%]
80
60
40
20
0
-90 -60 -30 0 30 60 90
Steering Angle [degrees]
Left Right
207536
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
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) 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.
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)
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
#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
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
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
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
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.
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
206979
3-31
MAIN CONTROLLER
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
206796
Component Testing
NOTE
When installing wires and cables, be sure to
bind them together.
3-33
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.
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
3-36
MAIN CONTROLLER
3-37
MAIN CONTROLLER
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.
3-38
MAIN CONTROLLER
WARNING
Disconnect the battery plug before approaching
the controller.
Normal value
Line, pump and
regeneration contactors 118 to 145 W
3-39
MAIN CONTROLLER
Contactor bridge
tightening torque 2 N·m (0.2 kgf·m)
WARNING
Disconnect the battery plug before approaching
the controller.
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
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.
WARNING
Disconnect the battery plug before approaching
the controller.
3-42
MAIN CONTROLLER
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.
3-44
MAIN CONTROLLER
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.
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
3-46
MAIN CONTROLLER
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.
3-47
MAIN CONTROLLER
• Replacement procedure
WARNING
Disconnect the battery plug before approaching
the controller.
WARNING
Disconnect the battery plug before approaching
the controller.
36 35
34 33
32 31
30 29
28 27
26 25
24 23
207468
3-48
MAIN CONTROLLER
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
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 (•)
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
3-51
MAIN CONTROLLER
NOTE
On heat sink, measurement should be taken
on 5.5-mm2 area at harness terminal mounting
location.
NOTE
On heat sink, measurement should be taken
on 5.5-mm2 area at harness terminal mounting
location.
• 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
3-53
MAIN CONTROLLER
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
206994
206793
Bracket D
206795
3-55
MAIN CONTROLLER
Cable
207473
4
5
207474
207475
3-56
MAIN CONTROLLER
4 3
Harness
207476
3 2
207477
3-57
MAIN CONTROLLER
207478A
8 7 6 5
207478B
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
Cable B
1 2
Harness A
207479
3-59
MAIN CONTROLLER
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.
8 7 6 5
207478B
207478A
3-60
MAIN CONTROLLER
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
207482
3-61
MAIN CONTROLLER
3 2
207477
4 3
Harness
207476
207475A
3-62
MAIN CONTROLLER
4
5
207474
Cable
207473
3
4
207474A
3-63
MAIN CONTROLLER
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.
(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
3-65
MAIN CONTROLLER
• Replacement procedure
WARNING
Disconnect the battery plug before approaching
the controller.
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.
3-66
MAIN CONTROLLER
WARNING
Thermistor
Disconnect the battery plug before approaching
the controller.
3-67
MAIN CONTROLLER
R (100°C) = 3.3 KW ± 3%
B (0/100) = 3970 K ± 2%
3-68
MAIN CONTROLLER
R (100°C) = 3.3 KW ± 3%
B (0/100) = 3970 K ± 2%
3-69
MAIN CONTROLLER
R (100°C) = 3.3 KW ± 3%
B (0/100) = 3970 K ± 2%
3-70
MAIN CONTROLLER
CN16-146B CN1-45
CN15-148G CN1-49
3-71
MAIN CONTROLLER
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
3-77
TROUBLESHOOTING FOR CONTROL CIRCUITS
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
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
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.
Continuity, no No continuity,
shorting or shorted
To Negative To Negative
207693
4-3
TROUBLESHOOTING FOR CONTROL CIRCUITS
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.
Continuity
No continuity
(7) Faulty logic card
207694
4-4
TROUBLESHOOTING FOR CONTROL CIRCUITS
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)
207695
4-5
TROUBLESHOOTING FOR CONTROL CIRCUITS
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
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.
Disconnect
(3) Inspection battery plug.
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.
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
140L (blue) and NEG, and between 139O (orange) and controller CN2-32.
Continuity No continuity
(6) Faulty logic card
(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
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
wire
Problem: Right Motor, Transistor Open
207700
4-10
TROUBLESHOOTING FOR CONTROL CIRCUITS
(2) Cause
Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty
wiring.
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.
207700
4-11
TROUBLESHOOTING FOR CONTROL CIRCUITS
Indication: “12” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Acceptable Unacceptable
Acceptable Unacceptable
207700
4-12
TROUBLESHOOTING FOR CONTROL CIRCUITS
(1) Situation
(2) Cause
Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty
wiring.
