Foreword

Foreword
This manual includes explanations of the vehicle system, and

instructions for disassembly and assembly for DOOSAN forklift models
B15/18/20T-7, B18/20TL-7, and B16/18/20X-7.
This manual has been developed for the purpose of helping the reader
understand and repair vehicles correctly. DOOSAN does not take
responsibility for hazardous situations that may arise due to the
reader’s neglect to pay attention to the explanations and instructions in
this manual.
DOOSAN reserves the right to change the content of this manual

according to the inclusion of updated components, new components, or
alterations made to the system. It is the responsibility of the service
man or mechanic to keep up to date with the most relevant information
for his lift truck, which is available from DOOSAN dealers.
October 2015
Doosan Corporation Industrial Vehicle
* All rights reserved. No part of this manual may be copied, printed, or distributed
without prior permission from Doosan Corporation Industrial Vehicle.
SB4449E00
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 SERVICE MANUAL
CONTENTS
GENERAL l 1
ELECTRICAL SYSTEM l 2
DRIVE/BRAKE SYSTEM l 3
HYDRAULIC SYSTEM l 4
LIFT/TILT/AUX SYSTEM l 5
STEERING SYSTEM l 6
FRAME l 7
FINGERTIP OPTION l 8
SCHEMATICS l 9
1 General
1-1 How to use this manual ...............................2
1-1-1 Construction of this manual ....................................2
1-1-2 Warning label definition ..........................................4
1-2 Glossary ........................................................5
1-3 Exterior and specifications .........................9

1-3-1 B15/18/20T-7 and B18/20TL-7 ...............................9
1-3-2 B16/18/20X-7 ........................................................15
1
1-4 Safety precautions .....................................19
General
1-5 Maintenance ................................................26
1-6 Lubricants ...................................................30

1-6-1 Recommended viscosities and capacities ............30
1-6-2 Lubricant specifications ........................................31
1-7 Disassembly/assembly instructions ........35
1-8 Standard torques ........................................44

1-8-1 Standard torques for bolts and nuts .....................44
1-8-2 Standard torques for tightening fittings .................46
1-1 How to use this manual
1-1-1 Construction of this manual

This Service Manual provides the information service
engineers and mechanics require for vehicle
maintenance and repair; it does not contain instructions
for vehicle operation.
The introductory section of this manual provides an

overview of the vehicle’s features, particularly focusing its
different components. The individual sections, which you
will find in the main body of the manual, provide more
specific details, including schematic diagrams of the
vehicle’s components, how they work, what to check,
service procedures, and data and information required for
repair and maintenance along with descriptions to aid the
reader.
To help the reader find the information they need for

service and training quickly and easily, the chapters are
classified according to the different systems that the
vehicle is comprised of (see the table below).
Section Title
1 General
2 Electrical system
3 Drive/Brake system
4 Hydraulic system
5 Lift/Tilt/Auxiliary systems
6 Steering system
7 Frame
8 Fingertip option
9 Schematics
To help you identify what information each page contains,

the current chapter title is shown at the middle right of
each odd numbered page and the subsection’s title and
the model name of the vehicle at the bottom of each
page.
How to use this manual 1-2 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

A typical example how each page is configured:
Part’s image
General
Chapter title
Work procedure
Section title Applicable models
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-3 How to use this manual

1-1-2 Warning label definition
This manual uses the following three types of warning
labels: “DANGER,” “WARNING,” and “CAUTION.
Each label is designed to indicate to the reader the

severity of a potential hazard, its nature, its consequence,
and a precaution for preventing it. You will find these
labels throughout the manual. Ensure that you pay
careful attention to them as they have been included for
your safety.
DANGER
The label Danger indicates a hazardous
situation that will lead to death or severe
injury if not prevented.
WARNING
The label Warning indicates a
hazardous situation that may lead to
death or severe injury if not prevented.
CAUTION
The label Caution indicates a
hazardous situation that may lead to
minor injury if not prevented.
How to use this manual 1-4 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

1-2 Glossary
The following are terms used in this service manual and their descriptions.
Terms Descriptions
A device that converts mechanical movement into an analog voltage
Accelerator
pattern and sends it to the controller to control the vehicle’s drive speed
A device that converts hydraulic power into mechanical force and motion
Actuator
(e.g. hydraulic cylinders and motors)
The unit of measurement for current flow. The amount of current that one
Ampere (amp)
volt can push through a resistance of one ohm.
Anti-cavitation
A valve that helps prevent the effects of cavitation—metal erosion caused
valve
1
Battery Two or more cells connected together to supply an electric current.
(Battery Discharge Indicator) An electrically controlled display which
BDI
shows the operator the battery’s current charge level.
Bus bar A heavy electrical conductor to which other smaller wires are connected.
General
The CAN (Controller Area Network) is a standard for communication
CAN
between micro-controllers and/or devices.
Capacitor A device used to store electrical energy for short periods of time.
Carriage A support structure to which the forks are mounted
A valve that controls the charging of a hydraulic accumulator within an
Charging valve
adjustable switching range
Check valve A valve that allows oil to flow in one direction and not another
A path along which a current can travel from the positive (+) side to the
Circuit negative (-) side of an electrical power source. This can be through wires
and electrical components.
A component made from many circles or turns of wire that is used to
Coil
concentrate a magnetic field.
A part of a wire assembly or harness that connects with another wire
Connector assembly or harness that makes the task of disassembly and assembly
easier.
Contact tips or The portion of a switch, relay or contactor where the circuit can be opened
contacts or closed.
An electrical component consisting of an electromagnetic coil and a set of
Contactor
heavy contact tips. A control current passes through the coil, building a
assembly
magnetic field that closes or opens the contact tips.
An electromagnet used to open or close contact tips in a contactor
Contactor coil
assembly.
A valve unit comprised of several directional valve blocks, each with a
Control valve
corresponding actuator(s)
The main printed circuit board containing a microprocessor and circuits to
Controller condition the voltage signals that go into or come out of the logics. Its
function is to electronically monitor and controls the truck's functions.
A weight installed at the back of the forklift to ensure it is properly stable at
Counter weight
all times, especially when lifted heavy loads
The movement or flow of electricity through a conductor. A circuit must be
Current
complete for a current to flow.
The maximum allowable armature current of a stalled drive motor during
Current limit
pulsing.
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-5 Glossary

Terms Descriptions
A container that keeps pressurized oil and converts hydraulic power into
Cylinder
linear motion
DC-DC converter A device which converts DC battery voltage to DC 12 V.
A signal in which the elements may be either of two distinct values, for
Digital signal
example, high voltage and low voltage.
A semiconductor device that allows current to flow in one direction—from
Diode
the anode to the cathode.
A valve that determines the direction of oil flow based on the position of its
Directional valve
spool.
Display An electrical device that converts voltage inputs to a visual output.
Drift Motion of a cylinder or motor caused by a leakage in the hydraulic circuit.
Drive axle An axle that receives power from the drive motor
A control device for a drive motor, which is comprised of an inverter and

Drive controller
logic circuit.
A service tool program designed for the calibration and diagnostics of
EasyView
trucks used by the CURTIS Controllers.
A pair of brakes that are electromagnetically activated against their
EM parking brake
respective motors when the vehicle is stationary
A device which detects the direction and rotation speed of the motor to
Encoder
generate pulse signals.
Extension module A device used to extend the controller’s ports.
Fan A device that generates air flow to cool the motor and controller.
A mechanical device used to house a filter element, a straining device
Filter
used to prevent contaminants flowing through a system
A valve that blocks the control valve’ withdrawal of hydraulic oil from the
Flow protector lift cylinders when the hydraulic lines are unexpectedly broken. This
prevents a sudden drop of the mast.
A valve that reduces pressure by reducing the amount of flow travelling
Flow regulator
through a hydraulic line
Fork Two prong-shaped objects
Splined to the helical gear, friction discs stop the motion of the drive axle
Friction discs
when compressed by the steel plates
A component in an electrical circuit that opens the circuit if too much
Fuse
current it travelling through a given section of it.
Harness An assembly made of two or more wires that are held together.
Heat sink A mounting frame used for cooling the semiconductors.
Height option
A controller for measuring the height of the fork.
module
Hydraulic system A circuit of hydraulic components that transport oil pressure
Hydraulic tank A chamber that stores oil for the hydraulic system
Indicator A symbol that indicates the vehicle’s condition when it turns on or flashes.
Lift lock solenoid A valve that disables the lift lever when the operator leaves the seat.
A large bracket mounted to the top of the carriage to protect the operator
Load backrest
when carrying large loads.
Main hydraulic A gear pump that, using mechanical power from a motor, pressurizes oil
pump stored in the tank to distribute it to a number of actuators.
A vertical structure at the front of the forklift that extends and retracts to lift
Mast
and lower a load.
Master cylinder A hydraulic cylinder responsible for actuating the service brake
Glossary 1-6 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

Terms Descriptions
A semiconductor component used in electric forklift models as an
electronic switch. A MOSFET most often has three terminals, a GATE (G),
MOSFET a DRAIN (D), and a SOURCE (S). A MOSFET is a voltage-controlled
device and only requires a small input current. The switching speed is
very high.
A valve used to manually lower the mast when the lift lever is not
Needle valve
available.
A term used with a switch or relay. Their “normal condition” is when they
Normal condition are not controlled by the application of force, temperature, pressure, or
electricity.
The unit of resistance. The amount of resistance that will let one volt push
Ohm(Ω)
only one ampere of current through it.
On-time The amount of time it takes for a current to flow through a transistor.
Open circuit The wiring or components of a circuit that have no continuity.
Orifice
A restricted passage in a hydraulic circuit included for the purpose of
limiting flow or creating pressure in a given chamber (e.g. a small drilled
1
hole)
General
Overhead guard An overhead frame structure that protects the operator from falling objects
The presence of a voltage or current which is greater than a given
Overload
electrical circuit or component’s capacity.
An oil pressure to shift a spool in a hydraulic device. Lower than regular
Pilot pressure
pump oil pressure, it is used as a command signal.
Piston A part that pushes the oil in a cylinder chamber
A portion of electrical braking where the generated current is directed
Plugging
back through the armature.
Port An input or output point on a hydraulic component
A connecting socket installed on a truck to supply 12 V power to external
Power socket
devices.
Pressure A force of fluid per unit area
A sensor able to detect the presence of nearby objects without any
Proximity sensor
physical contact.
A control device for the hydraulic motor, comprised of an inverter and
Pump controller
logic circuit.
An electrical component consisting of an electromagnetic coil and a set of
small contact tips. A control current passes through the coil, building a
Relay magnetic field which either closes or opens the contact tips. When the
contact tips are closed, a low current can flow in a separate isolated
circuit.
Relief valve A valve that limits hydraulic system pressure by releasing excess oil
Resistor A component made of a material with a specific resistance to current flow.
Return filter A filter that collects contaminants from oil returning to the hydraulic tank
Rotor The part that rotates the motor.
A line drawing of an electrical or electronic assembly which uses symbols
Schematic to show how individual components, wires and connectors function
electrically.
Serial port A port for one-to-one communication with controller.
A pair of brakes each of which is built in a drive axle to hold the vehicle
Service brake
stationary when the operator applies the pedal
Short circuit An unwanted electrical connection between two or more components.
Sideshifter An attachment that moves forks and the loads on them to the left and right
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-7 Glossary

Terms Descriptions
The female contact of a connector that slips over a male contact (pin) of
Socket
another connector.
A directional valve whose spool shifts position when its solenoid coil is
Solenoid valve
electromagnetically charged.
A term that refers to semiconductor components, or circuits that use them,
Solid state
that have no moving parts, such as diodes and transistors.
Stator A fixed part in a motor
Steel plates activate the service brake function by compressing friction
Steel plate
discs at either side
Steer axle An axle to which the rear wheels of a vehicle are mounted
A column that connects the steering wheel to the steering unit, allowing
Steering column
the operator to control the unit by using the steering wheel
A circuit of hydraulic components comprised of a steering unit, lines and
Steering system
actuators
A hydraulic component which sends oil to the right or left side of steering
Steering unit
cylinder depending on the demands of the operator
Switch (SW) A component used to control an electric circuit by opening or closing it.
The electrical components, circuits, and connections that deliver power to
Systems
perform specific tasks.
Terminal An electrical connection point on an electrical component.
Thermal sensor A sensor that activates at a set temperature.
A valve that opens only when an external pressure reaches the set value
Unloading valve
of its precision spring
USB A connecting device that supplies 5 V power.
A part that controls the pressure, direction, or rate of flow within a
Valve
hydraulic system
The unit of measurement for electromotive force. One volt is the force
Voltage needed to make one ampere of current flow through one ohm of
resistance in a circuit.
The unit of measurement for power. The amount of power used when one
Watt volt pushes one ampere of current through a resistance of one ohm. The
result of amperes (current) multiplied by volts (voltage) is watts (power).
A conductor used to provide a path for a current to flow to and from
Wire
different electrical components.
A drawing that visual represents components the way they actually look. It
Wiring diagram is used to show the locations of components and the connections
between them.
A special diode used to regulate voltage or protect the system from over-
Zener diode
voltage.
Glossary 1-8 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

1-3 Exterior and specifications
1-3-1 B15/18/20T-7 and B18/20TL-7
Head lamp Overhead guard
Mast
Steering wheel
Lift cylinder
General
Battery
Forks Tilt cylinder
Drive wheel
Backup lamp
Load backrest
Instrumentation penal
Hydraulic levers
Control valve
Steer wheel
Fig. 1-1
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-9 Exterior and specifications

36 V models
1 Manufacturer DOOSAN
CHARACTERISTICS
2 Model B15T-7
3 Load Capacity at rated load center Q lb(kg) 3000 (1500)
4 Load center c in(mm) 24 (500)
5 Power type AC Electric
6 Operator type Driver Seated
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion E, C
8 Wheels (x=Driven) Number of front / rear x2/2
9 Max.Fork Height with STD 2-stage mast in(mm) 130 (3300)
10 Free Lift in(mm) 5.1 (130)
12 Fork carriage ISO Class CLASS Ⅱ
Thickness x Width x Length in(mm) 1.4x3.9x41.3 (35x100x1050)
13 Fork
Fork Spacing (Min. x Max.) in(mm) 9.5x35.6 (240x905)
14 Tilt of Mast Forward / Backward deg 5/7
15 Length to Fork Face in(mm) 74.4 (1891)
DIMENSIONS
16 Overall Width in(mm) 42.9 (1090)

17 Mast Lowered Height in(mm) 78.7 (2000)
Overall Dimensions
18 Mast Extended Height in(mm) 159.3 (4045)
19 Overhead Guard Height in(mm) 79 (2010)
20 Seat Height in(mm) 36.2 (919)
Outer Turning Radius in(mm) 59.6 (1515)
21
Inner Turning Radius in(mm) 0
22 Load Moment Center Center of drive axle to fork face in(mm) 14.8 (376)
Right Angle Stacking Aisle Width Pallet 40in × 48in crossways in(mm) 126.6 (3216)
23
(With Pallets & Clearance) Pallet 32in × 48in lengthways in(mm) 131.5 (3341)
24 Speed Travel Loaded / Unloaded mph(km/h) 8.7/8.7 (14.0/14.0)
PERFORMANCE
25 Lifting Loaded / Unloaded fpm(mm/s) 61/108 (310/550)

26 Lowering Loaded / Unloaded fpm(mm/s) 98/89 (500/450)
28 Max. Drawbar pull Loaded at 1.6km/h lb(kg) 2734 (1240)
30 Max. Gradeability Loaded at 1.6km/h % 24
32 Total weight with min. weight of battery lb(kg) 6821 (3094)
WEIGHT
33 Loaded , Front / Rear lb(kg) 8858 / 1269 (4018 / 576)

Axle Load
34 Unloaded , Front / Rear lb(kg) 3362 / 3459 (1525 / 1569)
35 Number of Wheels (Front / Rear) 2/2
36 Tires Front 18x7x12.12
Size
37 Rear 15x6x11.25
38 Wheel Base Distance in(mm) 52 (1323)
CHASSIS
Front in(mm) 35.5 (902)

39 Tread Width
Rear in(mm) 7.8 (198)
40 at lowest in(mm) 3.4 (86)
Ground clearance Loaded
41 at center of wheel base in(mm) 3.9 (100)
42 Brakes Service Hydraulic
43 Parking Auto-Electric
Type Lead-acid
Voltage V 36
BS type AH 660
Capacity Normal
DIN type AH -
(5 Hours
45 Battery Rating) BS type AH 770
Max.
POWER TRAIN
DIN type AH -
Battery compartment sizes Normal / BS type in(mm) 20.8x39.1x27.5 (528x992x698)
(W x L x H) DIN type in(mm) -
Min. Weight lb(kgf) 1543 (700)
47 Drive motor rating at S2 60 minute hp (kW) 8.0 (6.0) x 2
Electric Motors
48 Lifting motor rating at S3 15% hp (kW) 18.8 (14.0)
54 Control Type Drive and Hydraulic Type MOSFET Inverter
55 Drive Axle Brake Type Type ODB
System psi (kPa) 2550 (17600)
57 Relief Pressure
Attachment psi (kPa) 2040 (14000)
Exterior and specifications 1-10 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

DOOSAN DOOSAN 1
B18T-7 B20T-7 2
3500 (1750) 4000 (2000) 3
24 (500) 24 (500) 4
AC Electric AC Electric 5
Driver Seated Driver Seated 6
E, C E, C 7
x2/2 x2/2 8
130 (3300) 130 (3300) 9
5.1 (130) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ 12
1.4x3.9x41.3 (35x100x1050) 1.6x3.9x41.3 (40x100x1050)
13
9.5x35.6 (240x905) 9.5x35.6 (240x905)
5/7 5/7 14
78.4 (1991) 79.9 (2029) 15
42.9 (1090) 42.9 (1090) 16
78.7 (2000)
159.3 (4045)
79 (2010)
78.7 (2000)
159.4 (4050)
79 (2010)
17
18
19
1
36.2 (919) 36.2 (919) 20
General
63.6 (1615) 64.9 (1648)
21
0 0
14.8 (376) 15.0 (381) 22
130.5 (3316) 132 (3354)
23
135.5 (3441) 137 (3479)
8.7/8.7 (14.0/14.0) 8.7/8.7 (14.0/14.0) 24
61/108 (310/550) 61/108 (310/550) 25
98/89 (500/450) 98/89 (500/450) 26
2734 (1240) 2734 (1240) 28
23 22 30
7072 (3208) 7910 (3588) 32
9673 / 1256 (4388 / 570) 10785 / 1534 (4892 / 696) 33
3439 / 3633 (1560 / 1648) 3688 / 4221 (1673 / 1915) 34
2/2 2/2 35
18x7x12.12 18x7x12.12 36
15x6x11.25 15x6x11.25 37
56 (1423) 57 (1446) 38
35.5 (902) 35.5 (902)
39
7.8 (198) 7.8 (198)
3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 41
Hydraulic Hydraulic 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
36 36
825 825
- -
970 970 45
- -
25.1x39.1x27.5 (638x992x698) 25.1x39.1x27.5 (638x992x698)
- -
1764 (800) 2315 (1050)
8.0 (6.0) x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter 54
ODB ODB 55
2880 (19860) 3125 (21550)
57
2040 (14000) 2040 (14000)

48 V models
CHARACTERISTICS
2 Model B15T-7
3 Load Capacity at rated load center lb(kg) 3000 (1500)
4 Load center in(mm) 24 (500)
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion E, C
9 Max. Fork Height with STD 2-stage mast in(mm) 130 (3300)
Thickness x Width x Length in(mm) 1.4x3.9x35.4 (35 x 100 x 900)
13 Fork
DIMENSIONS

Overall Dimensions
21
Inner Turning Radius in(mm) 0
Right Angle Stacking Aisle Width Pallet 1000 x 1200 crossways in(mm) 126.6 (3216)
23
(With Pallets & Clearance) Pallet 800 x 1200 lengthways in(mm) 131.5 (3341)
24 Speed Travel Loaded / Unloaded mph(km/h) 10.6 / 10.6 (17 / 17)
PERFORMANCE
25 Lifting Loaded / Unloaded fpm(mm/s) 79 / 118 (400 / 600)

26 Lowering Loaded / Unloaded fpm(mm/s) 98 / 89 (500 / 450)
WEIGHT
33 Axle Load Loaded , Front / Rear lb(kg) 8792 / 1190 (3988 / 540)
1)
36 Tires Front 18x7-8
Size 2)
37 Rear 15x4.5-8
CHASSIS
39 Tread Width Front in(mm) 35.5 (902)

Rear in(mm) 6.6 (167)
42 Brakes Service Hydraulic
Type Lead-acid
Voltage V 48
BS type AH 440
Capacity Normal
DIN type AH 460
(5 Hours
Rating) BS type AH 575
45 Battery Max.
DIN type AH 500
POWER TRAIN
Normal in(mm) 20.8x39.1x27.5 (528x992x698)

Battery compartment sizes
BS type in(mm) 20.8x39.1x27.5 (528x992x698)
(W x L x H)
DIN type in(mm) 20.8x33.1x27.5 (528x842x698)
Electric Motors
57 Relief Pressure

DOOSAN DOOSAN DOOSAN DOOSAN 1
B18T-7 B18TL-7 B20T-7 B20TL-7 2
3500 (1750) 3500 (1750) 4000 (2000) 4000 (2000) 3
24 (500) 24 (500) 24 (500) 24 (500) 4
AC Electric AC Electric AC Electric AC Electric 5
Driver Seated Driver Seated Driver Seated Driver Seated 6
E, C E, C E, C E, C 7
x2/2 x2/2 x2/2 x2/2 8
130 (3300) 130 (3300) 130 (3300) 130 (3300) 9
5.1 (130) 5.1 (130) 5.3 (135) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ CLASS Ⅱ CLASS Ⅱ 12
1.4 x3.9x35.4 (35x100x900) 1.4 x3.9x35.4 (35x100x900) 1.6x3.9x35.4 (40x100x900) 1.6x3.9x35.4 (40x100x900)
13
9.5x35.6 (240x905) 9.5x35.6 (240x905) 9.5x35.6 (240x905) 9.5x35.6 (240x905)
5/7 5/7 5/7 5/7 14
78.4 (1991) 83.9 (2132) 79.9 (2029) 84.1 (2137) 15
42.9 (1090)
84.6 (2150)
171.1 (4345)
42.9 (1090)
84.6 (2150)
171.1 (4345)
44.1 (1119)
84.6 (2150)
171.3 (4350)
44.1 (1119)
84.6 (2150)
171.3 (4350)
16
17
18
1
79 (2010) 79 (2010) 79 (2010) 79 (2010) 19
General
36.2 (919) 36.2 (919) 36.2 (919) 36.2 (919) 20
63.6 (1615) 69.1 (1756) 64.9 (1648) 69.1 (1756)
21
0 0 0 0
14.8 (376) 14.8 (376) 15.0 (381) 15.0 (381) 22
130.5 (3316) 136.1 (3457) 132 (3354) 136.3 (3462)
23
135.5 (3441) 141.0 (3582) 137 (3479) 141.2 (3587)
10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 24
79 / 118 (400 / 600) 79 / 118 (400 / 600) 79 / 118 (400 / 600) 79 / 118 (400 / 600) 25
98 / 89 (500 / 450) 98 / 89 (500 / 450) 98 / 89 (500 / 450) 98 / 89 (500 / 450) 26
2866 (1300) 2866 (1300) 2866 (1300) 2866 (1300) 28
25 25 24 24 30
6927 (3142) 7348 (3333) 7654 (3472) 7348 (3333) 32
9608 / 1177 (4358 / 534) 9639 / 1570 (4372 / 712) 10673 / 1391 (4841 / 631) 10514 / 1243 (4769 / 564) 33
3373 / 3554 (1530 / 1612) 3605 / 3743 (1635 / 1698) 3578 / 4076 (1623 / 1849) 3605 / 3743 (1635 / 1698) 34
2/2 2/2 2/2 2/2 35
18x7-8 18x7-8 200x50-10 200x50-10 36
15x4.5-8 15x4.5-8 16x6-8 16x6-8 37
56 (1423) 61 (1554) 57 (1446) 61 (1554) 38
35.5 (902) 35.5 (902) 35.9 (912) 35.9 (912)
39
6.6 (167) 6.6 (167) 7.9 (201) 7.9 (201)
3.4 (86) 3.4 (86) 3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 3.9 (100) 3.9 (100) 41
Hydraulic Hydraulic Hydraulic Hydraulic 42
Auto-Electric Auto-Electric Auto-Electric Auto-Electric 43
Lead-acid Lead-acid Lead-acid Lead-acid
48 48 48 48
510 600 585 600
525 690 575 690
690 - 690 -
45
625 750 625 750
25.1x39.1x27.5 (638x992x698) 29.4x39.1x27.5 (746x992x698) 25.1x39.1x27.5 (638x992x698) 29.4x39.1x27.5 (746x992x698)
23.9x39.1x27.5 (608x992x698) - 23.9x39.1x27.5 (608x992x698) -
25.1x33.1x27.5 (638x842x698) 29.4x33.1x27.5 (746x842x698) 25.1x33.1x27.5 (638x842x698) 29.4x33.1x27.5 (746x842x698)
1764 (800) 2205 (1000) 2205 (1000) 2205 (1000)
8.0 (6.0) x 2 8.0 (6.0) x 2 8.0 (6.0) x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter MOSFET Inverter MOSFET Inverter 54
ODB ODB ODB ODB 55
2886 (19900) 2886 (19900) 3133 (21600) 3133 (21600)
57
2040 (14000) 2040 (14000) 2040 (14000) 2040 (14000)

Fig. 1-2

1-3-2 B16/18/20X-7
Overhead guard
Head lamp
Mast
Steering wheel
Lift cylinder
General
Battery
Forks
Tilt cylinder
Drive wheel
Backup lamp
Load backrest
Instrumentation penal
Hydraulic levers
Control valve
Steer wheel
Fig. 1-3

B16/18/20X-7
CHARACTERISTICS
2 Model B16X-7
3 Load Capacity at rated load center lb(kg) 3500 (1600)
4 Load center in(mm) 24 (500)
7 Tire Type P : Pneumatic, E : Solid Soft, C : Cushion P, E
9 Max. Fork Height with STD 2-stage mast in(mm) 130 (3300)
Thickness x Width x Length in(mm) 1.4x3.9x35.4 (35x100x900)
13 Fork
DIMENSIONS

Overall Dimensions
21
Inner Turning Radius in(mm) 19.4 (494)
Right Angle Stacking Aisle Width Pallet 1000 x 1200 crossways in(mm) 136.5 (3466)
23
(With Pallets & Clearance) Pallet 800 x 1200 lengthways in(mm) 144.2 (3662)
24 Travel Loaded / Unloaded mph(km/h) 10.6 / 10.6 (17 / 17)
PERFORMANCE
25 Speed Lifting Loaded / Unloaded fpm(mm/s) 79 / 118 (400 / 600)

26 Lowering Loaded / Unloaded fpm(mm/s) 98 / 89 (500 / 450)
WEIGHT
33 Loaded , Front / Rear lb(kg) 9337 / 1219 (4235 / 553)

Axle Load
36 Tires Front 18x7-8
Size
37 Rear 16x6-8
CHASSIS
Front in(mm) 35.5 (902)

39 Tread Width
Rear in(mm) 35.0 (890)
42 Service Hydraulic
Brakes
Type Lead-acid
Voltage V 48
BS type AH 585
Capacity Normal
DIN type AH 575
(5 Hours
Rating) BS type AH 690
45 Battery Max.
DIN type AH 625
POWER TRAIN
Normal in(mm) 25.1x39.1x27.5 (638x992x698)

Battery compartment sizes
BS type in(mm) 23.9x39.1x27.5 (608x992x698)
(W x L x H)
DIN type in(mm) 25.1x33.1x27.5 (638x842x698)
Electric Motors
57 Relief Pressure

DOOSAN DOOSAN 1
B18X-7 B20X-7 2
4000 (1800) 4400 (2000) 3
24 (500 24 (500 4
AC Electric AC Electric 5
Driver Seated Driver Seated 6
E E 7
x2/2 x2/2 8
130 (3300) 130 (3300) 9
5.1 (130) 5.3 (135) 10
CLASS Ⅱ CLASS Ⅱ 12
1.4 x3.9x35.4 (35x100x900) 1.6x3.9x35.4 (40x100x900)
13
9.5x35.6 (240x905) 9.5x35.6 (240x905)
5/7 5/7 14
83.5 (2120) 83.7 (2125) 15
44.1 (1119)
84.6 (2150)
171.1 (4345)
44.1 (1119)
84.6 (2150)
171.3 (4350)
16
17
18
1
79 (2010) 79 (2010) 19
General
36.2 (919) 36.2 (919) 20
74.3 (1886) 74.3 (1886)
21
19.5 (496) 19.5 (496)
14.8 (376) 15.0 (381) 22
136.5 (3466) 136.7 (3471)
23
144.2 (3662) 144.4 (3667)
10.6 / 10.6 (17 / 17) 10.6 / 10.6 (17 / 17) 24
79 / 118 (400 / 600) 79 / 118 (400 / 600) 25
98 / 89 (500 / 450) 98 / 89 (500 / 450) 26
2866 (1300) 2866 (1300) 28
25 24 30
7233 (3281) 7630 (3461) 32
10033 / 1168 (4551 / 530) 10739 / 1301 (4871 / 590) 33
3739 / 3494 (1696 / 1585) 3730 / 3900 (1692 / 1769) 34
2/2 2/2 35
200x50-10 200x50-10 36
16x6-8 16x6-8 37
58.9 (1495) 58.9 (1495) 38
35.9 (912) 35.9 (912)
39
35.0 (890) 35.0 (890)
3.4 (86) 3.4 (86) 40
3.9 (100) 3.9 (100) 41
Hydraulic Hydraulic 42
Auto-Electric Auto-Electric 43
Lead-acid Lead-acid
48 48
585 585
575 575
690 690
45
625 625
25.1x39.1x27.5 (638x992x698) 25.1x39.1x27.5 (638x992x698)
23.9x39.1x27.5 (608x992x698) 23.9x39.1x27.5 (608x992x698)
25.1x33.1x27.5 (638x842x698) 25.1x33.1x27.5 (638x842x698)
2315 (1050) 2315 (1050)
6.0 x 2 8.0 (6.0) x 2 47
18.8 (14.0) 18.8 (14.0) 48
MOSFET Inverter MOSFET Inverter 54
ODB ODB 55
2886 (19900) 3133 (21600)
57
2040 (14000) 2040 (14000)

Fig. 1-4

1-4 Safety precautions
The following safety section is comprised of the following
subsections: general, personal safety, maintenance
safety, compressed air hazards, hydraulic fluid hazards,
mechanical hazards, electrical hazards, and fire and burn
hazards. Under each title are listed the precautions you
should take to ensure that you remain safe when working
on your vehicle.
The reader is responsible for thoroughly reading,

understanding, and putting into practice all the
1
precautions listed below.
Also note that the safety instructions outlined below are

not only for the sake of the reader’s safety, but for those
General
around him, too. So for your own personal safety and the
safety of those around you, ensure that you read through
the following instructions thoroughly:
General
Safety notes
• Familiarize yourself with the safety instructions

immediately visible on your vehicle. These
include warning plates, stickers, engravings, and
so on. Make a note of reading them prior to
operating, lubricating or repairing the vehicle
(See Safety section of Operation and
Maintenance Manual).
Fig. 1-5
• Ensure you follow all the safety rules,

regulations, and instructions when performing
maintenance. Pay special attention to the
hazard warnings which occur throughout this
manual, which will notify you of potential
hazardous circumstances.
• Do not assume that you can perform the

procedures outlined in this manual based on
Fig. 1-6
previous maintenance experience from servicing
similar models. The weights and specifications
for different models vary respectively and should
be paid close attention to in order to avoid
hazardous situations, injury, and/or damage to
components.
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-19 Safety precautions

Personal safety
Fit for the job
• Do not operate the vehicle or perform License

maintenance on it if unauthorized or untrained.
• Do not operate the vehicle or perform

maintenance on it after the consumption of
alcohol or medication that impairs your judgment.

maintenance on it if you have any illness or Fig. 1-7
condition that limits physical movement.
Work wear

maintenance if you are wearing loose clothing or
if your hair is long and is not tied back. Both
have the potential to be caught in moving
components, causing severe injury.
• Wear the appropriate protective gear for the

maintenance task you are performing. Items
may include hard hat, glasses/visor, ear
defenders, gloves, and protective shoes.
• Wear a mask when sanding the body of the

vehicle, and wear an air-fed breathing apparatus
when spraying it with paint.
• Wear welder’s gloves, welding mask/goggles,

apron and other appropriate welding apparel
when welding.
Fig. 1-8
Maintenance safety
Pre-maintenance
• Ensure the vehicle is in a clear, open

environment, and free from traffic and other
people.
• Ensure that the vehicle is parked safely and that

the vehicle will not suddenly move. Place
wooden props before and after the wheels, and
make sure the parking brake is properly Fig. 1-9
engaged.
Safety precautions 1-20 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

• Ensure the vehicle is unloaded and unoccupied,
the forks are lowered, all hydraulic controls are
in the neutral position, and the key is switched to
OFF. Attach a "Do Not Operate" or similar
warning tag to the start switch or controls before
servicing or repairing the forklift.
• Make sure that the tools are in good condition.

Fig. 1-10
Mounting and dismounting
• Clean any mud or debris from steps, walkways

or work platforms before you mount the vehicle.
• Face the vehicle when using steps, ladders or
1
walkways to mount or dismount it.
• Use the steps and grab the handles to mount or

dismount the vehicle. When you are not able to
General
use the steps, use ladders, scaffolds, or work
platforms to perform the repair operations safely.
Heavy lifting
• Check the weight of each component before

removing it. Some of the components on this
vehicle are extremely heavy and could cause
severe injury.
• Use proper lifting procedures when removing

any components. Fig. 1-11
• To avoid back injury, use a hoist when lifting

components which weigh 23 kg (50 lb) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity.
Be sure hooks are positioned correctly. Lifting
eye bolts are not to be side loaded during a
lifting operation.
Asbestos Fig. 1-12
• Components in DOOSAN products that may

contain asbestos fibers are brake pads, brake
band and lining assemblies, clutch plates and
some gaskets.
 The asbestos used in these components is
usually bound in a resin or sealed in some way.
Normal handling is not hazardous as long as
airborne dust which contains asbestos is not
generated.

• If dust which may contain asbestos is present,
there are several common sense guidelines that
must be followed:
 Never use compressed air for cleaning.
 Avoid the brushing or grinding of materials
containing asbestos.
 For clean up, use wet methods or a vacuum
equipped with a high efficiency particulate air
(HEPA) filter.
 Use exhaust ventilation on permanent
machining jobs.
 Wear an approved respirator if there is no
other way to control the dust.
 Comply with applicable rules and regulations
for the work place.
 Follow environmental rules and regulations for
the disposal of asbestos.
 Avoid areas where asbestos particles may be
in the air.
Assembly/disassembly
• Ensure that the assembly/disassembly work site

is kept clean and in good order, and keep your
hands and tools clean.
• When you tighten/loosen bolts and nuts, use the

right-sized wrench and always pull toward your
body. Using a wrench the wrong size or pushing
away from your body to loosen/tighten bolts or
nuts may cause unexpected accidents due to a
slip of your grip.
• If two or more persons work, use signs or

signals for communication so that the work is
done with agility as if the work is done by one
man.
• Be careful when you remove a cover plate.

Slowly loosen the last bolt or the two nuts in the
opposite direction to each other from the cover
unit, twist the cover to loosen the tension or
other pressure, and then remove the last bolt or
the two nuts completely.
• Reinstall all the fasteners with the same part

number. If any fastener needs replacing, use a
quality fastener and be careful not to use the
metric system fasteners mixed with inch
fasteners.

Compressed air hazards
• Pressure air can cause personal injury. When
using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
• The maximum air pressure must be below 205

kPa (30 psi) for cleaning purposes.
Hydraulic fluid hazards
Carefully follow the instructions below for safety tips

regarding the maintenance of the hydraulic system.
1
Escaping oil under pressure, even a pinhole size leak,
can penetrate body tissue, causing serious injury, and
possible death. Because it is toxic; hot, pressurized
hydraulic oil injected into the skin—although it may
General
appear benign at first—will infect the immediate area and
then spread, causing large cracks in the skin. If you think
you have been exposed to hydraulic oil in this way, seek
Fig. 1-13
medical attention immediately.
• Wear gloves, goggles, and make sure your arms

and legs are fully covered.
• Relieve all pressure from the hydraulic system

before any lines, fittings or related items are
disconnected or removed, and wait for the
system to cool if it has just been running.
 Even after you have completed the pressure
removal process, there is no guarantee
pressure has completely exited the system.
Exercise extreme caution.
• Never touch a pressurized hose with your hand

and do not bend or strike a hose.
• Never check for pinhole leaks with your hand;

this is how oil injection related injuries most
commonly occur! Use cardboard or another
solid surface instead.
• Hold a rag over ports when removing filler caps,

breathers and plugs to prevent being sprayed or
splashed by liquids under pressure.
• Have a container ready to catch any hydraulic

oil that might run out of the hoses/ports.
• Make sure all raised components are blocked

correctly.

• When reinstalling the lines ensure they are
tightened to the correct torque (See Section 1-8).
• Make sure that all heat shields, clamps and

guards are installed correctly to avoid excessive
heat, vibration or friction with other parts during
operation.
• Shields that protect against oil spray onto hot

exhaust components in the event of a line, tube
or seal failure must be installed correctly.
Mechanical hazards
• Keep objects away from moving fan blades.
They will throw or cut any object or tool that falls
or is pushed into them.
Do not operate a machine if any rotating part is
damaged and contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
• Support equipment and mounted components

properly when working beneath them. Do not
expect hydraulic cylinders will stay mounted.
Any attachment can fall if a control lever is
moved or if a hydraulic line breaks.
• Chips or other debris can fly off objects when

struck. Make sure no one will be injured by flying
debris before striking an object. Fig. 1-14
Electrical hazards
• Do not damage the wiring during removal
operations. When reinstalling the wiring, make
sure it is installed in such a way that it is
protected from being damaged by sharp corners,
friction with different objects, or hot surfaces.
• Do not connect wiring to a line containing oil.
• Do not smoke, or expose battery to sparks or

flame when checking, charging or servicing the
battery. Keep chains and metallic tools away
from the top of the battery. Electrolyte is an acid
and can cause personal injury if it contacts skin
or eyes. Fig. 1-15

Fire and burn hazards
• To avoid burns, be alert for hot parts on
machines which have just been stopped and hot
oils in lines, tubes and compartments.
• All fuels, most lubricants and some coolant

mixtures are flammable. If a pipe is loose or
damaged, a fire might occur.
• Keep all fuels and lubricants stored in properly

marked containers and away from unauthorized
persons.
• Store all oily rags or other flammable material in

a protective container, in a safe place.
• Do not weld or flame cut pipes or tubes that

contain flammable oils. Clean them thoroughly
1
with nonflammable solvent before welding or
General
flame cutting them.
• Remove all residual flammable materials on the

forklift, such as fuel and oil before they
accumulate.

1-5 Maintenance
The following describes key items and replaceable parts
to inspect at maintenance intervals.
NOTICE: Except for the daily checkup made by the driver

of the vehicle, all maintenance and repair should be
carried out by qualified and authorized engineers.
NOTICE: Careless disposal of waste oil may not only
harm to the environment but also endanger human health.
Waste oil should always be placed in a container and
disposed by an authorized person at a designated site.
Inspection when required
Items Inspection criteria and method

• Press Enter down for 3 seconds
Instrument panel - By pressing this button with the key switch on, you can access
Diagnosis and Calibration modes.
- By pressing this button while driving, you can access Diagnosis mode.
• Measure the distance from the bottom of

the inner mast to the bottom of the carriage
bearing with the inner mast standing
upright, and then adjust the extrusion of
Carriage roller the roller.
Height of carriage roller extrusion (A)
STD mast FF mast FFT mast
-6 mm 8 mm 8 mm
(-0.2 in) (0.3 in) (0.3 in)
• Check the fuse for detached elements and replace if required.

- 5A: Backup/stop lamps, ISO relay/power supply, fan, fingertip, strobe,
flasher, rear/head lamps
Fuse box
- 10 A: Key switch
- 20 A: DC-DC converter and horn
- 500 A: Main fuse
• Check if the driver’s seat operates normally and then lightly lubricate the
Driver’s seat
slider track.
• Check the fastening of wheel bolts and nuts.

Wheel bolt - Standard steering wheel fastening torque: 113 N·m (83 lb·ft)
- Standard drive wheel fastening torque: 180 N·m (133 lb·ft)
Drive axle gear • Check the gear box for lubrication.

box - Refill lubricant up to the plug opening for housing level inspection.
Maintenance 1-26 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

Inspection every 10 service hours or daily
• Check for loosened parts and fasteners.

• Check Instrument panel indicators for abnormality.
• Check if horns and other alarms operate normally.
• Check the mast and the lift chain for wear and pins/rollers for
abnormality.
• Check the carriage, fork, and attachments for damage and abnormality.
Daily inspection
• Check the tires, valves, and wheels for abnormality.
• Check the overhead guard for damage and abnormality.
• Check the hydraulic system for oil leaks and damage.
• Check the drive axle for oil leaks.
• With the driver’s seat adjusted and the control lever to neutral, turn on
1
the key switch and check the overall operation of the system.
General
Mast • Lubricate the beams on which rollers are seated.
• Inspect the battery’s installation position and check to see if it is properly

Battery placed, tightened, and cleaned.
- Check specific gravity of the battery (refill if it is 1.15 or lower).
Instrument panel • Check if the parking brake lamp works normally and if the battery is not
indicators discharged.
• Check tires and valve stems for wear, cut, groove, and contamination,
Tires and wheels
and check tire’s air pressure.
Inspection first 50–10 service hours or a week

Drive axles • Replace drive axle oil.
Inspection every 250 service hours or monthly

Brake oil • Check the brake oil level and refill if required.
Hydraulic oil • Check the hydraulic oil level and refill if required.
• Check if the controllers of the lift, tilt, and attachments operate normally.
• Check if carriage bolts and nuts are loosened, and remove contaminants
Mast, carriage, if found.
chains, and
attachments • Check if the forks and attachments operate normally.
• Lubricate all chains using a brush, and check their anchors for
abnormality.
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-27 Maintenance

Inspection every 500 service hours or 3 months
• Lubricate the chassis and mast pivot eye bolt fittings.

- Check pins for loose retainer bolts or wear.
• Measure and adjust the extension of the cylinder rods (up to 3.18
Tilt cylinders
mm/0.13 in)
- Standard bolt fastening torque: 95±15 N·m (70±11 lb·ft)
• Check the cross head roller guard and retainer for damage.
Mast • Lubricate two fittings of the mast hinge pin.
Steering axle • Lubricate the fittings of the steering axle.
• Check bolts for damage.

Overhead guard
- Standard bolt fastening torque: 60 ± 10 N·m (44±7 lb·ft)
• Clean the control panel.

Control panel - Maximum allowable air pressure: 2.05 bar (29.7 psi)
• Check cables, fuse, and battery connectors.
Control levers • Check the base of the levers and their operations
Inspection every 1,000 service hours or 6 months

Air bleeders • Replace the air bleeder.
Drive axles • Replace oil.
Drive and hydraulic • Dust off and check the drive motors and the end shield area.
pump motors - Maximum allowable air pressure: 2.05 bar (29.7 psi)
• Check tires for wear, cut, groove, contaminants, etc.

Tires and wheels • Check rim components for cracks, wear, damage, corrosion, etc.
• Standard torque of drive wheel: 180 N·m(133 lb·ft)
• Perform a lift chain abrasion test by measuring the wear of the chain
links and pins.
- Measure the distance in mm from the center of a pin to the 10th
chain link.
Lift chains
- Replace the chain if the wear rate is 2% or higher.
※ Chain’s wear rate (%) = [(measurement–15.88x10)/(15,88x10)]x100
• Check if tension is equal on the both sides of each lift chain set.
• Adjust the lift chains.
Hydraulic return • Replace the return filter in the hydraulic tank.
filter
Maintenance 1-28 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

Inspection every 2,000 service hours or yearly

• Replace oil and filters.
Hydraulic and • Replace bearings inside/outside the wheels.
steering systems
- Standard torque of the fastening nuts: 135 N·m (100 lb·ft)
- Re-fastening torque of the fastening nuts: 50 ± 5 N·m (37±4 lb·ft)
• Disassemble and assemble the steering wheels to reassemble the

bearings.
Steering wheels - Standard torque of the steering wheel nuts: 113 N·m (83 lb·ft)
- Nut-fastening torque: 34 N·m (25 lb·ft)
- Re-fastening torque of the fastening nuts: 11 ± 3 N·m (8±2 lb·ft)
• Under normal conditions, perform regular inspections at least every 12

months. But if your type of work causes more labor and stress on the
1
vehicle (i.e. long operating hours, or heavy lifting) perform inspections
General
on a 6 month regular basis.
• Replace if any of the following conditions are found:
- Cracks on a fork’s heal, welding, bracket, etc.
- A fork is so worn that its thickness is lower than 90% of the initial
thickness.
Forks
- Angle between the top of the blade and the front face of the shank
exceeds 90±3º.
- The deviation from the straightness of the upper face of blade or the
front face of shank exceeds 0.5 percent of the length of the blade
and/or the height of the shank respectively 5 mm/1000 mm (0.18
in/36 in).
- Tolerance in the heights of two or more ends of the fork: 6.5 mm(0.3
in) (palette fork), 3.0 mm(0.1 in) (tapered fork)
※ The height tolerance between forks is 3% of the length of the blade.
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-29 Maintenance

1-6 Lubricants
The following is a detailed explanation of the lubricants needed and the parts to be lubricated.
Some of the classifications and abbreviations used follow S.A.E. (Society of automotive Engineers)
J754 nomenclature while others follow S.A.E. J183. All MIL specifications are U.S.A. Military.
Greases are classified according to the National Lubricating Grease Institute (NLGI) based on ASTM
D217-68 worked penetration characteristics which give a defined consistency number.
1-6-1 Recommended viscosities and capacities

The SAE grade number indicates the viscosity of oil. A
proper SAE grade number should be selected according
to ambient temperature.
NOTICE: The amount of lubrication varies with the

remaining oil level. Therefore make sure to check the oil
gauge before lubrication.
Lubricant viscosities Refill

for ambient (outside) temperatures capacities
Compartment or
system Lubricant Temperatures (°C/°F)
Liters (l)
Viscosities Min. Max.
ISO VG 22 -30/-86 +20/+68
Hydraulic and power
steering ISO VG 32 -20/-68 +30/+86
18.0
system ISO VG 46 -10/-50 +40/+104
ISO 6743/4 HM
ISO VG 68 0/32 +50/+122
API SAE 10 W -20/-68 +22/+71.6
Drive axle housing 1.1
CD/TO-2 SAE 30 +10/+50 +50/+122
Brake oil reservoir ISO VG 10 -30/-86 +50/+122 0.6
Note) For detailed information on lubricants, see Section 1-6-2.
Lubricants 1-30 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

1-6-2 Lubricant specifications
Chain and linkage oils (DEO or EO)
The following engine oils are recommended for use on

the chains and linkages:
Items Spec.
European CCMC D3
API CD, CD/SF, CE
Military MIL-L-2104D or E
Fig. 1-16
Hydraulic oils (HYDO)

1
The following commercial classifications can be used in
General
the hydraulic system.
These oils should have antiwear, antifoam, antirust and

antioxidation additives for heavy duty use as stated by
the oil supplier. An ISO viscosity grade of 32 would
normally be selected.
Items Spec.
ISO 6743/4 HM
AFNOR NFE 48-603 HM
DIN 51524 TEIL 2 H-LP
Fig. 1-17
HAGGLUNDS DENISON HFO-HF2
CINCINNAT P68, 69, 70
NOTICE: Correct hydraulic oil should be used to achieve

the maximum life and performance from hydraulic system
components. The above hydraulic oil is recommended in
most hydraulic and hydrostatic systems.
Oil added to the hydraulic tank must mix with the oil
already in the system. Use only petroleum products
unless the system is equipped for use with a certain
special product.
If the hydraulic oil becomes cloudy, this means that water
or air has entered the system. Water or air in the system
will cause pump failure. Drain the oil, retighten all
hydraulic suction line clamps, and then purge and refill
the system.
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-31 Lubricants

Drive axle oil
The following products are certificated as universal

transmission tractor oils (UTTO).
Suppliers Products
TOTAL TRANSMISSION MP
MOBIL MOBIL OIL 422 MOBIL OIL 425
MOTUL TRM 97
OPAL OPAL OIL TA/HIS
GS Caltex Doosan DX 10W
Brake oil
Use a heavy duty hydraulic brake oil certified by the oil

supplier to meet ISO 6743/4 HM VG 10 latest revision.
Suppliers Products
TOTAL Azolla ZS 10
AGIP Acer 10
BP Energol HP 10 HLP 10
CALTEX Spindurn 10
ELF Spinelf 10
ESSO Nuto H 10 Spinesso 10
Fig. 1-18
FINA Hydran 10
MOBIL Velocite Oil No. 5 Velocite Oil E
SHELL Tllvs Oil C10 / Morlina 10
Lubricating grease (MPGM)
Use Multipurpose Molybdenum Grease (MPGM) for all

lubrication points. If MPGM grease cannot be used, a
multipurpose type grease which contains 3% to 5%
molybdenum disulfide can be used.
NLGI NO.2 grade is suitable for most temperatures. Use

NLGI No.1 or No.0 grade for extremely low temperature.