(3) Inspection
207701
4-13
TROUBLESHOOTING FOR CONTROL CIRCUITS
ity.
Acceptable Unacceptable
Indication: “14” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “14” display. Vehicle operation disabled.
(2) Cause
(3) Inspection
207700
4-14
TROUBLESHOOTING FOR CONTROL CIRCUITS
Indication: “15” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “15” display. Vehicle operation disabled.
(2) Cause
(3) Inspection
Disconnect battery plug. Inspect regen and line contactor for welded tips. Make sure each
sor.
(4) Test CS1 current sen- Acceptable
207701
4-15
TROUBLESHOOTING FOR CONTROL CIRCUITS
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.
H bridge
card
207702
4-16
TROUBLESHOOTING FOR CONTROL CIRCUITS
Acceptable Unacceptable
(7) Do not operate vehicle for more than set time under a condition that causes the motor to
stall.
Indication: “17” display. Vehicle operation disabled. (7) Replace H bridge card.
(1) Situation
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
(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
H bridge
card
207702
4-18
TROUBLESHOOTING FOR CONTROL CIRCUITS
Problem: Right Motor, Faulty Field Drive
(1) Situation
Indication: “18” display. Vehicle operation disabled.
(2) Cause
Faulty right motor field circuit, faulty logic card.
(3) Inspection
Disconnect battery plug.
logic card.
(5) Replace logic card.
card.
(6) Replace H bridge Problem: Right
tion disabled.
Indication: “20” display. Vehicle opera-
(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.
207703
4-20
TROUBLESHOOTING FOR CONTROL CIRCUITS
(2) Cause
Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty
wiring.
Problem: Left Motor, Transistor Open (7) Replace CS2 current sensor.
207703
4-21
TROUBLESHOOTING FOR CONTROL CIRCUITS
(2) Cause
Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.
abled.
(8) Replace drive motor drive board.
207703
4-22
TROUBLESHOOTING FOR CONTROL CIRCUITS
Indication: “23” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “23” display. Vehicle operation disabled.
CS2
207701
4-23
TROUBLESHOOTING FOR CONTROL CIRCUITS
(3) Inspection
Disconnect battery plug.
Acceptable Unacceptable
207703
4-24
TROUBLESHOOTING FOR CONTROL CIRCUITS
Indication: “24” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
(2) Cause
Faulty CS2 current sensor, faulty wiring, faulty logic card.
(3) Inspection
Test CS2 current sensor.
Acceptable Unacceptable
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
H bridge
card
207702
4-26
TROUBLESHOOTING FOR CONTROL CIRCUITS
Indication: “26” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
(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
H bridge
card
207702
4-27
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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
H bridge
card
207702
4-28
TROUBLESHOOTING FOR CONTROL CIRCUITS
(1) Situation
(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.
Indication: “28” display. Vehicle opera- Indication: “29” display. Vehicle oper-
tion disabled.
(1) Situation
tion disabled.
Indication: “29” display. Vehicle opera-
(2) Cause
tion disabled.
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
(2) Cause
Faulty pump motor circuit, faulty line contactor, faulty D1P diode, faulty pump motor
CS3
T1P
207703
4-30
TROUBLESHOOTING FOR CONTROL CIRCUITS
Acceptable Unacceptable
(7) Check CS3 current sensor for abnormality.
Acceptable Unacceptable
(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
CS3
T1P
207703
4-31
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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
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
CS3
207701
4-33
TROUBLESHOOTING FOR CONTROL CIRCUITS
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.
CS3
T1P
207703
4-34
TROUBLESHOOTING FOR CONTROL CIRCUITS
Line
contactor
207705
4-35
TROUBLESHOOTING FOR CONTROL CIRCUITS
(2) Cause
Shorting in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic card.
Indication: “33” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “33” display. Vehicle operation disabled.
(5) Test CS3 current sensor.
REGEN
CTR
207706
4-36
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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
Pump
contactor
207706
4-37
TROUBLESHOOTING FOR CONTROL CIRCUITS
(1) Situation
(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
207707
4-38
TROUBLESHOOTING FOR CONTROL CIRCUITS
Unacceptable
207708
4-39
TROUBLESHOOTING FOR CONTROL CIRCUITS
(1) Situation
Indication: “41” display. Vehicle operation disabled.