<Greasing points for models B15/18/20T-7 and B18/20TL-7>
General
Fig. 1-19
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-33 Lubricants

<Greasing points for models B16/18/20X-7>
Fig. 1-20

1-7 Disassembly/assembly instructions
The following disassembly/assembly section is comprised
of the following subsections: preparations before
disassembly, check and test before disassembly,
precautions when disassembling, precautions after
disassembly, precautions when assembling, handling
general parts, and hydraulic line fittings. Under each title
are listed the precautions you should take to carry out the
disassembly/assembly work correctly.
Preparations before disassembly

• Wash off dust and contaminants from the
vehicle before you send it to the service center. 1
Dust or contaminants brought into the service
General
center may stain parts and get into them to
make scratches.
• An electric forklift operates based on the

electrical system. Do not let any water into the
system.
• To avoid unnecessary disassembly work,

prepare the necessary tools, a box to put the
parts in, and make it a priority to always keep
your worksite clean.
Check and test before disassembly

• Before you start disassembling, make sure to
record any problems. This may prevent
unnecessary disassembly, loss of replacement
parts, and repetitive failures caused by the same
problem.
• To prevent malfunction, keep a record of the

failure and the parts required for replacement.
Also make sure you check and record the
Fig. 1-21
following information:
 Vehicle’s model number, serial number, and
hours of operation
 Reason why the vehicle needs disassembling
 Check the symptom, location, and cause of the
failure (If needed, reproduce the same failure).
 Check if any parts are out of place.
 Check for damaged or loosened parts.
 Check how well the vehicle has been
maintained if possible.
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-35 Disassembly/assembly instructions

Precautions when disassembling
Disassembly
• Identify how the parts are assembled (front/back,

left/right, and up/down connections) to
determine the order of disassembly.
• Before you start disassembling the parts, note

the connecting points of parts and mark them
using a punch to avoid misplacing the parts
during assembly.
• Use the right tools to remove specific parts.
• If any part is not dismounted and even the

mounting bolts and nuts were removed, do not
use excessive force. Check and find the cause.
• Put the disassembled parts to one side in the

order of their disassembly, putting a tag or mark
on those parts which similar in appearance.
• Store common parts such as bolts and nuts in

an orderly manner.
Check and test during disassembly
• Sometimes the cause of failure is found during

disassembly. Therefore, it is very important to
carefully check the state of the friction surface
and contacting parts.
• During disassembly, measure and record the

gap, distortion, projections, and other factors
that may cause the failure.
Maintaining gaps
• Make sure the shims and washers you install

produce the specified gap value required.
Link adjustment
• If the rod needs no readjustment, keep the initial

length. If you need to move the end of the rod,
measure and record its length before
disassembling.
Disassembly/assembly instructions 1-36 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

Disassembling press-fitted components
• Remove any dents or marks caused by

hammering and polish the area.
• If any press-fitted component is loosened,

identify and remove the cause to avoid problems
during assembly.
Disassembling bearings
• Do not remove bearings by force but use a

bearing puller as shown in Fig. 1-22.
Precautions after disassembly
Cleaning 1
• Clean the disassembled parts, arrange them by
General
assembly unit, and keep them away from
contaminants. Give particular attention to
removing contaminants from the oiling lines or
Fig. 1-22
the pipes of components.
• An efficient way of cleaning is to use two

vessels of detergent: one for washing dirty parts
and the other for rinsing them.
• When you clean special parts, increase the

number of detergent vessels and clean several
times.
• Kerosene or neutral acid anhydride diesel is

suitable for cleaning sticky oil in bearings.
• In the case of large castings, soak them in a pH

10 to 12 alkaline detergent, at 50 to 70 ℃ (122
to 158 ℉) and then rinse with water.
• When you use a hazardous chemical detergent,

be careful not to let your skin or eyes contact it.
Old oil should be disposed of at a designated
place using a specified container.
Dust prevention
• Keep cleaned parts free from dust and

contaminants using a dust cover and plug up the
ends of all pipes.
• Rustproof any parts you might store away

before installing again.

Precautions when assembling
Parts installation
• Keep all parts clean before you assemble them.

Check their surface for flaws and repair as
needed. Make sure not to stain the friction
surface with any contaminants that may reduce
the service life of the parts.
• Wash off the rust proofing agent from the parts

using a detergent before you start assembling.
• Identify the marks you have made for fitting

parts together before you start assembling.
• Use a press-fitting tool to assemble bearing,

bushing, and oil seal, and use designated tools
for specific parts.
• Before press-fitting parts, grease their surface

with molybdenum bisulfide.
Tightening bolts and nuts
• To ensure bolts and nuts are all torque evenly,

tighten them in the order shown in Fig. 1-23,
tightening one and then the other on the
opposite side. This method is called the
“template method” that repeats loosening and Fig. 1-23
tightening gradually to ensure even contact.
• Lubricating the screwing part of the bolts with

engine oil will make bolt tightening easier and
stronger.
• Use wire, cotter pins, lock washers, or other parts

shown in Fig. 1-24 to secure bolts, nuts, or other
important fastener that cannot be visually checked.
Fig. 1-24
Check during assembly
• At each step of the assembly procedure, check

and record gaps, free play, projections, and
distortion.
Reassembling shims
• Install shims and washers in the same places as

before and then check if the gaps are correct.
Assembling adjustment links
• If no adjustment is needed, assemble them to

make the same length as before.

Assembling press-fitted parts
• Repair scratches and dents as required and

keep the parts clean before inserting them.
• Note that insufficiently tightened press-fitted

parts may become loose.
Assembling keys and keyways
• Check if keyways and keys are loosened and if

they contact the key head. If the key head
contacts the keyway, remove the remaining part
of the key head.
1
Handling general parts
Handling packing
General
• Packing, gaskets, and copper packing should all
be replaced as instructed. Assemble the gaskets
specified in this Service Manual after applying
an adhesive. When you apply an adhesive to a
gasket, note the following:
 Completely remove old adhesive, scratches,
dust, paint, and grease left on the surface of
the gasket.
 Evenly coat both sides of the gasket with an
appropriate sealant and wait for several
minutes until it dries.
 Once the sealant has dried to the extent that
when touched it does not stick to your hand,
assemble the parts.
 Soak leather packing in oil before use.
Handling O-rings
• Always remember to check the condition of O-

rings. Do not use O-rings that have become
hard from being stored away for a long time.
• Only use those O-rings that are specified in the

Parts List. For example, O-rings for engine oil
are made from special materials such as silicon
rubber and are resistant to heat and aging.
Installing a different type of O-ring in this case
could cause severe damage to a system and its
components.
• Lubricate O-rings to avoid scratching their

surface during installation. Silicon rubber O-
rings are easily damaged, so be careful not to
overstretch them.

Handling oil seal
• Prevent oil seals from gathering dust,

particularly in their lips, and make sure there is
no rust or scratches.
• Evenly lubricate the lip surface opposite to the

sealing of an oil seal.
• Check if the surface of the axle to which an oil

seal is mounted is contaminated, rusted, or
scratched, then apply grease or lubricant so that
the oil seal can be installed easily. Fig. 1-25
• Check the surface of the oil seal lip for scratches

by lightly rubbing a wire on the surface. If there
are any scratches, replace the oil seal.
• When you insert an oil seal, use a guide and jig

as shown in Fig. 1-26 to avoid damaging it.
• After you have inserted an oil seal, check the

inclination (tolerance of inclination: 0.2 mm/100
mm, 0.008 in/3.937 in diameter). Guide Jig
• When you apply adhesive to an oil seal, ensure Fig. 1-26

that no adhesive makes contact with the lip’s
surface. Completely remove residual adhesive
on the guide and jig before you insert another
seal.
Handling bearings
• To assemble a bearing correctly and avoid

damaging it, take note of the following:
 Completely remove dust and other
contaminants that might shorten the bearing’s
service life. Keep the bearing as packed until
its installation.
 Do not impact the bearing. Never turn the
bearing excessively in order to remove the
purifier by blowing in compressed air. Ensure
that the oil seal ring is installed in the right
direction.

• Pay attention to the following when you install
bearings.
 Neither hit the outer race with a hammer to
install it, nor hit the inner race to insert the
outer race. Hammering like this will cause
damage to the track of the bearing.
 When you insert the inner race of a bearing
with a reasonable tolerance, use a jig as
shown in Fig. 1-27 and put pressure on the
inner race. When you perform thermal
insertion with a press-fitting tolerance, heat the
bearing up to 120 ℃ (248 ℉). Note, however, Fig. 1-27
that excessive heating may lower the hardness
of the surface of bearing.
 When you insert a non-split bearing with an
inner race and outer race at a reasonable
tolerance, use a jig as shown in Fig. 1-28 and
press in both the inner and outer races at the
1
same time.
General
Fig. 1-28
Handling retaining rings
• When you remove or install a retaining ring, use

a pair of right ring pliers and be careful not to put
too much stress on the retaining ring.
• After you have installed the retaining ring, check

if it is correctly inserted into the groove.

Hydraulic line fittings
Hydraulic line installation
1. For a metal tube to hose installation, install the

tube and tighten all bolts finger tight.
2. Tighten the bolts at the rigid end.
3. Install the hose and tighten all bolts finger tight.
4. Put the hose in a position so that it does not

make contact with the machine or another hose.
5. Tighten the bolts on both connections.
6. Start the engine.
7. Move the implement control levers to all

positions.
8. Look at the hose during movement of the

implement. Make sure the hose is not in contact
with the machine or other hoses.
9. Shut off the engine.
10. If necessary, put the hose in a new position

where it will not make contact when the
implement is moved.
Assembly of fittings with straight threads and O-ring seals

(common to different applications)
1. Put locknut (3), backup washer (4) and O-ring (1) Connection to tube
seal (5) as far back on fitting body (2) as possible. (2) Fitting body
2. Turn the fitting into the part it is used on until

backup washer (4) just makes contact with the
face of the part.
3. To put the fitting assembly in its correct position,

turn fitting body (2) out (counterclockwise) a (3) Locknut
maximum of 359° . (4) Backup washer
(5) O-ring seal

4. Tighten locknut (3) to the torque shown in the
correct chart for the fitting used.
(6) Connection to other part
5. If a fitting body’s tube end is shaped as shown in
Fig. 1-29 (either an elbow or a straight body), put Fig. 1-29
a sleeve on the tube before connecting the tube
to the end.

NOTICE: If the fitting is a connector (straight fitting), the
hex on the body takes the place of the locknut. To install
this type of fitting, tighten the hex against the face of the
part it goes into.
Tightening other fitting types
• Hi-duty (shear sleeve) tube fittings: After the

tube has been put through the nut and makes
contact against the tube shoulder in the fitting
body, turn the nut with a wrench until a small Fig. 1-30
decrease in torque is felt. This is an indication
that the sleeve has been broken off the nut.
Hold the tube to prevent turning and tighten the
•
nut 1-1/2 turns.
Hi-seal fittings: Put the nut and the sleeve over

1
the tubing with the short heavy end of the sleeve
General
facing the end of the tubing. Put the tube end
against the counterbore in the body of the fitting
Fig. 1-31
and tighten until the nut is over the last thread
on the body. The remainder of space is used
whenever the fitting is removed and installed
again.
• Ermeto tube fittings: Put the nut and sleeve

over the tube with head or shoulder end of
sleeve next to the nut. Push the tube into Fig. 1-32
counterbore of fitting body as far as possible.
Turn the nut clockwise until sleeve holds the
tube and prevents movement. Tighten the nut 1-
1/4 turns more to seat sleeve and give a locking
action. When necessary to assemble again, put
sleeve over the tube and tighten the nut until a
sudden increase in torque is felt. Then tighten
1/6 to 1/3 turn more to seat the sleeve.
• Flex fittings: Put the nut and sleeve over the

tubing and push the tube in to counterbore of
fitting body as far as possible. Tighten the nut
until it is against the hex part of the fitting body. Fig. 1-33

1-8 Standard torques
1-8-1 Standard torques for bolts and nuts

Be careful to avoid mixing metric and inch dimensioned
fasteners. Mismatched or incorrect fasteners can result in
vehicle damage or malfunction, or possible injury.
Exceptions to these torques are given in the Service
Manual where needed.
Prior to the installation of any hardware, be sure

components are in near new condition. Bolt and nut
threads must not be worn or damaged. Hardware must
be free of rust and corrosion. Clean hardware with a non-
corrosive cleaner and apply engine oil to threads and
bearing face. If thread lock or other compounds are to be
applied, do not apply engine oil.
After loosening fasteners, keep them well and reuse only

those in fine conditions. When replace with a new one,
make sure to select a fastener of the same size and class.
Usually, you can identify a bolt’s strength according to the

number marked on its head (e.g. 8.8 or 10.9) as shown in
Fig 1-34. The table below lists the standard torques for
Fig. 1-34
standard bolts and nuts, and taperlock studs as shown in
Fig 1-34.
Standard bolt
Taperlock stud
Fig. 1-35
Standard torques 1-44 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

For metric fasteners
Thread size Metric nuts and bolts Metric taperlock studs

(mm) (N·m) (lb·ft) (N·m) (lb·ft)
M6 12 ± 3 9±2 8±3 6±2
M8 28 ± 7 20 ± 5 17 ± 5 13 ± 4
M10 55 ± 10 40 ± 7 35 ± 5 26 ± 4
M12 100 ± 20 75 ± 15 65 ± 10 48 ± 7
M14 160 ± 30 120 ± 22 - -
M16 240 ± 40 175 ± 30 110 ± 20 80 ± 15
M20 460 ± 60 340 ± 44 170 ± 30 125 ± 22
M24 800 ± 100 600 ± 75 400 ± 60 300 ± 45
M30 1600 ± 200 1200 ± 150 650 ± 80 480 ± 60
1
M36 2700 ± 300 2000 ± 225 870 ± 100 640 ± 75
For inch fasteners
General
Thread size Inch nuts and bolts Inch taperlock studs
(inch) (N·m) (lb·ft) (N·m) (lb·ft)
1/4 12 ± 3 9±2 8±3 6±2
5/16 25 ± 6 18.0 ± 4.5 17 ± 5 13 ± 4
3/8 47 ± 9 35 ± 7 35 ± 5 26 ± 4
7/16 70 ± 15 50 ± 11 45 ± 10 33 ± 7
1/2 105 ± 20 75 ± 15 65 ± 10 48 ± 7
9/16 160 ± 30 120 ± 20 - -
5/8 215 ± 40 160 ± 30 110 ± 20 80 ± 15
3/4 370 ± 50 275 ± 35 170 ± 30 125 ± 22
7/8 620 ± 80 460 ± 60 260 ± 40 190 ± 30
1 900 ± 100 660 ± 75 400 ± 60 300 ± 45
1-1/8 1300 ± 150 950 ± 100 500 ± 70 370 ± 50
1-1/4 1800 ± 200 1325 ± 150 650 ± 80 480 ± 60
1-3/8 2400 ± 300 1800 ± 225 750 ± 90 550 ± 65
1-1/2 3100 ± 350 2300 ± 250 870 ± 100 640 ± 75
B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-45 Standard torques

1-8-2 Standard torques for tightening fittings
Standard torques for O-ring face seal fittings
Thread size Straight thread O-ring fitting O-ring
(inch) (N·m) (lb·ft)

O-ring groove
5/16-24 5.0 ± 1.5 45 ± 15

3/8-24 12 ± 2 110 ± 20
7-16-20 20 ± 4 15 ± 3
1/2-20 40 ± 5 30 ± 4 O-ring
9/16-18 40 ± 5 30 ± 4 O-ring face seal nut
3/4-16 100 ± 15 75 ± 10 Straight thread
O-ring port fitting end
7/8-14 135 ± 15 100 ± 10
1 1/16-12 200 ± 25 150 ± 20 Fig. 1-36
1 3/16-12 250 ± 25 185 ± 20
1 5/16-12 300 ± 40 225 ± 30
1 5/8-12 300 ± 40 225 ± 30
1 7/8-12 300 ± 40 225 ± 30
2 1/2-12 300 ± 40 225 ± 30
Thread size O-ring face seal fitting nut

(inch)
(N·m) (lb·ft)
9/16-18 16 ± 3 12 ± 2
11/16-16 30 ± 4 22 ± 3
13/16-16 50 ± 7 37 ± 5
1-14 90 ± 10 65 ± 7
1 3/16-12 120 ± 15 90 ± 10
1 7/16-12 160 ± 20 120 ± 15
1 11/16-12 190 ± 20 140 ± 15
2-12 215 ± 25 160 ± 20
Hose clamp-band type
Clamp Torque on new Retightening

width hose torque
7.9 mm 0.9 ± 0.2 N·m 0.7 ± 0.2 N·m
(0.312 in) (8 ± 2 lb·in) (6 ± 2 lb·in)
13.5 mm 4.5 ± 0.5 N·m 3.0 ± 0.5 N·m
(0.531 in) (40 ± 5 lb·in) (25 ± 5 lb·in)
15.9 mm 7.5 ± 0.5 N·m 4.5 ± 0.5 N·m
(0.625 in) (65 ± 5 lb·in) (40 ± 5 lb·in)
Fig. 1-37

37°flared and straight thread O-ring fittings
37° flared O-ring fitting-plug Swivel nuts

Fig. 1-38
37° flared and straight thread O-ring fittings (except O-ring face seal fittings)
Nominal tube O.D. Thread size Standard torque
Metric Inch (inch) (N·m) (lb·ft)
1
3.18 0.125 5/16 5.0 ± 1.5 4±1
4.76 0.188 3/8 11.0 ± 1.5 8±1
6.35 0.250 7/16 16 ± 2 12 ± 1
7.94 0.312 1/2 20 ± 5 15 ± 4
General
9.52 0.375 9/16 25 ± 5 18 ± 4
9.52 0.375 5/8 35 ± 5 26 ± 4
12.70 0.500 3/4 50 ± 7 37 ± 5
15.88 0.625 7/8 65 ± 7 48 ± 5
19.05 0.750 1-1/16 100 ± 10 75 ± 7
22.22 0.875 1-3/16 120 ± 10 90 ± 7
25.40 1.000 1-5/16 135 ± 15 100 ± 11
31.75 1.250 1-5/8 180 ± 15 135 ± 11
38.10 1.500 1-7/8 225 ± 15 165 ± 11
50.80 2.000 2-1/2 320 ± 30 240 ± 22

45°flared and 45°inverted flare fittings
Inverted 45° flared 45° flared

Fig. 1-39
45° flared and 45° inverted flare fittings

Nominal tube O.D. Thread size Standard torque
Metric Inch (inch) (N·m) (lb·ft)
3.18 0.125 5/16 5.0 ± 1.5 4±1
4.76 0.188 3/8 8.0 ± 1.5 6±1
6.35 0.250 7/16 11 ± 2 8±1
7.94 0.312 1/2 17 ± 3 13 ± 2
9.52 0.375 5/8 30 ± 3 22 ± 4
11.11 0.438 11/16 30 ± 3 22 ± 2
12.70 0.500 3/4 38 ± 4 28 ± 3
15.88 0.625 7/8 50 ± 5 37 ± 4
19.05 0.750 1-1/16 90 ± 8 65 ± 6
22.22 0.875 1-1/4 100 ± 10 75 ± 7

Air conditioning and tapered pipe thread fittings
O-ring 45° flare Fig. 1-40
Air conditioning fittings

45° flare fitting end
Thread size O-ring fitting end
1
Steel the tubes Aluminum the tubes
(inch)
N·m (lb·ft) N·m (lb·ft) N·m (lb·ft)
5/8-18 18 ± 4 13 ± 3 30 ± 3 22 ± 2 23 ± 3 17 ± 2
General
3/4-16 37 ± 4 27 ± 3 52 ± 5 38 ± 4 33 ± 4 24 ± 3
7/8-14 40 ± 4 30 ± 3 60 ± 7 44 ± 5 38 ± 4 28 ± 3
1 1/16-14 45 ± 5 33 ± 4 75 ± 8 55 ± 6 50 ± 5 37 ± 4
Tapered pipe thread fittings
Thread size Threads with 1e2200e sealant Threads without sealant

(inch) (N·m) (lb·ft) (N·m) (lb·ft)
1/16-27 15 11 20 15
1/8-27 20 15 25 18
1-14-18 25 18 35 26
3/8-18 35 26 45 33
1/2-14 45 33 60 45
3/4-14 60 45 75 55
1-11 1/2 75 55 90 65
1 1/4-11 1/2 95 70 110 80
1 1/2-11 1/2 110 80 130 95
2-11 1/2 130 95 160 120

2 Electrical system
2-1 Overview........................................................2
2-1-1 Components............................................................2
2-1-2 Communication protocol .........................................4
2-2 Battery ...........................................................6

2-2-1 Exterior and specifications ......................................6
2-2-2 Functions ................................................................8
2-2-3 Wiring ......................................................................9
2-2-4 Test .......................................................................10
2-2-5 Maintenance .........................................................12
2
2-2-6 Removal and installation.......................................14
2-3 Motors, controllers, and related devices .16

2-3-1 Exterior and specifications ....................................16
Electrical system
2-3-2 Circuit and functions .............................................18
2-3-3 Wiring ....................................................................20
2-3-4 Test .......................................................................23
2-4 Other DC devices (fuse/converter/loads) .28

2-4-1 Fuse box ...............................................................28
2-4-2 DC-DC converter ..................................................31
2-4-3 Lamp group ...........................................................34
2-4-4 Horn ......................................................................35
2-5 Instrument panel ........................................36

2-5-1 Names and functions ............................................36
2-5-2 Diagnosis ..............................................................41
2-5-3 Calibration .............................................................43
2-6 Application “EasyView” .............................45

2-6-1 Installation and initial settings ...............................45
2-6-2 Controller firmware update ...................................51
2-6-3 “Tools” menu description ......................................54
2-6-4 “Administration” menu description ........................62
2-7 Diagnosis/calibration/handling faults ......82

2-7-1 Diagnosis codes ...................................................82
2-7-2 Parameter calibration codes .................................84
2-7-3 Handling faults on instrument panel/EasyView ....87
2-1 Overview
2-1-1 Components
Drive motor controller Pump motor
Pump motor controller Battery cover Horn Accelerator Drive motor
Line contactor F/R Unit DC-DC Converter EM Brake
Line fuse Control valve

(containing F/R switch and hydraulic switches)
Fig. 2-1
Overview 2-2 B15/18/20T, B18/20TL, B16/18/20X-7

This model is equipped with an electrical system that
consists of the following components:
• Battery supplies power to the electrical system.

[Section 2-2]
• Motor, controllers, and related devices provide

the vehicle with necessary drive and pump power
based on their interaction with sensors, switches,
relays, and actuators as well as a number of
parameter settings. [Section 2-3]
• Fuse box protects all the DC loads from

overcurrents by cutting off the power supply to a
load when the load is supplied with a current
higher than the limit. [Section 2-4-1]
• DC-DC converter converts the battery’s high

voltage to 12V for low voltage loads [Section 2-4-2]
• Other DC loads, activated by direct demand from

the operator, work independently from controllers.
2
Primarily, they are not regulated by controllers nor
Electrical system
is their purpose to signal them. However, they may
interact with them in some configurations. These
loads includ the lamp group and horn. [Section 2-4-
3 to 2-4-4]
• Instrument panel monitors the vehicle to inform

the user of its conditions and provides basic
functions for mode setting, diagnosis, and
calibration [Section 2-5]
• Software for diagnosis and calibration provides

the same kinds of functions as the instrument
panel but in more specific detail [Section 2-6]
B15/18/20T, B18/20TL, B16/18/20X-7 2-3 Overview

2-1-2 Communication protocol
Fig. 2-2
In order to enable all the electrical devices of a vehicle
and provide the user with diagnosis and parameter
calibration functions, data sharing between these
controllers and instrument devices is required. For this
purpose, CAN (Controller Area Network) is used as a
standard protocol.
A circuit diagram displaying communications between

major electrical devices using the CAN protocol is shown
above.
NOTICE: See Section 2-6 for how to install the

application to check the vehicle’s conditions and to
perform parameter calibration via CAN communication.

Display
Drive
Controller Calibrating
PC Software
Pump
Controller
UART Fig. 2-3
Drive
Controller
Calibrating
PC Software
2
Electrical system
CAN
Display
Pump
Controller Fig. 2-4
This CAN communications effectively overcomes the

shortcomings of the point-to-point communication-based
UART (Universal Asynchronous Receiver/Transmitter)
system that has been widely used in the past. Due to
one-to-one communication between individual devices,
the UART system is limited in the number of available
communication devices and cabling as well as in
improving vehicle performance.
The diagrams above compare CAN and UART

communications.

2-2 Battery
2-2-1 Exterior and specifications
Basic conditions
Items Spec.
Final discharge voltage 42.5 V
Electrolye Refined dilute sulfuric acid
Replenisher Distilled water
Insulation resistance Over 1 MΩ
Specific gravity by temperature Fig. 2-5
Temperaures
-15℃ -5℃ 0℃ 5℃ 15℃ 25℃ 35℃ 45℃ Charing level

(-59℉) (-41℉) (32℉) (41℉) (59℉) (77℉) (95℉) (113℉)
1.108 1.101 1.098 1.094 1.087 1.08 1.073 1.066 0%
1.118 1.111 1.108 1.104 1.097 1.09 1.083 1.076 5%
1.128 1.121 1.118 1.114 1.107 1.1 1.093 1.086 10%
1.138 1.131 1.128 1.124 1.117 1.11 1.103 1.096 15%
1.148 1.141 1.138 1.134 1.127 1.12 1.113 1.106 20%
1.158 1.151 1.148 1.144 1.137 1.13 1.123 1.116 25%
1.168 1.161 1.158 1.154 1.147 1.14 1.133 1.126 30%
1.178 1.171 1.168 1.164 1.157 1.15 1.143 1.136 35%
1.188 1.181 1.178 1.174 1.167 1.16 1.153 1.146 40%
120% 1.191 1.188 1.184 1.177 1.17 1.163 1.156 45%
121% 1.201 1.198 1.194 1.187 1.18 1.173 1.166 50%
1.218 1.211 1.208 1.204 1.197 1.19 1.183 1.176 55%
1.228 1.221 1.218 1.214 1.207 1.2 1.193 1.186 60%
1.238 1.231 1.228 1.224 1.217 1.21 1.203 1.196 65%
1.248 1.241 1.238 1.234 1.227 1.22 1.213 1.206 70%
1.258 1.251 1.248 1.244 1.237 1.23 1.223 1.216 75%
1.268 1.261 1.258 1.254 1.247 1.24 1.233 1.226 80%
1.278 1.271 1.268 1.264 1.257 1.25 1.243 1.236 85%
1.288 1.281 1.278 1.274 1.267 1.26 1.253 1.246 90%
1.298 1.291 1.288 1.284 1.277 1.27 1.263 1.256 95%
1.308 1.301 1.298 1.294 1.287 1.28 1.273 1.266 100%
* Formula: D25 = Dt + 0.0007(t-25)

D25: converted specific gravity at 25℃ (77℉)
Dt: specific gravity at t℃
t: temperature of the electrolyte when its specific gravity was measured (℃)
/Battery 2-6 B15/18/20T, B18/20TL, B16/18/20X-7

Battery compartment dimension
Battery compartment dimension (mm)
Models
Length Width Height
B15T-7 528 992 (842) 2) 698
1) 2)
B18T-7 638 (608) 992 (842) 698
2)
B18TL-7 746 992 (842) 698
B20T-7 638 (608) 1) 992 (842) 2) 698
2)
B20TL-7 746 992 (842) 698
B16X-7 638 (608) 1) 992 (842) 2) 698
1) 2)
B18X-7 638 (608) 992 (842) 698
B20X-7 638 (608) 1) 992 (842) 2) 698
1)
When “BS type battery” is selected (choose a battery capacity that is compatible with the following capacities:
575/630/690 Ah)
2)
When “DIN type battery” is selected
Recommended battery dimension and weight

Min/max Dimension (mm) Capacity (Ah)
Models
B15T-7 (36V)
weight
(kg)
700/945
L
519
W
980
H1
610
H2
625
h
585
BS
Norminal / max
660/770 ( 850)
3)
DIN
Norminal / max
-
2
3)
B15T-7 (48V) 700/833 519 980 610 625 585 440/575 (600) 460/500
Electrical system
3)
B18T-7 (36V) 800/1200 627 980 610 625 585 825/970 (1050) -
3)
B18T-7 (48V) 800/1057 627 980 610 625 585 510/690 (750) 525/625
B18TL-7 (48V) 800/1057 738 980 610 625 585 600/ - 690/750
3)
B20T-7 (36V) 1050/1200 627 980 610 625 585 825/970 (1050)
3)
B20T-7 (48V) 1000/1250 627 980 610 625 585 585/690 (750) 575/625
B20TL-7 (48V) 1000/1250 738 980 610 625 585 600/ - 690/750
3)
B16X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 575/625
3)
B18X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 575/625
B20X-7 (48V) 1050/1250 627 980 610 625 585 585/690 (750) 3) 575/625
3)
When “special battery” is selected
Fig. 2-6
• Recommended cable length: 1000mm
• Recommended cable size: over 1/0 GA (50mm2)
• Battery connector (BS type): SB350 or SBE320

(confirm the vehicle connector type before installing),
BS connector handle: DIV Part No.D290575
• Battery connector (DIN type): DIN320 (confirm the

vehicle connector type before installing)
B15/18/20T, B18/20TL, B16/18/20X-7 2-7 /Battery

2-2-2 Functions
This model uses a lead storage battery as its power
supply to electrical systems.
The lead storage battery comprises the anode/cathode

plates to store electrical energy, a separator to prevent
short circuit in the plates, an electrolyte that acts as an
electrical conductor and agent within the battery, a
battery jar made of special plastics that houses these,
and a cover, plus an electrode that serves a gateway for
electrical energy, and various other fittings.
• Anode plate: The anode plate consists of tubes

inserted into each core metal of the lead alloy grid,
an active material (lead powder) filled between the
tube and the core metal, and a sealer that seals
the top and bottom of the tubes to prevent the
active material from getting out. This type of pole
plate is called a grid anode plate that features long
service life and high performance.
• Cathode plate: Having the lead alloy grid coated

with an active material (a paste made of lead
powder and a dilute sulfuric acid), this plate is
called a paste type cathode plate.
• Electrolyte: The electrolyte used in the battery is

a mixture of a high-purity, colorless and odorless
concentrated sulfuric acid (KSM 1203) and purified
water, of which the specific gravity is 1.280 (25 ℃,
77 ℉) at a specified level when fully charged.
• Separator: The separator features high

resistance to acid and oxidization, long longevity,
and low electrical resistance.
/Battery 2-8 B15/18/20T, B18/20TL, B16/18/20X-7

2-2-3 Wiring
Terminal Wiring Terminal Wiring Connection
Connection (terminal no.)
no. color no. color (terminal no.)
F_CONN. A (FINGERTIP)
FUSE BOX (A) (10)
BATTERY (1)
RD
(+) F_CONN. A (FINGERTIP)
EMERGENCY SW (OPT)
(5)
F/R UNIT (6) POWER (OPT) (2)
F/R UNIT (7) DIODE-COMP. (2)
DC-DC CONVERTER (1) LIFT SOL VALVE (B)
BATTERY
DC-DC CONVERTER (6) BK FAN RELAY (OPT) (30)
(-)
FLASHER UNIT (OPT) (86) CONTROLLER FAN (2)
BATTERY EMERGENCY C (1) R-LAMP CONN (2)
BK
(-) BACK-UP BUZZER (OPT)
EMERGENCY C (3)
(2)
SERIAL PORT (1) HORN (2)
INSTRUMENT MONITOR (6) L-LAMP CONN (2)
BACK UP LAMP (OPT) (85) LICENCE LAMP (OPT) (2)
OPT LAMP CONN. (2)
Electrical system
B15/18/20T, B18/20TL, B16/18/20X-7 2-9 /Battery

2-2-4 Test
A. Battery condition inspection

A weak battery can cause or contribute to problems in the
Logic Control Board and power circuits. Verify that the battery
is in good condition before troubleshooting other areas.
Preliminary steps
1. Verify that there is proper polarity at the battery
connector and the control panel. The positive
cable should be at the line fuse and the negative
at the negative on the control panel.
When the vehicle is operational

<Battery load test>
1. Turn the range switch on the multimeter to read
battery voltage.
2. Connect the battery
3. Connect the multimeter leads between positive
(+) cable connection (1), and negative (-) cable
connection (2).
4. In a safe area, operate the hydraulic system, (hold
tilt lever to maximum position momentarily) while
reading the voltage indicated on the multimeter.
5. If the indication is less than the limit (34.5 V for a 36 V Fig. 2-7
model; 45.6 V for a 48 V model), the battery needs to be
charged or repaired before continuing to troubleshoot.
When the vehicle is not operational and the battery is the suspected cause
<Cell voltage test>
1. With the vehicle powered up and the pump (Idle)

motor running, measure the voltage at each cell.
 Normal voltage should be between 1.95V and
2.12V per cell. If the voltage on each cell is
below 1.95V, the battery must be charged or
repaired before continuing to troubleshoot.
 The indication between cells should not differ
more than 0.05 volts. If it does, the battery must
have an equalizing charge or be repaired.
<Hydrometer test>
1. Test each cell of the battery with a hydrometer.

 If the specific gravity indication is below 1.140,
the battery must be charged. The battery is
fully charged if the indication is 1.265 to 1.285
(See Section 2-2-1).
 The indication between cells should not differ
more than 1.020. If it does, the battery needs
an equalizing charge or needs to be repaired.
/Battery 2-10 B15/18/20T, B18/20TL, B16/18/20X-7

B. Resistance to chassis
Resistance between any point in the truck wiring and the

chassis should be a minimum of 10,000 ohms or more.
Many malfunctions are caused by shorts to chassis.

Usually, two shorts must exist before a malfunction will
occur. But, since batteries can have chassis leakage,
only one short to chassis in the truck wiring can cause
problems. To prevent problems because of shorts, do the
following:
1. Disconnect the battery and discharge the

controller.
2. Randomly measure any component connection

or wiring connection in respect to the lift truck
2
chassis for a minimum resistance of 10,000
ohms.
 Any test point with low resistance must have
the short to chassis removed.
Electrical system
3. Always keep batteries clean to minimize current
leakage to the chassis.
4. Routinely clean the brush dust from the motors.
5. Be sure that all attachments, such as horns and

lights are designed for no chassis connection (a
two wire system).
B15/18/20T, B18/20TL, B16/18/20X-7 2-11 /Battery

2-2-5 Maintenance
The care and maintenance of batteries is most important
to maximize battery life and efficient vehicle operation.
Periodic inspection and service will increase the life of
batteries. Special attention should be given to the rules
that follow:
• Keep batteries clean at all times. Cleaning will

prevent corrosion, current leakage and shorts to
the chassis. Tighten all vent plugs, wash the
battery with water and a brush, then dry it with an
air hose. It may be necessary to use a baking soda
solution if water alone will not clean the top of the
battery.
• Add enough water to cover the plates before

charging. This will ensure the proper chemical
reaction over the entire plate surface. After
charging is complete, add water until it is about
12.7 mm (0.50 in) above the plates. Use distilled
water or water that has tested free from minerals.
• Charge the battery correctly. A battery should be Min. level Max. level
(refilling required) (normal)
discharged to 80% of its capacity then fully
recharged. It should cool four to eight hours to
allow the voltage to stabilize before being put back
into use. The battery should have an equalizing Float Float
charge (an extra three or four hour charge at a low
Fig. 2-8
finish rate) once a month to make sure all cells are
in a fully charged condition. Properly charged
batteries should be identified to prevent low
batteries from being installed in vehicles.
• Operation with a low battery must be prevented.

Low battery operation may damage the battery and
will cause a current in the electrical system that is
higher than normal. High current draw due to a low
battery will damage contactor tips and shorten
motor brush life.
/Battery 2-12 B15/18/20T, B18/20TL, B16/18/20X-7

• The battery's maximum temperature is critical. The
electrolyte temperature should never exceed 55 °C
(131°F) either while operating or charging.
Overcharging a battery will cause it to overheat
and it’s plates to warp. Maximum battery life will
result from maintaining 25˚C (77°F) electrolyte
temperature. Most of the charging equipment is
fully automatic but should be checked periodically
to ensure proper working order.
Electrolyte Charged Electrolyte Charged

temp. ℃ (℉) (%) temp. ℃ (℉) (%)
5 to 25 110 to -15 to -10
140 to 150
(41 to 77) 125 (-59 to 50)
-10 to 5 125 to Not
Below -15 (-59)
(-50 to 41) 140 chargeable
• Keep accurate battery records. Regular battery
readings should be taken with a battery tester or
voltmeter and recorded. The specific gravity and 2
voltage of each cell should be checked and
recorded at least once a month. This inspection
Electrical system
should be made after an equalizing charge.
Readings should never be taken directly after
water has been added. Records of all battery
maintenance should be made and filed so it will be
known which batteries are being mistreated or
wearing out.
NOTICE: Repairs should be made immediately otherwise

the battery may become damaged. Batteries stored in a
discharged condition may be difficult to recharge due to
sulfate formation.
B15/18/20T, B18/20TL, B16/18/20X-7 2-13 /Battery

2-2-6 Removal and installation
WARNING
Careless use of the battery may
cause an electric shock.
Be sure to follow the safety precautions
given in Section 1-4.
CAUTION
A short-circuit may occur in the
course of removal, transport, and
installation of batteries.
Always ensure that the battery is
covered with an insulating material
(polywood) before removing and
installing it and no metallic material
contacts the top of battery cells.
1. Park the vehicle.
2. Lower the forks and tilt the mast forward until the
tips of the forks touch the ground.
3. Turn off the key switch.
4. Disconnect battery connector (1).
5. Place the steering column vertically and move

the seat back completely.
Fig. 2-9
6. Open hood latch lever (2) that holds the seat and
battery cover.
7. Raise the seat and battery cover.
8. Discharge the power supply module by keeping

the key switch on for approx. 30 seconds twice.
NOTICE: Failure to discharge the power supply module

may cause an electric shock.
9. Remove the battery using a hoist.

Fig. 2-10
10. To install the battery, perform the procedure
above in the reverse sequence.
/Battery 2-14 B15/18/20T, B18/20TL, B16/18/20X-7

2
Electrical system
B15/18/20T, B18/20TL, B16/18/20X-7 2-15 /Battery

2-3 Motors, controllers, and related devices
A. Motor
Pump motor
Drive motor
Fig. 2-11
Items Drive motor Pump motor

Quantity 2 (left and right) 1
Voltage 48 VAC 48 VAC
Power 6.0 kW 14.0 kW
Voltage 30 V 30 V
Current 152 A 352 A
Speed 2650 rpm 2140 rpm
Max. speed 5000 rpm 4500 rpm
Frequency 90 Hz 74 Hz
Protection degree IP43 IP43
Weight 33.0 kg (72.8 lb) 41.5 kg (91.5 lb)
Motors, controllers, and related devices 2-16 B15/18/20T, B18/20TL, B16/18/20X-7

B. Controller panels
2
Fig. 2-12
Electrical system
Items Spec.
300611-00989 (L. drive motor controller)
Part no. 300611-00990 (R. drive motor controller)
300611-00991 (Pump motor controller )
Voltage 36/48 V
PWM frequency 10 kHz
Controllers Drive maximum current 450 A
Pump maximum current -40 to +50 °C (-104 to 122 ℉)
Operating ambient temperature
-40 to +95 °C (-104 to 203 ℉)
range
Maximum temperature +95 °C (203 ℉)
IP degree (dust & water proof) IP65
Part no. 300717-00443
Operating Voltage 36 VDC
Coil Resistance 94Ω (20 ℃, 68 ℉)
Line contactor
Pull In Voltage 24 VDC
Drop Out Voltage 7.2 VDC
Coil Power Dissipation 21 W
Part no. 300803-00262
Voltage rating 80 V
Line fuse
Current rating 500 A
Cold Resistance 0.06 mΩ
B15/18/20T, B18/20TL, B16/18/20X-7 2-17 Motors, controllers, and related devices

2-3-2 Circuit and functions
Fig. 2-13

Key on  power supply to controller
This model is equipped with two drive motors and one
pump motor, which are controlled by different individual
controllers. Keying on the vehicle to close the key switch
powers the controllers at their pins #1, turning them on.
Current to line contactor  power supply to motor
Once the controllers are supplied with power, the magnetic

coil built in the line contactor (Fig. 2-14) receives power from
pin #13 on the left drive motor controller. Then the two
contact points that act like a switch will contact each other
and subsequently connect the lines between the battery and
three inverters. The battery power accordingly turns into a 3-
phase 3-line AC power and is transferred to the motors
through each set of U.V.W. connections. The line contactor
is equipped with a 500A fuse which prevents overcurrent.
Motor controllers 2
Electrical system
The three controllers are connected with the following
sensors, switches, relays, and actuators.
• Key switch
• Emergency switch
• Forward/backward unit
Fig. 2-14
• Accelerator
• Seat switch
• Brake pedal switch
• Parking brake switch
• EM brake
• Steering angle sensor
• Hydraulic control switches
• Fan relay
• Backup relay
• Lift solenoid valve relay
Supplied with DC power, these devices interact with the

controllers, which based on a number of parameter settings
activate or receive data from them to control the motors.
In terms of hardware, the three motor controllers are

identical, but each is programmed with different kinds of
firmware for different functions.
For detailed explanations of how the drive and pump

motors work, see Section 3-2-2 and 4-2-2 respectively.

2-3-3 Wiring
Drive motor controllers use a 35 pin AMP connector.
Controller connector Fig. 2-15
Left drive motor controller connector pins Harness Fig. 2-16
Wiring Wiring
Pin no. Connection (terminal no.) Pin no. Connection (terminal no.)
color color
Left Drive Controller (12) 8 VO LM Thermal (1)
Pump Controller (1) 10 OR Left Drive Controller (1)
Lift Sensor (1) 12 OR Left Drive Controller (1)
Auto Tilt SW3 (1) FAN Realy (86)
13 OR/RD
Mast Tilt SW2 (1) EM CONN A (4)
Height SW1 (1) Right Drive Controller (23)
Tilt Lever (1) Pump Controller (23)
DC-DC Converter (3) 23 GN CONN A (13)
1 OR
F_CONN A (6) CAN Port (7)
OSS Controller 2P (1) F_CONN A (3)
Pedal Brake SW (1) 24 GN Angle Sensor (2)
CONN A (1) CONN A (4)
25 RD/WH
F/R Unit (2) Angle Sensor (1)
Right Drive Controller (1) LM Encode (1)
26 RD
Right Drive Controller (11) Accelerator (3)
Left Drive Controller (10) 28 BU Serial Port (7)
2 RD/BK FAN Relay (85) 29 VO Serial Port (2)
3 YL Lift SOL Relay (85) 30 RD CONN A (5)
5 WH/RD EM CONN A (3) 31 LG LM Encode (3)
6 BR EM SW (1) 32 GY LM Encode (4)
Accelerator (1) Right Drive Controller (23)
CONN A (2) Pump Controller (23)
LM Encoder (2) 35 YL CONN A (13)
LM Thermal (2) CAN Port (7)
7 WH
OSS Controller 8P (6) F_CONN A (3)
Seat SW (2)
Seat Belt SW (2)
Angle Sensor (3)
Note) Consult the motor controller circuit in Fig. 2-13.