(4) Check CS2 current sensor for abnormality (7) Replace faulty component (D1L).
Acceptable Unacceptable
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-
(4) Check CS3 current sensor for abnormality (7) Replace faulty component (D1P).
Acceptable Unacceptable
D1P
CS3
207709
4-41
TROUBLESHOOTING FOR CONTROL CIRCUITS
Faulty regeneration diode (wire breakage, shorting), faulty CS1/CS2 current sensors, faulty
logic card.
Drive
motor (R)
207710
4-42
TROUBLESHOOTING FOR CONTROL CIRCUITS
(2) Cause
Faulty right diode (wire breakage, shorting), faulty CS1 current sensor, faulty logic card.
(3) Inspection
(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.
Drive
motor (L)
207711
4-43
TROUBLESHOOTING FOR CONTROL CIRCUITS
(1) Situation
Indication: “45” display. Vehicle operation disabled.
Pump
fuse
Pump motor
207712
4-44
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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
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
(1) Situation
Indication: “48” display. Vehicle operation disabled.
abled.
(2) Cause
Accelerator
control switch
207714
4-46
TROUBLESHOOTING FOR CONTROL CIRCUITS
Indication: “50” display. Vehicle operation (drive and pump motors) disabled.
(1) Situation
Indication: “50” display. Vehicle operation disabled.
(2) Cause
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)
Speed
sensor
Right
207715
4-47
TROUBLESHOOTING FOR CONTROL CIRCUITS
Continuity No continuity
(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.
Speed
sensor
Left
207716
4-48
TROUBLESHOOTING FOR CONTROL CIRCUITS
Conduction No conduction
(4) Check voltage without pressing accelerator pedal and while pressing accelerator pedal
fully.
Acceptable Unacceptable
(5) Replace logic card.
Forward/Reverse
lever assembly Accelerator pedal
Accelerator
control
switch
207718
4-49
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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
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
CN3-45B (black)
Continuity, no short to negative
No continuity, or
shorted to negative
Lift
207720
4-51
TROUBLESHOOTING FOR CONTROL CIRCUITS
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
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.
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.
ATT2
207723
4-54
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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.
(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.
Display
207724
4-55
TROUBLESHOOTING FOR CONTROL CIRCUITS
(6) Proper starting procedure requires that lift lever be in OFF position when key switch is turned on.
(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
4-56
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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,
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
(1) Situation
(2) Cause
Key switch turned on while Aux2 lever was in ON position. Faulty Aux2 lever switch,
207726
4-58
TROUBLESHOOTING FOR CONTROL CIRCUITS
(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
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)
(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
5
POWER TRAIN
102658
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
206921 (2)
206922
5-2
POWER TRAIN
(ii) (i)
(iii)
(v)
(iv)
(vi)
206824
5-3
POWER TRAIN
(2)
206925
(1)
206926
5-4
POWER TRAIN
Left Right
transfer transfer
(iii)
Gravity
center
(ii) (ii)
(i)
(i)
Frame
Frame (iv)
Gravity (iii)
(iv)
center
206927
5-5
POWER TRAIN
5-6
POWER TRAIN
Installation
Follow the removal sequence in reverse. For instal-
lation, follow the instructions below.
3 3
4 4
5
5
2
2
1
1 206785
5-7
POWER TRAIN
Right transfer
(2)
(1)
206786
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
Specifications ............................................................................................................................ 6 - 1
Structures .................................................................................................................................. 6 - 2
Troubleshooting ........................................................................................................................ 6 - 17
6
Service Data .............................................................................................................................. 6 - 18
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
6-3
MOTORS
6-4
MOTORS
206994
206899
6-5
MOTORS
206994
6-6
MOTORS
101907
Stopper plate
101895
206900
6-7
MOTORS
206902
Installation
Follow the removal sequence in reverse.
6-8
MOTORS
Pump motor
Removal
(1) Disconnect the battery plug.
206994
206903
206904
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
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
6-11
MOTORS
Pump motor
8
3
10
6 *5 9
*2
*7
4
S2 A1
Output side
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.
Measuring
terminals S1 (D1) - S2 (D2) 0 W
Drive motor
Measuring
terminals A1 - A2 0W
Measuring
Pump motor S2 - A1 0W
terminals
206001
206002
6-13
MOTORS
NOTE Field
When removing the armature, be careful not
Support 206004
to damage the field coil.