Right drive motor controller connector pins
Wiring Wiring
color color
Left Drive Controller (12) 8 YL RM Thermal (1)
Pump Controller (1) EM CONN A (2)
13 YL/GN
Lift Sensor (1) F_CONN B (2)
Auto Tilt SW3 (1) Left Drive Controller 23)
Mast Tilt SW2 (1) Pump Controller (23)
Height SW1 (1) 23 YL/BK CAN Port (7)
Tilt Lever (1) CONN A (13)
DC-DC Converter (3) F_CONN A (3)
1 OR
F_CONN A (6) 26 RD RM Encoder (1)
OSS Controller 2P (1) 28 BU/RD Serial Port (8)
Pedal Brake SW (1) 29 BU/WH Serial Port (3)
CONN A (1) 31 OR/RD RM Encoder (3)
F/R Unit (2)
Left Drive Controller (1)
32 YL RM Encoder (4)
Left Drive Controller (23)
2
Right Drive Controller (11) Pump Controller (23)
Electrical system
Left Drive Controller (10) 35 YL CONN A (13)
2 YL/RD F_CONN B (1) CAN Port (7)
5 BK EM CONN A (1) F_CONN A (3)
RM Encoder (2)
7 WH
RM Thermal (2)

Pump motor controller connector pins
Wiring Wiring
color color
Left Drive Controller (1) 14 WH/BK Height SW1 (2)
Left Drive Controller (12) 16 BK Accelerator (5)
Lift Sensor (1) 17 BR/YL Diode AS-Park (2)
Auto Tilt SW3 (1) 19 YL/GN Auto Tilt SW3 (2)
Mast Tilt SW2 (1) 20 YL/BU Tilt Lever (2)
Height SW1 (1) 21 OR/BK Pump Controller (34)
Tilt Lever (1) 22 YL Lift Sensor (6)
DC-DC Converter (3) Left Drive Controller 23)
1 OR
F_CONN A (6) Right Drive Controller (23)
OSS Controller 2P (1) 23 YL/BK CAN Port (7)
Pedal Brake SW (1) CONN A (13)
CONN A (1) F_CONN A (3)
F/R Unit (2) 24 GN/YL Lift Sensor (7)
Right Drive Controller (1) CONN A (9)
Right Drive Controller (11) 25 RD/GN Lift Sensor (2)
Left Drive Controller (10) Pressure Sensor (1)
2 BU/BK F_CONN B (3) PM Encoder (1)
26 RD
3 GN F_Back Up Relay (85) Accelerator (6)
4 WH/GN Tilt Solenoid (2) 28 BU Serial Port (9)
5 BU/GN F_CONN B (5) 29 VO Serial Port (4)
6 YL/WH Pressure Sensor (2) 31 GN/BK PM Encoder (3)
Lift Sensor (5) 32 BR PM Encoder (4)
Accelerator (4) 33 BK/WH Lift Sensor (8)
7 WH/BU CONN B (11) 34 OR/BK Pump Controller (21)
PM Encoder (2) Left Drive Controller (23)
PM Thermal (2) Right Drive Controller (23)
8 GN/RD PM Thermal (1) 35 YL CONN A (13)
9 BU Mast Tilt SW2 (2) CAN Port (7)
10 VO Lift Sensor (4) F_CONN A (3)
Tilt Solenoid (1)
13 BU/WH F_CONN B (4)
F_Back Relay (86)

2-3-4 Test
A. Controller
Measure the diode voltage of the AC MOSFET circuit

(Fig. 2-17) inside the controller to check for burnt
damages.
1. Remove the cables and harness connected to

the controller and discharge the internal
capacitor completely.
2. Using a multimeter, measure the voltage of the

diode (0.3–0.6V) and check if it is normal (Fig. 2-
18 and 2-19).
Diode Red lead Black lead Result

Approx.
2
Test 1 U, V, W B+
0.4–0.6 V
Approx.
Test 2 B- U, V, W
0.4–0.6 V
Electrical system
 Test 1: Measure voltage with the red lead to B- Fig. 2-17
and the black lead to U, V, and W.
○
W
○
V
-
○ ○
U ○
- ○
-
 Test 2: Measure voltage with the red lead to U, Fig. 2-18

V, and W, and the black lead to B+.
○
W
○
+
○ ○
+
+ ○
V
○
U
Fig. 2-19

B. Line contactor and fuse
Normal: 70 to 110 Ω
Fig. 2-20
Line contactor
Line fuse Fig. 2-21
1. For the line contactor and the line fuse, connect

an ohmmeter at the points shown in the figure
and check if it measures the values as specified.

A. Drive motor controller panel

(1) Drive motor controller panel (2) Connector (3) Bolt (4) Washer
B
A
Electrical system
Fig. 2-22
NOTICE: The controller contains ESD (Electro Static
Discharge) sensitive components. Use the appropriate
precautions when connecting, disconnecting or handling it.
Preliminary steps
2. Remove the top cover on the counterweight (See

Section 7-4).
Procedure
1. Remove connectors (2) from drive motor

controller panel (1).
2. Remove bolts (3) and washers (4) and then remove

drive motor controller panel (1) from the frame.
3. Follow the steps above in the opposite order to

install the drive motor controller.

B. Drive motor controllers, line contactor, and line fuse
(13) Bolt, Washer (14-1) Bracket
(1) Bolt
(12) Drive motor controller (14) Bracket (15) Bolt
(2) Nut
(3) Washer
(4) Line contactor
(5) Bracket
(6) Drive motor controller plate
(7) Bolt
(8) Bolt
(9) Fuse
(10) Washer
(11) Nut
(16) Drive motor controller panel

Fig. 2-23
1. Remove nuts (2) and washers (3).
2. Remove nuts (11) and washers using a 5 mm

socket wrench and then remove fuse (9).
3. Remove bracket (5) from line contactor (4).
4. Remove sets of bolts (7) and washers and sets

of bolts (8) and washers and then remove drive
motor controller plate (6) and line contactor (4).
5. Remove nuts (15) and washers using a 5 mm

socket wrench and then remove brackets (14)
and (14-1).
 Installation torque: 9.6±0.9 N·m (7.1±0.7 lb·ft)
6. Remove eight bolts (8) and washers and then

remove drive motor controller (12) from drive
motor controller ass’y (16).

install the drive motor, line contactor, and line
fuse.
 Apply a small amount of D557047 Thermal
Joint Compound on the control panel plate and
mating surface prior to assembly.

C. Pump motor controller
(1) Pump motor controller panel (2) Connector
(3) Bolt
(4) Bolt
(5) Pump motor controller
Electrical system
Fig. 2-24
The pump motor controller panel is located opposite to
the drive motor controller panel.
NOTICE: The controller contains ESD (Electro Static

Discharge) sensitive components. Use the appropriate
precautions when connecting, disconnecting or handling it.
Preliminary steps

Section 7-4).
Procedure
1. Remove connector (2) from pump motor

controller assembly (1)
2. Remove bolts (4) and washers and then remove

pump motor controller panel (1).
3. Remove bolts (3) and washers and then remove

pump motor controller (5).

install the pump motor controller.

2-4 Other DC devices (fuse/converter/loads)
2-4-1 Fuse box
A. Function and composition
To protect DC loads from overcurrent, the fuse box is

equipped with the following terminals:
Rated
Sets Items
capacity
DC-DC CONVERTER, HORN 20 A
KEY SWITCH 10 A
FAN, FINGERTIP (OPT) 5A
A
SOL VALVE, POWER (OPT) 5A
BACK-UP LAMP (OPT) 5A
5A Fig. 2-25
LEFT LAMP (OPT) 5A

10 A
OPT LAMP 5A
B RIGHT LAMP, LICENCE LAMP
5A
(OPT)
STROBE, FLASHER LAMP (OPT) 5A
REAR LAMP 5A
Other DC devices (fuse/converter/loads) 2-28 B15/18/20T, B18/20TL, B16/18/20X-7

B. Wiring
FUSE BOX (A) FUSE BOX (B)

Terminal Wiring Terminal Wiring
Connection (terminal no.) Connection (terminal no.)
no. color no. color
1 (n/a) 1 GN/YL LIGHT SW (OPT) (7)
2 RD/YL F/R UNIT (4) 2 YL/WH FLASHER UNIT (OPT)
(85)
STOP LAMP SW (OPT) (2) OPT LAMP CONN. (8)
BACK UP LAMP (OPT) (30) 3 OR/RD DC-DC CONVERTER (5)
F_BACK UP RELAY (OPT) (30) LIGHT SW (OPT) (2)
3 OR/RD DC-DC CONVERTER (5) 4 YL/GN R-LAMP CONN. (1)
LIGHT SW (OPT) (2) LICENCE LAMP (OPT) (1)
4 (n/a) 5 BU/RD OPT LAMP CONN. (4)
5 (n/a) 6 BU/YL LIGHT SW (OPT) (3)
6 OR/RD DC-DC CONVERTER (5) 7 (n/a)
LIGHT SW (OPT) (2) 8 (n/a)
7
8
(n/a)
(n/a)
9
10
BU/GN
BU/YL
L-LAMP CONN. (1)
LIGHT SW (OPT) (3)
2
9 RD/BU DC-DC CONVERTER (2) 11 (n/a)
Electrical system
10 RD BATTERY (+) 12 (n/a)
11 (n/a)
12 (n/a)
B15/18/20T, B18/20TL, B16/18/20X-7 2-29 Other DC devices (fuse/converter/loads)

C. Removal and installation
Preliminary steps

Section 7-4).
Procedure
1. Remove harness connectors (4) from fuse box

(1). (1) Fuse box
(2) Bolt
2. Remove bolts (2) and washers (3) and then (3) Washer
remove fuse box (1). (4) Connector
Fig. 2-26
3. To install the fuse box, perform the procedure

above in the reverse sequence.
 When you reconnect the connectors, note the
connection layout at the right.
Fig. 2-27

2-4-2 DC-DC converter
A. Exterior and specifications
Fig. 2-28 2
Items Spec.
Electrical system
Max Power 300 W
Supply Voltage 24/36/48 VDC
Output Voltage 12V ± 5%
Output Current Max. 25 A
Operating Temperature -30 to +55 °C (-86 to 131 °F)

B. Circuit and functions
12 FUSE BOX(A)
11
2/RD 10 D/D CONVERTER
98/RD/BU 9 20A HORN
8 KEY SWITCH
59/RD/WH 7 10A
43/OR/RD 6
5 FAN/FINGERTIP(OPT)
5A
4 SOL VALVE/POWER
5A
43/OR/RD 3
2/RD 2 BACK-UP
KEY SWITCH 5A
1 5A
ENABLE 3 3/OR
BATT + 2 98/RD/BU 12 FUSE BOX(B)
12V + 5 43/OR/RD 11
BATT - 1 1/BK 10
12V - 6 1/BK 9 L LAMP
5A
+ BATTERY 8
DC/DC CONVERTER 7 10A
6
5 OPT LAMP
5A
- BATTERY 4 R LAMP/LICENCE
5A
43/OR/RD 3
2 5A STROBE/FLASHER
1 REAR LAMP
5A
1/BK
Fig. 2-29
The DC-DC converter converts high voltage power from
the battery (48 V or 36 V) to a 12 V power that is suitable
for a number of loads.
Each of its terminals function as follows:
• Terminal 3 (ENABLE) receives power from the

battery to activate the DC-DC converter. It is also
connected with a key switch line to protect it from
an overcurrent higher than 10 A.
• Terminals 2 and 1 are connected to the positive

and negative poles of the battery respectively.
Unlike Terminal 3, these terminals are responsible
not to activate the converter but to resend battery
power to other loads. They are protected from an
overcurrent higher than 20 A
• Terminal 5 (12V+) is connected to the fuse box’s

terminals which cover the loads to be powered from
the converter. The power from the battery is
converted to 12 V and then sent through the fuse box
to the loads.
• Terminal 6 (12V-) is connected to the negative poles

of the loads that are to be applied at 12 V. Namely,
those currents which have passed through the loads
return to this terminal.

C. Wiring
Terminal Wiring Terminal Wiring

no. color no. color
F_CONN. A (FINGERTIP) (1) 4 (n/a)
1 BK F_CONN. A (FINGERTIP) (5) FUSE BOX (A) (6)
BATTERY (-) FUSE BOX (A) (3)
5 OR/RD
FUSE BOX (A) (9) FUSE BOX (B) (3)
2 RD/BU
F_CONN. A (FINGERTIP) (7) LIGHT SW (OPT) (2)
SAFETY RELAY (OSS) KEY SW F_CONN. A (FINGERTIP)
(1) (1)
3 OR 6 BK F_CONN. A (FINGERTIP)
F_CONN. A (FINGERTIP) (6)
(5)
PUMP CONTROLLER (P1-1) BATTERY (-)
NOTICE: Do not connect 12V output (-) terminal of the

convertor to the (-) tab of the battery. Incorrect power
supply may cause harm to related parts.
Electrical system

2-4-3 Lamp group
Fig. 2-30
This model is equipped with a variety of lamps, each with
different purpose.
• Head lamps (L/R) illuminate the path in front of the

vehicle
• Rear lamps illuminate the path behind the vehicle
• Backup lamp lights up during reverse drive
• Stop lamp lights up with the brake pedal pressed
• License lamp illuminates the license plate in dark

conditions

2-4-4 Horn
Electrical system
Fig. 2-31
Connected to the fuse box’s terminal is the “DC-DC &
HORN [20A],” which is used to set off an alarm to warn
those nearby.

2-5 Instrument panel
2-5-1 Names and functions

The instrument panel is located at the center of the
console cover. The symbols shown on the panel indicate
the values of the vehicle system’s essential analog and
digital parameters.
The indicator lamps and buttons are named as follows:
Fig. 2-32
No. Names No. Names
1 Fault indicator 11 Vehicle speed level and F/R direction indicator
2 Travel lamp indicator 12 EM brake indicator
3 Turn signal indicator 13 Brake oil pressure alarm indicator
4 Seat belt indicator 14 Over-temperature alarm indicator
5 Seat switch indicator 15 Maintenance time expiry indicator
6 Steering angle indicator 16 E-S-H button
7 E-S-H indicator 17 UP/TURTLE button
8 Turtle mode indicator 18 ENTER button
9 BDI indicator 19 DOWN button
10 Vehicle speed and fault indicator 20 Message box
Instrument panel 2-36 B15/18/20T, B18/20TL, B16/18/20X-7

Left LED Indicators
Located at the left side of the display are four LED

indicators that, when switched on, give the following
information:
Fig. 2-33
No. Indicators Descriptions

[Fault indicator]
• Lights up in red in the following situations:
- The instrument panel’s communication with the controllers is lost for
3 seconds.
1
- The circuit board in the instrument panel is failed.
- A fault code appears due to a problem with the vehicle.
- Under normal conditions, the indicator briefly blinks when the key
switch is on or off.
2
[Travel lamp indicator]
Electrical system
2
• Lights up in green to indicate the vehicle is being driven.
[Turn signal indicator]

3
• Lights up in green to represent the indicated direction (option).
[Seat belt indicator]

4
• Lights up in red for 10 seconds after the seat belt is released (option).
B15/18/20T, B18/20TL, B16/18/20X-7 2-37 Instrument panel

Indicator lamps in the display
Located at the center of the instrument panel are

indicator lamps that show the vehicle’s condition.
Fig. 2-34

[Seat switch indicator]
• This symbol indicates that the seat switch is open. At the appearance
of this symbol, fault code EE flickers and all the vehicle’s functions are
shut down.
• If the operator attempts to put the vehicle in forward or reverse before
5 the seat switch is on, fault code EE (Wrong Start) is displayed.
• If the LIFT/TILT/AUX1/AUX2 lever is activated before the seat switch is
on, fault code FL (Pump Sign On) is triggered.
• When fault code EE or FL occurs and the signal of the respective
function is deleted, the fault code disappears and the vehicle returns to
normal condition.
[Steering angle indicator]
6
• The steering angle is indicated in seven segments.
[E-S-H indicator]
• Lights up when shifting the curruent operation mode using the E-S-H
7
button at the bottom of the panel is enabled. The availity of this button
is set in the EasyView application.
[Turtle mode indicator]
8
• Indicates the vehicle is in low speed drive mode
[BDI indicator]
• Battery level, indicated by a 9 segment symbol.
Charge level BDI percent [%]
9 90%<
8 89%–80%
7 79%–70%
6 69%–60%
9 5 59%–50%
4 49%–42%
3 41%–34%
2 33%–26%
1 25%–20%
EL > 20%
• If the battery is completely discharged, the display will signal the alarm
code EL.

[Vehicle speed and fault indicator]
• When the Key is in the On position, the vehicle model ID code appears
on the display for 3 seconds.
- Vehicle type (e.g.: C2 [CURTIS
Controller])
- Battery voltage (e.g.: 48V)
- Software program code (e.g.: 56)
10 • After that, the vehicle’s drive speed is displayed in kmh or mph

• Pressing the down button once will allow you to alternate between the
accumulated driving time (hour meter) and distance (odometer) on the
display.
• In the following conditions, the indicator shifts to display the
corresponding fault code (See Section 2-7-3):
- Seat switch open
- CAN communication between display and controllers is not active
2
- Main contactor open
Electrical system
[Vehicle speed level and F/R direction indicator]
• Each segment on the indicator dial represents a different speed level,
11
ranging from 0 (no speed) to 9 (maximum speed).
• The position of the F/R switch is displayed in the center.
[EM brake indicator]

12 • When the accelerator pedal is depressed, the indicator turns off; when
completely released, it lights up three seconds after.
[Brake oil pressure alarm indicator]

13
• Lights up in red when the brake oil level is low
[Over-temperature alarm indicator]
• Blinks when a motor or its controller is overheated at a temperature
higher than the alarm limit and continues to blink once the temperature
14
exceeds the warning limit on the indicator.
• Fault codes E1 to E6 (over-temperature) blink when the temperature
exceeds the limit.
[Maintenance time expiry indicator]
15
• Lights up to indicate the vehicle is due for maintenance.
[Message box]
20
• Displays the message.

Command and service menu buttons
Located at the bottom are four buttons: E-S-H,

UP/TURTLE, DOWN, and ENTER.
Fig. 2-35
No. Buttons Descriptions

[E-S-H button]
• With this key, you can shift the operation mode between Economic,
Standard, and High Performance modes in this order.
• This button is only available after it has been set to enabled on EasyView;
16
there are also some parameters applicable to the respective modes which
can be modified only on EasyView (See Section 2-6).
• Pressing this key when you are in diagnostic mode allows you to see a
circular list of the 10 latest alarms.
[UP/TURTLE button]
• This button functions as TURTLE and UP buttons both.
• Pressing this button allows you to toggle between slow and normal
drive modes.
• In calibration mode, you can adjust the speed at which the vehicle
17 travels in speed limitation mode (calibration no. 84: TURTLE SPEED,
range 500–3500 rpm).
• Pressing this button in calibration or diagnostic mode allows you to
choose the previous parameter on display.
• After a parameter is selected in calibration mode, pressing this button
increases the parameter’s numeric value.
[ENTER button]
• Holding this button for 3 seconds after the key switch turns on gives
you a selection between calibration and diagnostic modes.
• Holding this button for 3 seconds while the vehicle is in normal
18 operation allows you to access to diagnostic mode.
• If the display is in diagnostic mode during normal operation, you can
exit this mode by pressing ENTER once more.
• After you choose a parameter or its setting value, pressing ENTER
confirms it.
[DOWN button]
• Pressing this button in calibration and diagnostic mode allows you to
choose the next parameter on display.
19 • After a parameter is selected in calibration mode, pressing this button
decreases the parameter’s numeric value.
• When the button is held for one second during normal operation, the display will
alternate between showing the accumulated driving time and distance.

2-5-2 Diagnosis
Parameter settings check
In diagnostic mode, you can check the main analog and

digital signals from the vehicle system as follows:
1. Hold ENTER for three seconds.

 If you have performed another task using the
instrument panel, it will enter immediately
diagnostic mode, displaying the symbol “d.” If it
is the first command after startup, the panel
will ask you to select between “c” and “d.”
Hold for 3 sec.

Fig. 2-36
2. Once you are given the two choices “c” and “d,”
press the down button to select “d” (diagnostic
mode). 2
Electrical system
3. In diagnostic mode, use the up and down button Fig. 2-37
to select the parameter number you want to
check (See Section 2-7-1).
 In the speed and warning section, the
parameter’s number is shown (blinking).
 In the time and distance section, the current
value is shown.
4. To return to diagnosis mode, hold ENTER for

three seconds.
Fig. 2-38
NOTICE: You can quit the diagnostic mode at any time
even if you have not finished the diagnosis procedure.
NOTICE: If a warning occurs when you are in diagnostic
mode and the vehicle system is normal, the panel will
automatically change the display to show the warning.

Check of stored fault codes
You can see the last 10 faults as follows:
1. Press the E-S-H button to see the three types of

stored fault messages.
Hold for 3 sec.
Fig. 2-39
 If there is no fault code stored, the number “0”

will appear in the speed and warning section.
Fig. 2-40
2. Use the up and down button to choose the fault

code you wish to check.
Fig. 2-41

2-5-3 Calibration
Using the instrument panel, you can modify a number of
different parameter settings. And although it may only
allow you to set a limited number of parameters this
function is especially useful when the PC application
EasyView is not available.
To calibrate parameter settings:
1. Turn the key switch off and on again to initialize

the instrument panel.
2. Hold ENTER for three seconds until a page

loads that prompts you to select between “c” and
“d.”
Hold for 3 sec.

2
Fig. 2-42
Electrical system
3. Press the up button to select “c.”
NOTICE: If parameter calibration code 40 ENABLE

TURTLE is set to “disable,” the up button will be disabled,
preventing you from entering calibration mode. If this
happens, key the vehicle off and on again to restart.
Fig. 2-43
4. Use the up and down buttons to select

parameter calibration code number 10 and then
press ENTER.
Fig. 2-44
5. Use the up and down buttons to set the

parameter value to “4” and then press ENTER.
Fig. 2-45

6. In the same way, set parameter calibration code
17 to “6.”
NOTICE: You can switch the order in which the two

parameter values are set. However, it is not possible to
modify other parameters before setting these two.
Fig. 2-46
7. Use the up and down buttons to select the

parameter you wish to set and then press
ENTER.
Fig. 2-47
8. Use the up and down buttons to modify the

selected parameter’s value and then press
ENTER.
NOTICE: Using the function that returns the parameter

settings to their default values will delete your current
settings.
Fig. 2-48
The parameter code number is displayed in the speed
and warning section, and its setting value in the time and
distance section. If the number in the time and distance
changes, this means the selected parameter’s value has
been updated in the controller’s memory.

2-6 Application “EasyView”
2-6-1 Installation and initial settings

As mentioned in the preceding section, electric vehicles
equipped with CURTIS controllers provide the functions
of diagnosis and parameter calibration not only on the
instrument panel but also on the PC application
EasyView.
To use EasyView, you will need to install it and the CAN

communications drivers on your laptop, and then connect
the PC to the vehicle with a communications cable
(A408026, Kvaser) and then carry out initial settings.
EasyView installation
1. Download the latest version of the application

2
EasyView at the site below:
Electrical system
 Refer to Service Bulletin SRB225-20140901
(https://doobiz.doosaninfracore.com/irj/portal)
Fig. 2-49
B15/18/20T, B18/20TL, B16/18/20X-7 2-45 Application “EasyView”

2. Unpack the downloaded file, and execute the file
<setup.exe> to install the application on the PC.
3. Check that EasyView’s icon is created on the Fig. 2-50

desktop.
CAN communications drivers installation
1. Access Kvaser’s website and click Support 

Downloads  Kvaser Driver for Windows.
 Direct link:
http://www.kvaser.com/software/7330130980
013/V5_11_0/kvaser_drivers_setup.exe
Fig. 2-51
Application “EasyView” 2-46 B15/18/20T, B18/20TL, B16/18/20X-7

2. Once the Installation Wizard page appears, click
Next; then click Display Release Notes to read
the release notes or Next to proceed installation.
Fig. 2-52
Electrical system
Fig. 2-53
3. Select Kvaser CAN driver components to install

and then click Next.
Fig. 2-54

4. Set the folder where Kvaser CAN Drivers will be
installed and then click Installation.
Fig. 2-55
Fig. 2-56

Initial settings for EasyView
1. Connect a CAN communications cable with one

end to your PC’s USB port and the other to the
vehicle’s CAN port near the controllers and then
turn on the key switch.
2. Double-click the EasyView icon to launch the

application.
 If the PC is not correctly connected to the
vehicle with the key switch on, a dialogue box
will appear and prompt you to select a vehicle
model as shown below:
Electrical system
Fig. 2-57
 When the boxes at right bottom are highlighted
in green, this means they are active, when the
PC and vehicle are correctly connected and
inactive in grey when they are not.
Fig. 2-58

3. When you are not logged in to the application,
only <Test Menu> is provided, which shows the
vehicle’s conditions. You can log in (password:
dbgby141) the application under the
Administration menu to access <Calibration
Menu>.
Fig. 2-59
Fig. 2-60

2-6-2 Controller firmware update
As the controllers’ performance and functions are
updated, so is the firmware. The latest update is available
at the dealer’s portal website
(https://doobiz.doosaninfracore.com/irj/portal).
You can install an update on the controllers using your

PC. This process is referred to as “flashing,” and it goes as
follows:
1. Select Flash under the Tool menu.
Electrical system
Fig. 2-61

2. EasyView will display the vehicle model type and
current software version, for example, Truck type:
56 Current SW Data:2015/3/6. Click browse to
find an update file on your PC, and then click
Flash to load the selected file into the controllers.
Fig. 2-62
Fig. 2-63

3. Click Close to return to the main menu.
Installation will take approximately 5–10 minutes.
Upon finishing it, a dialog box will appear; click
Close.
Electrical system
Fig. 2-64
NOTICE: While flashing is in progress, do not allow the
PC crash due to system error, external interference, or
the removal of the communications cable. Therefore,
make sure you use AC power, not a battery, for the PC.

2-6-3 “Tools” menu description
Flash
As described above, Flash is for updating the controllers’

firmware. For a detailed explanation, see Section 2-6-2.
Fig. 2-65
Fig. 2-66

Save parameters
In this menu, you can store all parameter settings except

for the values of sensors (accelerator, lift, steering, etc.)
in the PC as follows:
Click Browse, choose a location on the computer where

you wish to store the parameter file, and then click Save.
Electrical system
Fig. 2-67
Fig. 2-68

Data Logging
This function traces variables and helps the operator

analyze the vehicle’s conditions.
Enter a time scale in the time dialog box, which is set with
a default value to 0.5 seconds. Click Browse to select
where you wish to store the trace file and then click Start.
The data will then be logged at the selected file based on
the time scale specified. After clicking Stop, the operator
can check the data log file.
Fig. 2-69
Fig. 2-70

Faults
This menu contains three submenus: Faults active,

Faults history, and Clear faults history.
Electrical system
Fig. 2-71

Cloning
In this menu, you can either copy the parameter settings

applied to the vehicle to save them in the PC, or copy
parameter settings stored in the PC to apply them to the
vehicle.
• Browse/Open: Clicking this button enables you to

select a cloning file (*.csv). And then, parameter
settings from the selected file are displayed under
<File value>.
Fig. 2-72

• Read controller: Clicking this button loads
parameter settings from the controllers and
displays them under <Controller value>.
Electrical system
Fig. 2-73
• Save: Clicking this button saves parameter values
from the controllers in the cloning file on the PC.
Fig. 2-74

• Clone: Clicking this button copies the parameter
settings from the cloning file to the controllers while
automatically running the following three steps:
Verify, Writing, and Reading.
Step 1: Verify
Fig. 2-75
Step 2: Writing
Fig. 2-76

Step 3: Reading
Electrical system
Fig. 2-77

2-6-4 “Administration” menu description
As mentioned above, log in the application to use the
menu Administration, which enables <Calibration
Menu> as well as <Test Menu>.
Test Menu – Software Version Information
Fig. 2-78
No. Parameters Descriptions

1 Drive Software Type Driver software, 56 means B20
2 Drive Software Year Driver software revision year
3 Drive Software Month Driver software revision month
4 Drive Software Day Driver software revision day
5 Pump Software Type Pump software, 56 means B20T
6 Pump Software Year Pump software revision year
7 Pump Software Month Pump software revision month
8 Pump Software Day Pump software revision day

Test Menu – Drive
Electrical system
Fig. 2-79

1 L Motor Speed Left drive motor’s actual speed in revolutions per minute (rpm)
2 L Request Left drive motor speed request in revolutions per minute (rpm)
3 R Motor Speed Right drive motor’s actual speed in revolutions per minute (rpm)
4 R Request Right drive motor speed request in revolutions per minute (rpm)
5 T L Drive Motor Left drive motor temperature (℃, ℉)
6 T R Drive Motor Right drive motor temperature (℃, ℉)
7 T L Drive Module Left drive module temperature (℃, ℉)
8 T R Drive Module Right drive module temperature (℃, ℉)

9 L Motor Current Left drive motor current in Amps RMS (A)
10 R Motor Current Right drive motor current in Amps RMS (A)
11 Pedal Pedal input voltage A (V)
12 2nd Pedal Pedal input voltage B (V)
13 Steering Steering sensor voltage (V)
14 Seat Switch Seat switch state
15 Pedal Brake Brake switch state
State of forward direction, received from F/R switch. On indicates
16 Forward Switch
that the forward direction is selected.
State of reverse direction, received from F/R switch. On indicates
17 Reverse Switch
that the reverse direction is selected.
State of buzzer relay output at drive module pin 30. On indicates
18 Warning Buzzer that the buzzer relay driver is active. When a fault occurs, a buzzer
will sound.

State of main contactor output at drive module pin 6. On indicates
19 Main Contactor
that the main contactor driver is active.
20 L 5V Drive Encoder 5 V supply voltage at left drive module pin 26
Drive encoder phase A at left drive module pin 31. On indicates
21 L Motor Encoder A
pulse activity on the encoder phase A.
Drive encoder phase B at left drive module pin 32. On indicates
22 L Motor Encoder B
pulse activity on the encoder phase B.
23 R 5V Drive Encoder 5 V supply voltage at right drive module pin 26.
Drive encoder phase A at right drive module pin 31. On indicates
24 R Motor Encoder A
Drive encoder phase B at right drive module pin 32. On indicates
25 R Motor Encoder B
26 ISO Relay The state of ISO relay.
27 L EM Brake EM Brake state of the left motor.
28 R EM Brake EM Brake state of the right motor.

Test Menu – Pump
Electrical system
Fig. 2-80

1 Motor Speed Pump motor’s actual speed in revolutions per minute (rpm)
Pump motor speed request (from lift command input) in
2 Request
revolutions per minute (rpm)
3 T Pump Motor Pump motor temperature (℃, ℉)
4 T Pump Module Pump module temperature (℃, ℉)

5 Pump Motor Current Pump motor current in Amps RMS (A)
6 Lift Command Lift Command voltage (V) input from Analog1
7 Tilt Tilt switch command
8 Aux1 AUX1 switch command
9 Aux2 AUX2 switch command
10 Auto Tilt SW3 Auto Tilt switch command
11 Height SW1 Height switch command
12 Mast Tilt SW2 Mast Tilt switch command
Pump encoder phase A at pump module pin 31. On indicates
10 P Motor Encoder A
Pump encoder phase B at pump module pin 32. On indicates
11 P Motor Encoder B
12 Pump 5V Encoder 5V supply voltage at pump module pin 26.
13 ISO_Relay_On The driver output of ISO relay.

Test Menu – Fingertip and Valve
Fig. 2-81

1 KNOB Lift Command Lift command value from knob
2 KNOB Pot Lift State of lift signal from knob
3 KNOB Pot Lower State of lower signal from knob
4 KNOB Pot Drive F State of drive forward signal from knob
5 KNOB Pot Drive R State of drive reverse signal from knob
6 KNOB Pot Tilt Backward State of tilt up signal from knob
7 KNOB Pot Tilt Forward State of tilt down signal from knob
8 KNOB Pot AUX1 Left State of AUX1 left signal from knob
9 KNOB Pot AUX1 Right State of AUX1 right signal from knob
10 KNOB Pot AUX2 Left State of AUX2 left signal from knob
11 KNOB Pot AUX2 Right State of AUX2 right signal from knob
12 KNOB Auto tilt State of auto tilt signal from knob
13 KNOB Auto Clamp State of auto clamp signal from knob
14 Tilt Backward Sol Tilt back valve solenoid current (mA)
15 Lifting Sol Lifting valve solenoid current (mA)
16 Lowing Sol Lowing valve solenoid current (mA)
17 Tilt Forward Sol Tilt forward valve solenoid current (mA)
18 AUX1 Left Sol AUX1 left valve solenoid current (mA)
19 AUX1 Right Sol AUX1 right valve solenoid current (mA)
20 AUX2 Left Sol AUX2 left valve solenoid current (mA)
21 AUX2 Right Sol AUX2 right valve solenoid current (mA)
22 Unload Valve State of unload valve
23 Backup Alarm State of backup alarm

Test Menu – Battery
Electrical system
Fig. 2-82

1 Battery Voltage Battery voltage (V) measured at drive module pin 1
2 Inverter Voltage Inverter voltage (V) measured at drive module B+ stud
3 Battery Level Battery level measured from controller
4 BDI Percentage Battery discharge indicator level (%)

Test Menu – Timers
Fig. 2-83

Hour meter that counts the time that the seat switch is applied
1 Seat Switch Hour Meter
(closed) (Hr)
Hour meter that counts the time that the drive motor is active
2 Drive Motor Hour Meter
(Hr)
Hour meter that counts the time that the pump motor is active
3 Pump Motor Hour Meter
(Hr)
4 Odometer Vehicle distance traveled (km)
5 Odometer Vehicle distance traveled (km x 1000)

Calibration Menu – Pedal Set
Electrical system
Fig. 2-84

1 Pedal Voltage A (monitor variable) Voltage (V) at traction throttle pot wiper
2 Forward Switch (monitor variable) Forward switch state
3 Reverse Switch (monitor variable) Reverse switch state
Accelerator pedal voltage (V) with the pedal released.
Setting: Check the voltage value when you completely take
your foot off the accelerator in Value field at the top, enter
4 Min Accelerator A
the voltage value in the box at the bottom, and then press
Save.
[Range: 0.20–2.00 V, Default: 0.40 V]
Accelerator pedal voltage (V) with the pedal completely
pressed.
Setting: Check the voltage value when you fully press the
5 Max Accelerator A
accelerator in Value field at the top, enter the voltage value
in the box at the bottom, and then press Save.
[Range: 2.00–4.50 V, Default: 2.93 V]
NOTICE: In case you have replaced the accelerator

pedal or its reaction to your command is abnormal, newly
set the parameters #4 to #5.

Calibration Menu – Lift Set
Fig. 2-85

1 Lift Command (monitor variable) Lift command voltage (V) at pump module pin 24
Lift command voltage (V) with the lift lever released.
Setting: Check the voltage value when the lift lever is not
2 Lift Min moved in Value field at the top, enter the voltage value in the
box at the bottom, and then press Save.
[Range: 0.00–10.00 V, Default: 2.90 V]
Lift Command voltage (V) with the lift lever fully applied.
Setting: Check the voltage value when you fully pull the lift
3 Lift Max lever in Value field at the top, enter the voltage value in the
box at the bottom, and then press Save.
[Range: 0.00–10.00 V, Default: 9.81 V]
NOTICE: In case you have replaced the lift sensor or its

reaction to your command is abnormal, newly set the
parameters #2 to #3.

Calibration Menu – Steering Set
Electrical system
Fig. 2-86

Steering Voltage
1 Steer angle sensor voltage (V) at left drive module pin 24
(monitor variable)
Steer angle sensor voltage (V) when the rear wheels are
fully turned counterclockwise.
Setting: Check the voltage value when the rear wheels are
2 Steering CCW
fully turned left in Value field at the top, enter the voltage
value in the box at the bottom, and then press Save.
[Range: 0.00–10.00 V, Default: 7.20 V]
Steer angle sensor voltage (V) when the rear wheels are in
the middle.
3 Steering Middle
straight in Value field at the top, enter the voltage value in
the box at the bottom, and then press Save.
[Range: 0.00–10.00 V, Default: 4.50 V]
Steer angle sensor voltage (V) when the rear wheels are
fully turned clockwise.
4 Steering CW
fully turned right in Value field at the top, enter the voltage
value in the box at the bottom, and then press Save.
[Range: 0.00–10.00 V, Default: 2.00 V]
Maximum drive motor speed when the steer angle is at full
5 Steering Limit Max Speed lock counterclockwise or clockwise
[Range: 400–2000 rpm, Default: 1000 rpm]
NOTICE: In case you have replaced the lift sensor or its
reaction to your command is abnormal, newly set the
parameters #2 to #4.

Calibration Menu – Maintenance Timer
Fig. 2-87

Seat Switch Hour Meter Hour meter that counts the time that the seat switch is
1
(monitor variable) active (Hr)
When this parameter value is on, the maintenance function
2 Maintenance Time Set is enabled.
[Range: 0 (Off)/1 (On), Default: 0 (Off)]
When the Drive Hour Meter exceeds this parameter value,
the wrench icon on the vehicle display lights up, indicating
that vehicle maintenance is needed. Once the maintenance
3 Set Time is performed, the value of this parameter should be
increased to a setting when the next time maintenance is
scheduled.
[Range: 100–65500 hr, Default: 500 hr]

Calibration Menu – Timers
Electrical system
Fig. 2-88

The time delay since the driver leaves the seat and the
seat switch is open until the controller enters standby mode
1 Seat Switch Delay
and inhibits drive and lift functions
[Range: 1–9 sec, Default: 3 sec]
The time delay since no command is given (no traction and
2 Chat Time pump action) until the display shows “PP”
The time delay since no input has been received from LIFT,
3 Idle Time TILT, AUX1, AUX2, or steering until the pump motor stops
When a driver stops on a slope, if the pump shifts from
active to inactive, the vehicle will hold position on the slope
4 Stop on a Slope Timer for this amount of time. When this time expires the vehicle
will be released and slowly move down the slope.

Calibration Menu – Mode Selection
Fig. 2-89

1 E Mode (monitor variable) Indicates if Economic mode is active on the instrument panel.
2 S Mode (monitor variable) Indicates if Standard mode is active on the instrument panel.
Indicates if High Performance mode is active on the instrument
3 H Mode (monitor variable)
panel.
Maximum drive motor speed allowed in turtle mode
4 Max Speed in Turtle Mode
Maximum drive motor current allowed in “E” power mode.
Setting this parameter to a higher value allows a heavily
5 Drive Maximum Current E loaded vehicle to reach higher speeds. Setting this parameter
to a lower value limits the speed of a heavily loaded vehicle.
[Range: 20–100%, Default: 50%]
Maximum drive motor forward speed allowed in “E” power mode
6 Drive Forward Max Speed E
Maximum drive motor reverse speed allowed in “E” power mode
7 Drive Reverse Max Speed E
Maximum pump motor current allowed in “E” power mode at the
rated load pump speed (i.e. lift speed). Small changes in this
setting can result in big changes in the rated load lift speed.
8 Lift Current E Setting this parameter to a higher value increases the loaded lift
speed (and increase heating in the pump motor and pump module).
Setting this parameter to a lower value lowers the loaded lift speed.
[Range: 5.0–100.0%, Default: 80.0%]

Maximum pump motor speed allowed in “E” power mode as a
result of a maximum lift command. This setting controls the
9 Lift Max Speed E
maximum lift speed with no load (unloaded).
Maximum drive motor current allowed in “S” power mode.
10 Drive Maximum Current S loaded vehicle to reach higher speeds. Setting this parameter
Maximum drive motor forward speed allowed in “S” power
11 Drive Forward Max Speed S mode
Maximum drive motor reverse speed allowed in “S” power
12 Drive Reverse Max Speed S mode
Maximum pump motor current allowed in “S” power mode at
the rated load pump speed (i.e. lift speed). Small changes in
2
this setting can result in big changes in the fully loaded lift
speed.
13 Lift Current S Setting this parameter to a higher value increases the loaded
lift speed (and increase heating in the pump motor and pump
module). Setting this parameter to a lowers value lower the
Electrical system
loaded lift speed.
[Range: 5.0–100.0%, Default: 82.5%]
Maximum pump motor speed allowed in “S” power mode as a
14 Lift Max Speed S
Maximum drive motor current allowed in “H” power mode.
15 Drive Maximum Current H loaded vehicle to reach higher speeds. Setting this parameter
Maximum drive motor forward speed allowed in “H” power
16 Drive Forward Max Speed H mode
Maximum drive motor reverse speed allowed in “H” power
17 Drive Reverse Max Speed H mode
Maximum pump motor current allowed in “H” power mode at
the rated load pump speed (i.e. lift speed). Minor changes in
this setting can result in significant changes in the fully loaded
lift speed.
18 Lift Current H Setting this parameter to a higher value increases the loaded
lift speed (and increase heating in the pump motor and pump
module). Setting this parameter to a lower value lowers the
loaded lift speed.
[Range: 5.0–100.0%, Default: 82.5%]
Maximum pump motor speed allowed in “H” power mode as a
19 Lift Max Speed H

Calibration Menu – Drive Response
Fig. 2-90

The acceleration response to a full (>90%) accelerator pedal
command when the truck is at high speeds. Increasing this setting
Acceleration Rate HS results in a slower response; decreasing this setting results in a
1
(Full Accel Rate HS) faster response. The Acceleration Rate HS parameter is typically
set higher (slower) than the Acceleration Rate LS parameter.
[Range: 0.1–30.0 sec, Default: 6.0 sec]
The acceleration response to a full (>90%) accelerator pedal
command when the truck is at low speeds. Increasing this setting
Acceleration Rate LS results in a slower response; decreasing this setting results in a
2
(Full Accel Rate LS) faster response. The Acceleration Rate LS parameter is typically
set lower (faster) than the Acceleration Rate HS parameter.
The acceleration response to low (<10%) accelerator pedal
command. Acceleration response for intermediate (10% to 90%)
accelerator pedal commands is scaled between the Low Accel Rate
and either the Acceleration Rate LS or Acceleration Rate HS settings
3 Low Accel Rate (depending on the vehicle’s speed). Increasing this setting results in a
slower response; decreasing this setting results in a faster response.
The Low Accel Rate parameter is typically set higher (slower) than
both the Acceleration Rate LS and Acceleration Rate HS parameters.
The deceleration response when the accelerator pedal command is
released (to neutral) while the vehicle is travelling at high speeds. Increasing
Release Rate HS this setting results in a slower deceleration response; decreasing this setting
4
(Neutral Decel Rate HS) results in a faster deceleration response. The Release Rate HS parameter
is typically set higher (slower) than the Release Rate LS parameter.

released (to neutral) while the vehicle is travelling at low speeds.
Increasing this setting results in a slower deceleration response;
Release Rate LS
5 decreasing this setting results in a faster deceleration response. The
(Neutral Decel Rate LS)
Release Rate LS parameter is typically set lower (faster) than the
Release Rate HS parameter.
The deceleration response when the drive direction is reversed at full
(>90%) accelerator pedal command and while the vehicle is travelling at
high speeds. Increasing this setting results in a slower deceleration
Inversion Rate HS
6 response; decreasing this setting results in a faster deceleration
(Full Brake Rate HS)
response. The Inversion Rate HS parameter is typically set higher
(slower) than the Inversion Rate LS parameter.
The deceleration response when the drive direction is reversed at full
(>90%) accelerator pedal command and while the vehicle is travelling at
low speeds. Increasing this setting results in a slower deceleration
Inversion Rate LS
7 response; decreasing this setting results in a faster deceleration
(Full Brake Rate LS)
2
response. The Inversion Rate LS parameter is typically set lower
(faster) than the Inversion Rate HS parameter.
The response when the drive direction is reversed at low (<10%)
Electrical system
accelerator pedal command. Increasing this setting results in
slower deceleration response; decreasing this setting results in
8 Low Inversion Rate faster deceleration response. The Low Inversion Rate parameter
is typically set higher (slower) than both the Inversion Rate HS and
Inversion Rate LS parameters.
The speed below which a much slower deceleration rate is used to
give the vehicle a softer feel when coming to a stop and also to
reduce the amount of vehicle rollback on a slope (before position
hold takes control).
With vehicles that have fast deceleration, the driver may find the
final speed reduction to zero rpm uncomfortable; the vehicle may
even rock back as a result of tire wind-up. Soft Stop Speed allows
the vehicle to slow at the same fast rate until it reaches the set
9 Soft Stop Speed
threshold, at which point it changes to a slower (softer)
deceleration rate. However, if the threshold is set too high, the
vehicle feels like it is “running on.”
When throttle is released on a ramp, the vehicle may roll back
before Position Hold takes control. Soft Speed Stop can be used to
reduce the amount of rollback on a slope, but shouldn’t be set so
high the vehicle drives up the ramp after the throttle is released.
released to a lower command (but not to neutral). Increasing this setting
results in slower deceleration response. Decreasing this setting results
10 Partial Decel Rate in faster deceleration response. The Partial Decel Rate parameter is
typically set higher (slower) than both the Release Rate LS and
Release Rate HS parameters.