206005
Snap ring
206006
6-14
MOTORS
Snap ring
206008
206009
6-15
MOTORS
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
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]
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
7
TRANSFER UNITS
Specifications
Truck Models 1-ton class 2-ton class
Item EP16KT, EP18KT EP20KT
7-1
TRANSFER UNITS
Front of vehicle
7 7
A A
8 8
6 6
1 3
5
5 4
206785
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
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
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
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
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.
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
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
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
8
REAR AXLE
2
3
4
19
18
11 8
9
12
10
13
14
15
16
17
16 206811
Rear Wheels
2 3
206812
15 ¥ 4.5 - 8
Tire size
(15 ¥ 5 ¥ 11.5)
8-2
REAR AXLE
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.
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
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.
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
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
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
206820
8-8
REAR AXLE
8-9
REAR AXLE
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
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
12
Clearance – 0.01 to 0.035 mm= Shim thickness
(0.0004 to 0.0014 in.) 207206
8-13
REAR AXLE
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
Troubleshooting .......................................................................................................................... 9 - 11 9
Specifications
9-1
BRAKE SYSTEM
8 1
5 7
4
206824
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
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 fluid
6
3 7
4 1
206826
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
9-5
BRAKE SYSTEM
1
3
8
2
206828
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
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
9-8
BRAKE SYSTEM
9-9
BRAKE SYSTEM
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
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
Troubleshooting .......................................................................................................................... 10 - 14
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
E 7
F
D
A 1
F E
H
B
J
6 3 2 C
206834
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
13
T L RP
5 6 7 8 1 9 10 2 11 3 12 4
200786
10-3
STEERING SYSTEM
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
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.
10-5
STEERING SYSTEM
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
200666
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
Tightening torque
11.3 N.m (1.2 kgf.m) [8.3 lbt.ft] 200669
for set screw
NOTE
Make sure the spool rotates freely in the sleeve. Matching marks
200670
10-10
STEERING SYSTEM
207184
207195
NOTE
10-11
STEERING SYSTEM
207169
Port surface
Pin 207199
10-12
STEERING SYSTEM
O-ring
Drive spacer
207200
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
10-13
STEERING SYSTEM
10-14
STEERING SYSTEM
Troubleshooting
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
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
6 8
6
5
7
7
1
2
S
R 207772
Gear Pump
Driven gear
Driven gear
· ·
· ·
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.
Outlet 200333
11-3
HYDRAULIC SYSTEM
Control Valve
11 12 13 14
8
10
9
10
6 7
4
2 3
207773
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
15 13 14 13 12 11 10 1 12 13
8
6
3 5 4 2
206992
17 16 15 1 11 10 12 13 2
8
6
9
14 3 5 4 203489
11-5
HYDRAULIC SYSTEM
4 3 2 1
5
10
6 12
8 9 11
207776
13 10 11 12 14
3 4 9 5 6 8 1 2 7
203490
11-6
HYDRAULIC SYSTEM
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
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
Normal
Burst
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
206994
11-10
HYDRAULIC SYSTEM
*
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
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
6 207774
4 5
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
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
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
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
204933
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.
202983
11-18
HYDRAULIC SYSTEM
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
3
1
207612
Sequence
Suggestions
11-20
HYDRAULIC SYSTEM
207762
207616
207617
11-21
HYDRAULIC SYSTEM
202983
207618
Installation
11-22
HYDRAULIC SYSTEM
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
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
11-24
HYDRAULIC SYSTEM
* 4
1
* 3
7 * 2
*
5
207767
Disassembly sequence
11-25
HYDRAULIC SYSTEM
Reassembly
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.
11-26
HYDRAULIC SYSTEM
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
* 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]
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
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.
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.
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.
11-32
HYDRAULIC SYSTEM
5
3
203559
Disassembly sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims
NOTE
Replace the flow regulator valve an assembly
if any part is defective.
11-33
HYDRAULIC SYSTEM
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
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
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]
11-37
HYDRAULIC SYSTEM
[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
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.
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
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
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
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
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]
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]
11-45
HYDRAULIC SYSTEM
A : Assembly standard
Unit: mm (in.)