Calibration Menu – Pump Response
Fig. 2-91

The acceleration response of the pump motor. Increasing this
setting results in a slower response; decreasing this setting results
1 Acceleration Rate
in a faster response.
The deceleration response of the pump motor. Increasing this
setting results in a slower response; decreasing this setting results
2 Deceleration Rate
in a faster response.
Pump motor speed when tilt-backward function is active
3 Tilt Backward Speed
Pump motor speed when tilt-forward function is active
4 Tilt Forward Speed
Pump motor minimum speed when lift function is active
5 Lift Min Speed
Pump motor speed when lowering function is active
6 Lower Speed
Pump motor speed when AUX1 function is active
7 AUX1 Speed
Pump motor speed when AUX2 function is active
8 AUX2 Speed
Pump motor idle speed when there is no steering input
9 Idle Speed
Pump motor idle speed when there is no steering input (fingertip
10 Idle Speed fingertip only)

Pump motor speed during steering (excluding lift, tilt, etc.) when
11 Hydro Speed fingertip use is not active
Pump motor speed during steering (excluding lift, tilt, etc.) when
12 Hydro Speed fingertip fingertip use is active
Electrical system

Calibration Menu – Truck Setup
Fig. 2-92

Enable Working When this parameter value is on, the cooling fans function is enabled.
1
Fans [Range: 0 (Off)/1 (On), Default: 1 (On)]
When this parameter value is on, the vehicle display can be used to view and
Enable Calibration
2 change calibration parameters.
by Display
[Range: 0 (Off)/1 (On), Default: 1 (On)]
When this parameter value is on, the Turtle Speed function can be turned On
Enable Turtle
3 or Off from the vehicle display.
Speed by Display
When this parameter value is on, the speed limitation based on steering
Enable Steer
4 angle function is active.
Angle Sensor
When this parameter value is on, the EHS mode function can be selected
Enable EHS by
5 though the vehicle display.
Display
When this parameter value is on, the display is allowed to go to PP mode.
6 Chat Time Enable
When this parameter value is on, the vehicle buzzer sound when the reverse
Buzzer On
7 direction is selected.
Reverse Direction
When this parameter value is on, the vehicle buzzer sound when the forward
Buzzer On
8 direction is selected.
Forward Direction

When this parameter value is on, turtle mode is active, and the vehicle speed
Buzzer On Turtle
9 equals the Max Speed in Turtle Mode the vehicle buzzer will sound.
Speed
When this parameter value is on and the Lift function and any of the other
functions (Tilt, AUX1, AUX2) are operated simultaneously, the pump
operates at a speed that is the lowest speed among the inputs (Tilt, AUX1,
Lift Priority For AUX2 or Lift).
10 Pump Reference When this parameter value is off and the Lift function and any of the other
Speed functions (Tilt, AUX1, AUX2) are operated simultaneously, then the pump
operates at a speed that is the highest speed among the inputs (Tilt, AUX1,
AUX2 or Lift).
[Range: 0 (Off)/1(On), Default: 1 (On)]
Controller Fan When controller temperature is higher than the value of this setting, the
11 Starting cooling fan runs automatically.
Temp [Range: 0–160℃ (0–320℉), Default: 65℃ (149℉)]
When motor temperature is higher than the value of this setting, the cooling
Motor Fan fan runs automatically.
12
2
Starting Temp
[Range: 0–160℃ (0-320℉), Default: 65℃ (149℉)]
British Units Enables the use of British units (available only when OEM password is used).
13
Enable [Range: 0 (Off)/1(On), Default: 0 (Off)]
Electrical system
Enables the use of fingertip option (when installed).
14 Fingertip Enable
[Range: 0 (Off)/1(On), Default: 0 (Off)]
Auto Clamp Defines whether Auto Clamp function is used on this vehicle or not.
15
Enable [Range: 0 (Off)/1(On), Default: 0 (Off)]
Defines whether Auto Tilt function is used on this vehicle or not.
16 Auto Tilt Enable
Determines whether AUX2 is used on this vehicle or not. When this
17 Aux2 Enable parameter is On, the system will check for valve presence.
Auto Clamp first First time delay after auto clamp button pressed.
18
delay [Range: 0.0–20.0 sec, Default: 3.0 sec]
When first time delay after auto clamp button is pressed, any operating of
Auto Clamp
19 AUX2 will activate a new time delay for the auto clamp function.
interval delay
DSS (GSS) When this parameter value is on, the vehicle‘s DSS (GSS) function is enabled.
20
Enable [Range: 0(Off)/1(On), Default: 0(Off)]
Buzzer On High When this parameter value is on, the vehicle buzzer sound when the speed
21 Speed higher than the Buzzer On Speed.
Enable [Range: 0(Off)/1(On), Default: 0(Off)]
Defines the buzzer on high speed level, when motor speed is higher than this
22 Buzzer On Speed value, and Buzzer On High Speed Enable is ON, buzzer sound.
• Optional Guardian Stability System (GSS)

- Decrease of Travel Speed (50%) when the mast is raised above primary stage
- Forward tilt reduced 2° when the mast is raised above the primary stage
- Alarm when the mast, tilted more than 2°, is raised above primary stage
• Auto Tilt Leveling

- Returns the mast to vertical position easily by tilt angle sensing

2-7 Diagnosis/calibration/handling faults
2-7-1 Diagnosis codes

Panel’s
Display on
diagnosis Units Descriptions Remarks
instrument panel
codes
DRIVE MOTOR
1 rpm Left drive motor’s speed
SPD
D-MOTOR REF
2 rpm Left drive motor’s reference speed
SPD
RIGHT MOTOR
3 rpm Right drive motor speed
SPD
R-MOTOR REF
4 rpm Right drive motor reference speed
SPD
LIFT SENSOR Throttle output for
5 V Lift lever’s voltage
OUT lifting
Voltage on the key
6 BATT VOLTAGE V Battery’s voltage
switch
D-INVERTER
7 ℃ (℉) Left drive motor controller’s temp.
TEMP
P-INVERTER
8 ℃ (℉) Pump motor controller’s temp.
TEMP
PUMP MOTOR
9 rpm Pump motor’s speed
SPD
P-MOTOR REF
10 rpm Pump motor’s reference speed
SPD
Throttle A output for
11 ACCEL 1ST OUT V Accelerator potentiometer voltage
driving
Accelerator second potentiometer Throttle B output for
12 ACCEL 2ND OUT V
voltage driving
STEER SENSOR Output from the steer
13 V Steer sensor’s voltage
OUT sensor
R-INVERTER
14 ℃ (℉) Right drive motor controller’s temp.
TEMP
15 D-MOTOR I-U mA Left drive motor’s U-phrase current
16 D-MOTOR I-V mA Left drive motor’s V-phrase current
17 D-MOTOR I-W mA Left drive motor’s W-phrase current
18 R-MOTOR I-U mA Right drive motor’s U-phrase current
19 R-MOTOR I-V mA Right drive motor’s V-phrase current
20 R-MOTOR I-W mA Right drive motor’s W-phrase current
21 P-MOTOR I-U mA Pump motor’s U-phrase current
22 P-MOTOR I-V mA Pump motor’s V-phrase current
23 P-MOTOR I-W mA Pump motor’s W-phrase current
24 D-MOTOR TEMP ℃ (℉) Left drive motor’s temperature
25 R-MOTOR TEMP ℃ (℉) Right drive motor’s temperature
26 P-MOTOR TEMP ℃ (℉) Pump motor’s temperature
Time period while
27 SEAT H METER Hour Seat switch hour meter
seat switch is on
Diagnosis/calibration/handling faults 2-82 B15/18/20T, B18/20TL, B16/18/20X-7

Panel’s
Display on
diagnosis Units Descriptions Remarks
instrument panel
codes
Time period while
28 DRIVE H METER Hour Drive motor hour meter drive motors are
working
Time period while
29 PUMP H METER Hour Pump motor hour meter pump motor is
working
30 SEAT SWITCH - Seat switch ON(1)/OFF(0)
31 PARK SWITCH - Parking brake switch ON(1)/OFF(0)
33 REV SELECT SW - Reverse drive switch ON(1)/ OFF(0)
34 FWD SELECT SW - Forward drive switch ON(1)/OFF(0)
PEDAL BRAKE
35 - Accelerator pedal switch ON(1)/OFF(0)
SW
37 AUX1 OUTPUT - AUX1 switch ON(1)/OFF(0)
38 AUX2 OUTPUT - AUX2 switch ON(1)/OFF(0)
Speed limit for high lift switch 1
40 HIGHT SW - ON(1)/OFF(0)
2
(GSS option selected)
41 TILT SWITCH OUT - Tilt switch ON(1)/OFF(0)
MAST TILT Tilt angle limit for high lift switch 2
42 - ON(1)/OFF(0)
SWITCH (GSS option selected)
Electrical system
43 CONTACTOR - Contactor switch ON(1)/OFF(0)
44 5V OUT - 5V output ON(1)/OFF(0)
45 12V OUT - 12V output ON(1)/OFF(0)
AUTO TILT Automatic tilt switch 3
46 - ON(1)/OFF(0)
SWITCH (GSS option selected)
48 FANS - Activation of fans ON(1)/OFF(0)
B15/18/20T, B18/20TL, B16/18/20X-7 2-83 Diagnosis/calibration/handling faults

2-7-2 Parameter calibration codes
Parameter Adjustable range on
Instrument panel message
calibration Unit Default instrument panel
(EasyView message)
code (EasyView)
TURTLE ALARM 0–1
8 - 0
(Buzzer On Turtle Speed) (Off–On)
0–9
10 1st PASSWORD digit -
(not used)
SEAT SW DELAY
11 sec 3 1–9
(Seat Switch Delay)
CHAT TIME 1–9
12 sec 6
(Chat Time) (1–9)
IDLE TIME 10–20
13 sec 10
(Idle Time) (10–20)
MAINT TIME ON 0–1
14 - 0
(Maintenance Time Set) (Off–On)
0–9
17 2nd PASSWORD digit -
(not used)
HANDLE TURN-L 6.0–10.0
18 V 7.2
(Steering CCW) (0.00–10.00)
HANDLE TURN-R 0.5– 4.0
19 V 2.0
(Steering CW) (0.00–10.00)
WHEEL STRAIGHT 3.0 –7.0
20 V 4.5
(Steering Middle) (0.00–10.00)
ACCEL MIN VALUE 0.2–2.0
23 V 0.40
(Min Accelerator A) (0.20–2.00)
ACCEL MAX VALUE 2.0–5.0
24 V 2.93
(Max Accelerator A) (2.00–4.50)
SLOPE TIMER 3–10
26 sec 5
(Stop on a Slope Timer) (3–10)
LIFT PRI SPEED
0–1
27 (Lift Priority For Pump Reference - 1
(Off–On)
Speed)
FORWARD ALARM 0–1
30 - 0
(Buzzer On Forward Direction) (Off–On)
BACK UP ALARM 0–1
31 - 0
(Buzzer On Rerverse Direction) (Off–On)
LIFT MAX VALUE 3.0–10.0
32 V 9.81
(Lift Max) (0.00–10.00)
LIFT MIN VALUE 0–10.0
33 V 2.90
(Lift Min) (0.00–10.00)
START MOTOR FAN 0–100
35 ℃ (℉) 65(149)
(Motor Fan Starting Temp) (0–160)
ENABLE TURTLE 0–1
40 - 1
(Enable Turtle Speed by Display) (Off–On)
DRIVE MAX I (Drive Max Current) 20–100
41 % See note
(See note) (20–100)
FWD MAX SPEED
1000–4500
42 (Drive Forward Max Speed) (See rpm See note
(0–4000/5000)
note)

(EasyView message)
code (EasyView)
REV MAX SPEED
1000–4500
43 (Drive Reverse Max Speed) rpm See note
(0–4000/5000)
See note
44 D LIMIT MAX SPD 500–3500
STEER LIMIT SPD 400–2000
47 rpm 1000
(Steering Limit Max Speed) (400–2000)
D ACCEL RATE H 0.1–30.0
48 sec 6.0
(Acceleration Rate HS) (0.1–30.0)
D ACCEL RATE L 0.1–30.0
49 sec 6.5
(Acceleration Rate LS) (0.1–30.0)
D LOW ACCEL RATE 0.1–30.0
50 sec 10.0
(Low Accel Rate) (0.1–30.0)
D INVERS. RATE H 0.1–30.0
51 sec 5.0
(Inversion Rate HS) (0.1–30.0)
D INVERS. RATE L 0.1–30.0
52 sec 5.0
2
(Inversion Rate LS) (0.1–30.0)
D RELEASE RATE H 0.1–30.0
53 sec 6.0
(Release Rate HS) (0.1–30.0)
D RELEASE RATE L 0.1–30.0
Electrical system
54 sec 5.0
(Release Rate LS) (0.1–30.0)
D LOW BRAKE RATE 0.1–30.0
55 sec 5.0
(Low Inversion Rate) (0.1–30.0)
D SOFT STOP SPD 10–500
56 rpm 150
(Soft Stop Speed) (0–500)
START CONT. FAN 0–60
60 ℃ (℉) 65(149)
(Controller Fan Starting Temp) (0–160)
PARTIAL RELEASE 0.1–30.0
61 sec 30.0
(Partial Decel Rate) (0.1–30.0)
LOADED LIFT I 20.0–100.0
62 % See note
(Lift Current) See note (5.0–100.0)
LIFT MAX SPEED 1000–3500
64 rpm See note
(Lift Max Speed) See note (0–4000)
TILT SPEED 500–2000
65 rpm 800
(Tilt Backward Speed) (100–3000)
AUX1 SPEED 500–2000
66 rpm 800
(AUX1 Speed) (100–3000)
AUX2 SPEED 500–2000
67 rpm 800
(AUX2 Speed) (100–3000)
LIFT MIN SPEED 0–500
69 rpm 200
(Lift Min Speed) (0-500)
HYDRO SPEED 400–800
71 rpm 700
(Hydro Speed) (400–800)
IDLE SPEED 200–500
72 rpm 500
(Idle Speed) (400–800)
PUMP ACCEL RATE 0.1–30.0
73 sec 1.5
(Acceleration Rate) (0.1–30.0)
PUMP DECEL RATE 0.1–30.0
74 sec 1.5
(Deceleration Rate) (0.1–30.0)

(EasyView message)
code (EasyView)
TURTLE SPEED 500–3500
84 rpm 2000
(Max Speed in Turtle Mode) (500–3500)
BRITISH UNIT 0–1
85 - 0
(British Unit Enable) (Off–On)
E-S-H 0–1
87 - 1
(Enable EHS by Display) (Off–On)
TIMER-ODOMETER 0–1
88 -
(not used)
ENABLE FAN WORK 0–1
89 - 1
(Enable Working Fans) (Off–On)
ENABLE CHAT TIME 0–1
90 - 1
(Chat Time Enable) (Off–On)
ENABLE STR SENSR 0–1
91 - 1
(Enable Steer Angle Sensor) (Off–On)
MAITENANCE TIME 0–99990
92 hour 500
(Set Time) (100–65500)
0–1
93 EM BRAKE ENABLE - 1
(Off–On)
GSS ENABLE 0–1
94 - 0
(GSS Enable) (Off–On)
FINGERTIP ENABLE 0–1
95 - 0
(Fingertip enable) (Off–On)
AUTO CLAMP ENABLE 0–1
96 - 0
(Auto Clamp Enable) (Off–On)
AUTO TILT ENABLE 0–1
97 - 1
(Auto Tilt Enable) (Off–On)
TILT FWD SPEED 100–3000
98 rpm 800
(Tilt Forward Speed) (100–3000)
LOWER SPEED 100–2000
99 rpm 600
(Lower Speed) (100–2000)
AUX2 ENABLE 0–1
A2 - 0
(Aux2 Enable) (Off–On)
Note: The default settings and adjustable ranges of EasyView’s calibration parameters for the instrument
panel parameter codes 41, 42, 43, 62, and 64 vary depending on which is selected from the E-H-S modes. For
a detailed explanation, see Section 2-6-4.

2-7-3 Handling faults on instrument panel/EasyView
A. Fault Levels
One function of the instrument panel is to display faults

that have occurred in the vehicle. In the case where more
than one fault has occurred, the most serious fault
(lowest level number) is displayed.
• Fault Level 1: Main contactor drops; both drive

and pump motors stop. (At this, the buzzer sounds
and the red alarm LED on the instrument panel
lights up.)
• Fault Level 2: Drive or pump motors stop

individually or both stop together.
• Fault Level 3: Both drive and pump motor speed
•
are limited to 800 rpm.
Fault Level 4: Drive motor speed limited to 800

2
rpm.
Electrical system
• Fault Level 5: Drive motor torque reduced.
• Fault Level 6: Pump motor torque reduced.
• Fault Level 7: With the performance not limited,

only related component will stop functioning.
B. Measures for fault codes
Panel EasyView Fault Fault descriptions

codes codes levels Causes and solutions
EEPROM FAULT – Controller memory failed
Either the EEPROM memory on the drive or the pump module
F 1 1 Cause
has failed.
Solution 1. Replace the failed module.
MAX BATT VOLT – Battery voltage excessive
The battery voltage at terminal B+ on the drive or pump module
Cause
has reached a severe overvoltage limit (70 V).
F0 2 1 1. Reduce the battery voltage.
Solution 2. If problems persist, it is likely that battery resistance is too
high for the amount of regen current.
MIN BATT VOLT – Battery voltage insufficient
The battery voltage at terminal B+ on the drives or pump
Cause
module has reached a servere under voltage limit.
1. Increase the battery voltage to charge the battery.
F1 3 1 2. If problems persist, it is likely that the battery resistance is too
Solution high for the amount of drive current.
3. Check for a blown power fuse.
4. Non-module system drain on battery.

ACCEL FAULT – Signal from accelerator not received
The throttle pot wiper (pin 16) voltage is higher than the high
Cause
fault threshold or lower than the low fault threshold.
F2 4 2 1. See Monitor menu >> Inputs: Throttle Pot.
2. Check the wiring on driver controller pin 16 and pump pin 16.
Solution
3. Change the accelerator.
4. If problems persist, the controller is defective.
R-INVERTER FAULT – Right drive motor controller failed
Cause The right drive inverter detected an overcurrent.
F3 5 1 1. Check that the drive motor phase U, V or W has not shorted.

Solution 2. If problems persist, the drive module is defective and needs
to be replaced.
L-INVERTER FAULT – Left drive motor controller failed

Cause The left drive inverter detected an overcurrent.
F4 6 1 1. Check that the drive motor phase U, V or W has not shorted.
Solution 2. If problems persist, the drive module is defective and needs
to be replaced.
P-INVERTER FAULT – Pump motor controller failed
Cause The pump inverter detected an overcurrent.
F5 7 1 1. Check that the pump motor phase U, V or W has not shorted.
Solution 2. If problems persist, the pump module is defective and needs
to be replaced.
R-MOTOR I OFFSET – Right drive motor current failed
The current sensor offset reading from the right drive motor is
Cause
invalid.
F6 8 1 1. Check for leakage to the vehicle frame from the drive motor
phase U, V or W.
Solution
2. If problems persist, the drive module is defective and needs
to be replaced.
L-MOTOR I OFFSET – Left drive motor current failed
The current sensor offset reading from the left drive motor is
Cause
invalid.
F7 9 1 1. Check for leakage to the vehicle frame from the drive motor
phase U, V or W.
Solution
to be replaced.
P-MOTOR I OFFSET – Pump motor current failed
Cause The current sensor offset reading from pump motor is invalid.
1. Check for leakage to vehicle frame from pump motor phase
F8 10 1 U, V or W.
Solution
to be replaced.
STEER SENSOR OUT – Steer sensor output failed
Analog 1 inputs are higher than steer pot’s high limitation
Cause
threshold or lower than its low limitation threshold.
F9 11 4 1. Check left controller monitor menu: monitor>>inputs: Analog
Solution 1.
2. Check the steer sensor.

5V NOT OK – 5V output from a controller failed
Cause Drive or pump module 5 V supply detected out of range.
1. Check if there is a shorted device connected to the drive or
pump module 5 V supply.
FH 12 1 2. Reduce the load on the drive or pump module 5 V supply by
Solution disconnecting devices until the device that causes the
overload is found.
to be replaced.
R-MOTOR ENCODER – Right drive motor’s encoder failed
The right drive motor encoder phase failed, or no incoming
Cause
signal was detected.
FC 13 4 1. Check for faulty crimps and connections in the wires to the
Solution drive motor encoder.
2. If problems persist, replace the drive motor encoder.
L-MOTOR ENCODER – Left drive motor’s encoder failed
The left drive motor encoder phase failed, or no incoming signal
Cause
was detected.
2
FD 14 4 1. Check for faulty crimps and connections in the wires to the
Solution drive motor encoder.
2. If problems persist, replace the drive motor encoder.
12V NOT OK – 12V output from a controller failed
Electrical system
The drive or pump module 12V supply detected in overcurrent
Cause
condition (above 200mA).
FA 16 1 1. Check for a shorted device connected to the drive or pump
module 12 V supply.
Solution
2. Reduce the current draw on the drive or pump module 12 V
supply by disconnecting devices.
PUMP SIGN ON – Signal to move pump motor detected at startup
Cause A lever command (lift, lower, tilt, sideshift.) detected at startup.
FL 17 2 1. Return the lever to neutral position.
Solution
2. If problems persist, replace the lever.
R-INV OVERTEMP – Right drive motor controller overheated
(performance lowered)
The right drive module has reached the cutback temperature
limit (85 °C, 185 ℉) and is reducing the drive current (reduced
Cause
E1 18 5 motor torque) to protect the drive module’s temperature from
continuing to rise.
1. Drive module is operating in an extreme (hot) environment.
Solution 2. Excessive load on vehicle.
3. Improper mounting of module is preventing heat conduction.
L-INV OVERTEMP – Left drive motor controller overheated
(performance lowered)
The left drive module has reached the cutback temperature limit
(85 °C, 185 ℉) and is reducing the drive current (reduced
Cause
continuing to rise.

P-INV OVERTEMP – Pump motor controller overheated (performance
lowered)
The pump module has reached the cutback temperature limit
(85 °C, 185 ℉) and is reducing the pump current (reduced
Cause
continuing to rise.
1. Pump module is operating in an extreme (hot) environment.
R-MOTOR OVERTEMP – Right drive motor overheated (performance
lowered)
The right drive motor has reached the cutback temperature limit
E4 21 5 Cause
motor torque) to protect the drive module’s temperature from
continuing to rise.
1. Drive motor is operating in an extreme (hot) environment.
Solution
2. Excessive load on vehicle.
L-MOTOR OVERTEMP – Left drive motor overheated (performance
lowered)
The left drive motor has reached the cutback temperature limit
E5 22 5 Cause
continuing to rise.
1. Drive motor is operating in an extreme (hot) environment.
Solution
P- MOTOR OVERTEMP – Pump motor overheated (performance
lowered)
The pump motor has reached the cutback temperature limit
E6 23 6 Cause
continuing to rise.
1. Pump motor is operating in an extreme (hot) environment.
Solution
WRONG START – Signal to move pump motor detected at startup
Accelerator pedal switch or forward/reverse direction signal
Cause
detected active when truck is first switched on.
EE 24 2 1. Return the F/R switch to the neutral position.
Solution 2. Check the accelerator pedal.
If problems persist, replace the lever.
EE SEAT SW OPEN –Seat switch opened
(FLASHI 25 1 Cause The seat switch is open.
NG) Measure 1. Check the seat switch.
LOW BATT VOLT –Battery voltage insufficient (charge needed)
The battery voltage detected (at Pin 1 of Drive Module) below
Cause
the minimum battery voltage setpoint.
EL 26 3 1. Charge the battery.
2. Compare a voltage measurement (referenced to B-) at pin 1
Solution
of the drive module to the battery voltage; resolve any
differences between these measurements.

CAP NOT CHARGED – Capacitor not charged
The capacitor bank (both drive and pump module terminals B+)
Cause
could not be charged by the internal transistor.
1. Check for an external load on either (pump or drive module)
A 27 1 capacitor bank (terminal B+) that would prevent the capacitor
Solution bank from charging.
2. If the problem persist, the drive module defective and needs
to be replaced.
CONTACTOR FAULT – Contactor not working properly
Cause 1. The main contactor coil is either open or shorted.
1-1. Measure the main contactor coil to verify if it is either open
or shorted. If either, replace the main contactor.
Solution
1-2. Check for faulty crimps and connections in the wires to the
main contactor coil.
Cause 2. The main contactor contacts are welded closed.
2-1. Check that the main contactor contacts to verify if they are
closed (welded). If they are not, replace main contactor.
2-2. If the main contactor tips are open, check for alternate
2
Solution
voltage paths to terminal B+ of the drive module.
17 28 1 2-3. Drive motor phase U or V is open or disconnected.
Connect motor phase cables or replace the drive motor.
3. There are faulty crimps and connections in the wires to the
Cause
Electrical system
main contactor coil.
3-1. Check that the main contactor contacts to verify if they are
oxidized, burned or not making good contact. If the contactor is
not performing this function, replace the main contactor.
3-2. Check for a blown B+ power fuse.
Solution
3-3. Check for an external load on the drive module terminal
B+ that would prevent the main contactor from charging
the capacitor bank.
3-4. Check the polarity of the main contactor coil connections.
R-INV SHUTDOWN – Right drive motor controller overheated (system
halted)
The right drive module reached the shutdown temperature limit
Cause
66 33 1 (95 ºC, 203 ℉).
L-INV SHUTDOWN - Left drive motor controller overheated (system
halted)
The left drive module reached the shutdown temperature limit
Cause
67 34 1 (95 ºC, 203 ℉).
P-INV SHUTDOWN – Pump motor controller overheated (system
halted)
The pump module reached the shutdown temperature limit (95
Cause
ºC).
68 35 1
1. Pump module is operating in an extreme (hot) environment.
Solution
3. Improper mounting of pump module is preventing heat
conduction.

P-MOTOR ENCODER – Pump motor’s encoder failed
Cause 1. A pump motor encoder phase failure has been detected.
1-1. Check for faulty crimps and connections in the wires to the
Solution pump motor encoder.
1-2. If problems persist replace the pump motor encoder.
76 36 1 Cause 2. A pump motor stall (no movement) failure has been detected.
2-1. Check for an obstruction that is preventing the pump
motor from turning.
Solution 2-2. Check for faulty crimps and connections in the wires to the
pump motor encoder.
2-3. If problems persist, replace the pump motor encoder.
D-M TEMP SENSOR – Right drive motor’s thermal sensor failed
(display only, no change in vehicle performance)
Right drive motor thermal sensor voltage detected out of range
Cause (Continued operation with this fault may result in an overheated
drive motor, reducing its efficiency).
77 37 7 1. Check the wire connections (and external harness resistor) to
the drive motor thermal sensor.
2. Check that the correct motor thermal sensor is installed in the
Solution
drive motor.
3. Check the motor thermal sensor to see if it is shorted or
opened.
L-M TEMP SENSOR - Left drive motor’s thermal sensor failed
The left drive motor thermal sensor voltage detected out of
Cause range (Continued operation with this fault may result in an
overheated drive motor, reducing its efficiency).
the drive motor thermal sensor.
Solution
drive motor.
opened.
P-M TEMP SENSOR – Pump motor’s thermal sensor failed
The pump motor thermal sensor voltage has been detected out
Cause of range (Continued operation with this fault may result in an
overheated drive motor, reducing its efficiency).
the pump motor thermal sensor.
Solution
pump motor.
opened.
L-EM BRAKE – Left EM brake failed
Left motor EM brake fault, which can be caused by: an EM
Cause brake controller failed to set, controller coil2 driver open/short or
80 40 2 EM Brake open/short.
1. Check the controller fault history by a diagnosis device.
Solution
2. Check the EM brake.