Truck Models EP16KT
EP20KT
Items EP18KT
mm/sec (fpm)
[duplex mast]
mm/sec (fpm)
[triplex mast]
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)
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]
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
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]
6 5 8
3 4
2
7 1
202771
11-50
MAST AND FORK
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
Troubleshooting.......................................................................................................................... 12 - 38
Mast Systems
This manual applies to the following vehicle models (names).
NOTE : Maximum fork lift height (30 : 3,000 mm) [118 in.]
2G 15A 30
206837
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
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
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
207608
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
Ø Ø
11 Front Front
9
5
Ø Ø
Front Front
2
6
Ø
Front
Inner mast
Free-lift
height Outer mast
Inner mast
First lift cylinder
Middle mast
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
Suggestions
207084
12-6
MAST AND FORK
204845
Tilt socket
pin
207086
NOTE
Marks
Lay the mast assembly on a floor large enough
to disassemble the parts.
207087
12-7
MAST AND FORK
Installation
12-8
MAST AND FORK
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.
5
2 7 6 4 207777
Sequence
207613
12-9
MAST AND FORK
207762
207614
Tilt socket
pin
207086
207615
12-10
MAST AND FORK
Installation
6
To install, follow the removal sequence in reverse, 7
and service as follows.
12-11
MAST AND FORK
13 11
16
3
12
11
14
10
2
18
9
8
17
6
8
6 15
1
4
5 207763
Sequence
207089
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
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
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 Stamped mark
207094
12-15
MAST AND FORK
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
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
14 207621
12-17
MAST AND FORK
Reassembly
1. Main rollers
(1) Adjust the right and left clearances by increas-
ing or decreasing the thickness of shims 12.
207622
207623
202263
16 207632
12-18
MAST AND FORK
201752
1
4
Stamped mark
200383
12-19
MAST AND FORK
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
207624
10 207625
12 207626
12-21
MAST AND FORK
30
26 207627
Reassembly
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
12-22
MAST AND FORK
202263
207631
A 201752
1
4 Stamped mark
200383
12-23
MAST AND FORK
101628
12-24
MAST AND FORK
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
207633
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).
40% or less
207634
12-26
MAST AND FORK
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.
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).
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.
Shims (a)
207156
Clearance G2 01 to 0.5 mm
(0.004 to 0.020 in.) Side roller
Side roller
202277
Shims
Roller
Bracket
207098
Clearance G3 01 to 0.5 mm
(0.004 to 0.020 in.)
G3
207158
12-29
MAST AND FORK
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.
12-30
MAST AND FORK
J
207101
NOTE
Refer to Main Roller Shim Replacement.
Shims
207102
207103
12-31
MAST AND FORK
NOTE
Refer to Main Roller Shim Replacement.
Shims
207104
NOTE
Refer to Removal and Installation,
1. Lift bracket removal.
12-32
MAST AND FORK
NOTE
Refer to "Separating lift bracket" in the
Hydraulic System section.
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
NOTE
Refer to "Separating lift bracket" section in
the Hydraulic System section.
NOTE
In this condition, second lift cylinders cannot
be dismounted.
12-34
MAST AND FORK
207640
12-35
MAST AND FORK
200391
NOTE
Refer to Main Roller Shim Replacement.
200392
NOTE
It is not necessary to adjust the forward tilt angle
if the backward tilt angle is properly adjusted.
12-36
MAST AND FORK
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
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
12-39
MAST AND FORK
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
12-40
MAST AND FORK
12-41
MAST AND FORK
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
12-42
SERVICE DATA
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
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
13-1
SERVICE DATA
Periodic inspection
interval
Remarks
Service standard
13-2
SERVICE DATA
Periodic inspection
interval
Remarks
Service standard
13-3
SERVICE DATA
Periodic inspection
interval
Remarks
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
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
Service standard
13-6
SERVICE DATA
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
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
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)
Lift bracket (including backrest) 93.34 (205.8) 93.34 (205.8) 108.22 (238.6)
13-10
SERVICE DATA
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
13-11
SERVICE DATA
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
13-12
SERVICE DATA
Truck Models
1-ton 2-ton
Part No. Name class class
Application
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
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
1 203544 5 203552
Installer Installer
30 45
10
80
2 200447 6 200448
30
40 Flame-hardened Hv 500
30 depth 2 mm (0.08 in.)
3 200446 7 203556
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:
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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