R-EM BRAKE - Right EM brake failed
Right motor EM brake fault, which can be caused by: an EM
Cause brake controller failed to set, controller coil2 driver open/short or
81 41 2 EM Brake open/short.
1. Check the controller fault history by a diagnosis device.
Solution
2. Check the EM brake.
PAR CHANGE FAULT – Parameter change failed
A change to a system parameter has been detected that
Cause
83 43 1 requires this safety fault.
1. Cycle the key switch to clear the fault and operate with the
Solution
new parameter setting.
DUAL TRA FAULT – Dual traction failed
Faults relation with dual traction, which include fault on other
Cause traction fault, dual severe fault, dual motor parameter
84 44 1 mismatch.
1. Check both drive controllers’ fault histories.
Solution
2. Clear all the faults on both controllers.
R-INV UNDERTEMP- Right drive motor controller overcooled (-40 ºC, -104 ℉)
H1 45 1 Cause
The right drive module is below the lower temperature limit (-40
ºC, -104 ℉) shutdown.
2
1. Drive module is operating in an extreme (cold) environment.
Electrical system
Solution
2. Replace the faulty inverter.
L-INV UNDERTEMP - Left drive motor controller overcooled (-40 ºC, -104 ℉)
The left drive module is below the lower temperature limit (-40
H2 46 1 Cause
ºC, -104 ℉).
1. Drive module is operating in an extreme (cold) environment.
Solution
P-INV UNDERTEMP – Pump motor controller overcooled (-40 ºC, -104 ℉)
The pump module is below the lower temperature limit (-40 ºC,
H3 47 1 Cause
-104 ℉).
1. Pump module is operating in an extreme (cold) environment.
Solution
R-MOTOR OPEN – Right drive motor circuit short
The U, V or W phase of the right drive motor has been detected
Cause
as open.
H4 48 1 1. Check the motor phase cables for bad crimps or faulty wiring.
2. Check motor phase U, V or W for an open winding on the
Solution
drive motor.
3. If problems persist, replace the drive motor
L-MOTOR OPEN - Left drive motor’s circuit open
The U, V or W phase of the left drive motor has been detected
Cause
as open.
Solution
drive motor.
3. If problems persist, replace the drive motor.

P-MOTOR OPEN – Pump motor’s circuit open
The U, V or W phase of the pump motor has been detected as
Cause
open.
Solution
pump motor.
3. If problems persist, replace the pump motor.
CAN COMM FAULT – CAN communications faulted
Cause CAN Communication Fault.
1. Check the CAN bus wiring.
H7 54 1 2. Check can bus connection to all modules
Solution
3. Verify that the correct software is in both the drive and pump
modules.
SOFTWARE ERROR – Software failed
(CURTIS Code: 68, 71, 91, 98, 77, 78)
H8 55 1 Cause Software error was detected.
1. Re-program the drive and pump modules.
Solution
2. If problems persist, replace the controller.
SOFTWARE FAULT – Software failed
HH 56 5/6 Cause Failure to meet "Catch all" Condition in the software.
Measure 1. Check the fault history of all the controllers.
EXTENSION FAULT – Extension module internally faulted
Extension module internal fault (CURTIS Code: 11)
Cause EEPROM faulted (CURTIS Code: 11)
EF 57 7 Abnormal temperature (CURTIS Code: 23, 24)
1. Cycle power.
Solution 2. Reload or store defaults.
3. If problems persist, replace the extension model.
LIFT SOL FAULT – Lift solenoid valve faulted (pump stopped)
Cause Lift sol (J1-12) open/short
L1 231 2 1. Check the wire on extension model J1-12.
Solution
2. If problems persist, replace the lift valve.
LOW SOL FAULT – Lowering solenoid valve faulted (pump stopped)
Cause Lift sol (J1-13) open/short
Solution
2. If problems persist, replace the lowering valve.
TILT FWD SOLFAU – Tilt-forward solenoid valve faulted (pump
stopped)
L3 233 2 Cause Tilt Forward sol (J1-11) open/short
1. Check the wire on extension model J1-11.
Solution
2. If problems persist, replace the tilt forward valve.
TILT BACK SOLFAU – Tilt-backward solenoid valve faulted (pump
stopped)
L4 234 2 Cause Tilt Forward sol (J1- 9) open/short
1. Check the wire on extension model J1-9.
Solution
2. If problems persist, replace the tilt back valve.
AUX1 L-SOLFAU – AUX1-left solenoid valve faulted (pump stopped)
Cause AUX1 left sol (J1-10) open/short
Solution
2. If problems persist, replace the left valve belonging to AUX1.

AUX1 R- SOLFAU – AUX1-right solenoid valve faulted (pump stopped)
Cause AUX1 right sol (J1-14) open/short
Solution 2. If problems persist, replace the right valve belonging to
AUX1.
AUX2 L-SOLFAU – AUX2-left solenoid valve faulted (shut down PD)
Cause AUX2 left sol (P1-2) open/short
L7 237 7 1. Check the wire on pump model P1-2.
Solution
2. If problems persist, replace the left valve belonging to AUX2.
AUX2 R-SOLFAU - AUX2-right solenoid valve faulted (shut down PD)
Cause AUX2 right sol (D2-2) open/short
L8 238 7 1. Check the wire on right drive model D2-2.
Solution 2. If problems persist, replace the right valve belonging to
AUX2.
ISO/UNLOAD SOL – ISO/UNLOAD solenoid valve faulted (shut down
driver)
L9 239 7 Cause ISO (STD), unloading SOL (fingertip OPT) (P1-5) open/short
1. Check the wiring on pump model P1-5.
2
Solution
2. If problems persist, replace the ISO valve.
EXT VOLT FAULT –Extension module controller’s voltage faulted
(all extension module drivers disabled)
Overvoltage/undervoltage on the extension module (CURTIS
Electrical system
21 241 7 Cause
Code: 21, 22).
1. Check the voltage on the extension module.
Solution
2. Monitor the system voltage when fault occurs.
EXT TIME FAULT – Extension module controller’s communications
faulted (all extension module drivers disabled)
PDO timeout/SDO fault reported on Ext module (CURTIS Code:
Cause 51, 52)
51 242 7 CAN communication fault (CURTIS Code: 53)
1. Check the CAN bus cable.
Solution 2. Make sure the pump controller is equipped with the correct
software.
EXT CUR FAULT – Extension module controller’s current faulted
(all extension module drivers disabled)
C1 243 7 Cause Total current exceeded 18 A (CURTIS Code: 25)
1. Check the wiring on each valve.
Solution
2. If problems persist, change the extension module.
EXT POWER FAULT – Extension module controller’s power supply
faulted (none)
C2 244 7 Cause 12 V/5 V power supply fault (CURTIS Code: 13, 14, 15)
1. Check the loads in 12 V/5 V circuit.
Solution
2. If problems persist, change the extension module.
FINGERTIP FAULT – Fingertip faulted (pump stopped)
FF 245 2 Cause A fingertip knob is out of range.
Solution 1. Check the fingertip knop.

3 Drive/brake system
3-1 Overview........................................................2
3-1-1 Components............................................................2
3-2 Drive motor ...................................................4

3-2-2 How it works............................................................6
3-2-3 Drive motor, axle, and EM brake
removal/installation .................................................8
3-2-4 Drive motor disassembly/assembly and test ........10
3-2-5 Drive wheel removal/installation ...........................12
3-3 Drive axle.....................................................13

3-3-2 How it works..........................................................14
3-3-3 Adjustment ............................................................17
3-3-4 Disassembly and assembly ..................................18
3-4 Accelerator ..................................................24

3-4-1
3-4-2
Exterior and specifications ....................................24
How it works..........................................................25
3
Drive/brake system
3-5 F/R unit ........................................................27

3-5-2 How it works..........................................................28
3-5-3 Removal/Installation .............................................29
3-6 Service brake pedal ass’y..........................30

3-6-2 How it works..........................................................31
3-6-3 Brake pedal adjustment ........................................35
3-6-4 Air removal in brake oil .........................................36
3-6-6 Master cylinder disassembly/assembly ................40
3-7 EM parking brake .......................................42

3-7-2 How it works..........................................................43
3-7-3 Parking brake test .................................................44
3-7-4 Manual release of braking ....................................45
3-8 Troubleshooting .........................................46

3-8-1 Driving ...................................................................46
3-8-2 Service brake ........................................................48
3-8-3 EM parking brake ..................................................49
3-1 Overview
3-1-1 Components
Accelator pedal
Service brake pedal Drive wheel
Brake oil reservoir
Master cylinder
F/R unit
Controller group
EM Brake
(Parking)
Drive motor
Drive axle
Fig. 3-1
Battery
Electric Electric
power power
Magnetic
Digital power
signal EM (braking)
Accelerator parking
An brake
alo
gs Controller Drive
ign
al
motor Driving Driving
Digital signal power power
l
Drive Drive wheel
na axle
g sig
alo
An
F/R unit Mechanical Hydraulic Friction

power power (braking)
Brake Master Service
pedal cylinder brake
Fig. 3-2

The drive/brake system is comprised as follows:
• Drive motors, regulated by their respective

controllers, transfer a rotational force to the left and
right drive axles (electric power  mechanical
power). [Section 3-2]
• Drive axles convert the rotational forces

transferred from the drive motors to have a torque
and velocity appropriate for driving via their gear
set, and send them to the respective wheels
(mechanical power  mechanical power). They
also contain service brakes, which are actuated by
the depressing of the brake pedal to produce a
braking power (hydraulic power  friction force).
[Section 3-3]
• Accelerator sends an electric signal to the left

drive motor controller to accelerate the motors
(analog signal  digital signal). [Section 3-4]
• F/R unit sends an electric signal to the left drive

motor controller to determine the driving direction
of the motors (analog signal  digital signal). 3
[Section 3-5]
Drive/brake system
• Service brake pedal ass’y injects brake fluid to
the drive axles to actuate the service brake in them
(hydraulic power  friction force). [Section 3-6]
• EM parking brakes, attached to the ends of both

drive motors, fix the motors’ shafts three seconds
after the vehicle is parked in order to ensure the
vehicle stands still (electric power  magnetic
power). [Section 3-7]

3-2 Drive motor
A. Drive motor
Fig. 3-3
Items Spec.
Part number 300503-00080
Voltage 48 VAC
Power 6.0 kW
Voltage 30 V
Current 152 A
Speed 2650 rpm
Max. speed 5000 rpm
Frequency 90 Hz
Protection degree IP 43
Weight 33.0 kg (72.8 lb)
Drive motor 3-4 B15/18/20T, B18/20TL, B16/18/20X-7

B. Control panel
Fig. 3-4
Components Items Spec.

300611-00989 (L)
3
Part number
300611-00990 (R)
Drive/brake system
Voltage 36/48 V
Drive maximum current 450 A
Controllers
Pump maximum current -40 to +50 °C (-104 to +122 °F)
Operating ambient temperature
-40 to +95 °C (-104 to +203 °F)
range
Maximum temperature +95 °C (+203 °F)
Operating Voltage 36 VDC
Coil Resistance 94Ω (20 ℃/68 °F)
Line contactor
Pull In Voltage 24 VDC
Drop Out Voltage 7.2 VDC
Coil Power Dissipation 21 W
Voltage rating 80 V
Line fuse
Current rating 500 A
Cold Resistance 0.06 mΩ
B15/18/20T, B18/20TL, B16/18/20X-7 3-5 Drive motor

3-2-2 How it works
EMERGENCY SW (OPT)
LEFT DRIVE MOTOR 8 +12V F/R UNIT F/R SWITCH

CONTROLLER -12V
6
12V OUT (BACKUP) 1 +5V
1
5
+12V 2 GND
4 3
vcc Forward
9/BU/YL BATT +
2 4 Revers
20/YL/GN 20/YL/GN FWD
9/BU/YL 6/BR D1-6 FWD D1-22 3
21/BR REV
LINE CTR REV D1-33 21/BR 1
1/BK BATT -
7
13/OR/RD D1-13
GND
7/WH D1-7 7/WH 1 GND
D1-26 26/RD/BK 26/RD/BK 3 +5V
D1-16 16/OR/BK 16/VO/BK 2 OUT A
THM1 GND
8/VO D1-8 4
B1 6 +5V
32/GY D1-32 5 OUT B
A1
31/GN D1-31
ACCELERATOR
+5V
2
1
26/RD/BK 26/RD/BK D1-26 D1-17 18/BU/RD 17/GN/YL 17/GN/YL 1
D1-7 7/WH 7/WH 2
2 7/WH
SEAT SWITCH
1 30/RD D1-30
D1-24 101/GN
PIOLOT BUZZER
D1-25 25/RD/WH FAN RELAY (OPT)
(WARNING)
31/GN 87
8/VO LEFT TRACTION MOTOR 71/RD/BK 71/RD/BK 85
7/WH
+
D1-13 13/OR/RD 13/OR/RD 86

32/GY
ENCODER
30
GND A
MR
D1-14 77/GN/WH 77/GN/WH 2
1
B
BRAKE PEDAL SWITCH
EM BRAKE-LEFT
THERMAL THERMAL
SENSOR SENDER 13/OR/RD 4 126/BU/WH 126/BU/WH 2
7/WH 12/WH/RD 125/BU/RD 1
D1-5 12/WH/RD 3 125/BU/RD
75/YL/GN 2 128/BR/YL 128/BR/YL 2
76/BK 1 127/BU/YL 127/BU/YL 1
D1-23(CAN H) 23/YL/BK
D1-35(CAN L) 35/YL EM CONN A EM CONN B EM BRAKE-RIGHT
RIGHT DRIVE MOTOR

CONTROLLER
GND
51/WH D2-7 7/WH 3
101/GN 2
25/RD/WH 1
THM1 D2-1
52/BU/BK D2-8 ANGLE SENSOR
B1
53/BU/GN D2-32
A1
54/OR/RD D2-31 23/YL/BK
D2-23(CAN H)
51/WH +5V D2-35(CAN L) 35/YL
53/BU/GN 55/RD D2-26 D2-11
52/BU/BK 55/RD
RIGHT TRACTION MOTOR D2-28 73/BU/RD
54/OR/RD 74/BU/WH
+
D2-29
ENCODER
GND A
MR
D2-13 75/YL/GN
B
D2-5 76/BK
D2-2
THERMAL THERMAL
SENSOR SENDER
51/WH
Fig. 3-5
Each of the left/right drive motors turns the drive wheel by

transmitting power to the drive axle through an input shaft
so that the vehicle can move forward/backward. Both
B15/18/20T-7 and B16/18/20X-7 models have two drive
motors: one fitted to the left drive axle and one to the
right.
Controlling by controllers
As shown in the circuit diagram, the left/right drive motors

are connected to their respective controllers via an
encoder. Connected to a plethora of switches, the
controllers run the drive motors according to their inputs.

The drive motors run when the following conditions are met:
• The key switch is connected, thus powering the
motors (See Section 2-2 for power supply),
• The operator is seated (seat switch),
• Driving direction is determined (F/R unit), and
• The accelerator pedal is pressed (accelerator).
When the motors are stopped, the EM brake automatically

engages with them and functions as a parking brake.
When you steer the vehicle, an angle sensor detects the

angle at which the rear wheels are turned and accordingly
the controllers regulate the vehicle’s drive speed. The
vehicle starts to decelerate when the angle reaches 5º,
and it travels at the set speed limit (2 km/h, 6562 ft/h) with
a steer angle of 90º. The default speed of the drive motor
at this angle is 1,500 rpm, and you can adjust this speed
limit by setting the value of the parameter “STEER LIMIT
SPEED” (instrument panel no.: 47 / range: 400–2000 rpm).
Fig. 3-6
Motor speed detection (encoder operation) 3

An encoder is equipped with two hole sensors, and has a gear
Drive/brake system
installed on the drive shaft of the motor to interact with these
two hole sensors. This gear’s turning along with the drive shaft
causes the gear’s teeth periodically to pass the magnetic field
of each hole sensor. When a top land of the gear passes the
magnetic field, it comes closer to the hole sensor and thus the
Mechanical profile
magnetic flux increases. On the other hand, when a bottom
land passes the magnetic field, the distance increases and the
Magnetic profile
magnetic flux decreases accordingly.
Sensor electrical output profile

This cycle recurs and the magnetic flux has a waveform
Fig. 3-7
to produce a voltage pulse. The controller analyses the
amplitude of this pulse to compute the rpm of the motor.
A smaller amplitude means a higher rpm of the motor.
Like other sensors, the encoder too produces both a main

signal (signal A) and a reference signal (signal B) through the
two hole sensors. As shown in Fig. 3-8, the order of the signals
Clockwise rotation
produced changes depending on the direction of revolution.
Overheat protection (thermal sensor operation)
Each drive motor is equipped with a thermal sensor to

protect it from overheating. Once the motor reaches a Counterclockwise rotation
heat of 145 °C (293 ° F), an overheat alarm is activated
Fig. 3-8
and the working performance of the motors is limited.

3-2-3 Drive motor, axle, and EM brake removal/installation
Line connections
(1) Thermal sensor connector

(2) Encoder connector
(4) EM brake cable
(3) U.V.W. terminals
(6) Bleeder tube
(5) Brake oil tube
(10) Drive motor
(9) Drive axle

(7) Axle assembling screw
(13) Hub (8) Motor assembling screw
(11) EM brake assembling screw

(12) EM brake
Fig. 3-9
WARNING
The vehicle’s movement or its
moving parts can cause injuries.
Before you begin this procedure, make
sure that the vehicle is parked on a level
surface where there is no need for the
parking brake, and that the key switch is
off with no risk of acciedental start-up.
Preliminary steps
2. Remove the mast (See Section 5-3-10 A).
3. Remove the drive wheels (See Section 3-2-5).
4. Remove the floor plates in the compartment so

that you may see drive motors (10) as shown in
Fig. 3-10.
Fig. 3-10

Drive motor-axle removal/installation
1. Disconnect cables from thermal sensor

connector (1), encoder connector (2), and U.V.W.
terminals (3), and disconnect EM brake cable (4).
 Mark the cables as a reference for reassembly.
 Installation torque for U.V.W. terminals: 15
N·m (11 lb·ft)
2. Disconnect brake oil tube (5) and bleeder tube

(6).
3. Loosen axle assembling screws (7) and remove

drive motor-axle assembly—(9) and (10)—from
the frame.
 Installation torque: 240±40 N·m (177±30 lb·ft)
 Installation sealant: Loctite #262
Axle, motor, and EM brake separation/coupling
3
1. Loosen motor assembling screws (8) and
remove drive motor (10) from drive axle (9).
Drive/brake system
2. Loosen EM brake assembling screws (11) and

then dismount EM brake (12).
 Installation torque: 9.5 N·m (7 lb·ft)
NOTICE: At installation, take care not to damage the

splines of the flange disc when you mount it onto hub
(13). And do not grease these parts, as it may hinder the
brake’s performance.
3. Put the key into the shaft then remove hub (13)
from the shaft.
4. Follow the steps above in the reverse order for

installation.
 Operate the motor to check that all the moving
parts rotate smoothly.

3-2-4 Drive motor disassembly/assembly and test
(13) Retaining ring
(9-1) Nut (12) Encoder

(11) End bell
(9) Terminal block (16) Bearing (14) Sunk key
(8) Stator assembly
(9-2) Screw
(7) Rotor assembly
(6) Bearing
(4) End bell
(3) Oil seal

(2) O-ring
(5) Wave washer
Fig. 3-11
(1) Bolt
Disassembly/assembly
1. After removing the terminal protector, loosen nut

(9-1) and remove the terminals from terminal
block (9).
2. Loosen screw (9-2) and remove terminal block

(9).
3. Loosen bolts (12-1) and remove encoder (12).
4. When needed, remove retaining ring (13) and

sunk key (14).
5. Remove O-ring (2) and oil seal (3).
6. Loosen bolts (1) and remove end bell (4).
7. Remove stator assembly (8) by hand or using a

tool.
8. Remove wave washer (5) and bearing (6) from

rotor assembly (7).

9. Remove bearing (10) and rotor assembly (7)
from end bell (11).
 It is recommended to use a bearing puller as
shown in Fig. 3-12.

assemble the drive motor.
NOTICE: Before you reassemble the motor, you may test

its parts as follows.
Fig. 3-12
Rotor Test
1. Remove contaminants on the surface of the rotor

using compressed air and a soft cloth.
2. Measure the outer diameter of the rotor using a

vernier caliper.
 Specification: ø 123.1 mm ± 0.05 (ø 4.8 in ±
0.05)
3
Stator Test
Drive/brake system
1. Carefully wipe contaminants from the surface of
the stator using a clean cloth dampened with
alcohol. Fig. 3-13
NOTICE: Contaminants in the stator may cause damage

to the coil and consequently to the stator itself.
2. Measure resistance for each phase (U-V, V-W,

W-U) using a milli-ohmmeter.
 Rated resistance: 7.10 mΩ
Fig. 3-14
3. Test insulation at 1000 Vac and Min. 10 MΩ

using an insulation tester.
 If insulation is faulty, replace the stator with a
new one.
Fig. 3-15

3-2-5 Drive wheel removal/installation
(2) Drive tire
(3) Wheel
(1) Nut
Fig. 3-16
1. Place a jack or wooden block under the forklift

and loosen nut (1).
 Installation torque: 105 N·m (77 lb·ft)
2. Remove nut (1) and drive tire (2).

install the drive wheel.

3-3 Drive axle
Fig. 3-17
3
Functions Items Spec.
190101-00290 (L)
Part no.
190101-00291 (R)
Drive/brake system
Max. wheel load 2,800 kg (6,173 lb)
Max.input power 12.3 kW
Max. input torque 7.85 kg·m (56.78 lb·ft)
Gear ratio 24.25
Driving
Weight (without oil) 49 kg (108 lb)
Oil volume 0.5 L
Automatic transmission fluid
Oil type
(RUBIA S10W)
Wet disc brake
Brake type
(air cooled on the housing)
Brake fluid Hydraulic oil (AZOLLA Z510)
Braking
31.5 N·m per 1 bar
Brake pressure on piston
(23.2 lb·ft per 14.5 psi)
Brake pressure limit 110 bar (1,595 psi)
B15/18/20T, B18/20TL, B16/18/20X-7 3-13 Drive axle

3-3-2 How it works
A. Driving function
(6) Ring gear
(2) Pinion gear (5) Planetary gear
(1) Motor shaft (7) Pin
(3) Helical gear
(9) Drive shaft
(4) Sun gear
(8) Planetary carrier
Fig. 3-18
Power transfer route
The left/right drive axles transmit power received from their

respective motors to the wheels via a set of gears.
When motor shaft (1) rotates, pinion gear (2) connected to

the shaft also rotates, turning helical gear (3) and sun gear (4).
The turning of sun gear (4) makes three planetary gears (6) Ring gear
(5) move around sun gear (4). As encompassed by ring

gear (6), planetary gears maintain their circular
movement without becoming unmeshed. These gears are
named so because the way in which they function
together can be likened to the orbiting of planets around
the sun. The circular movement of three planetary gears (5) Planetary gear
(4) Sun gear
(5) turns ring gear (6) which encases them.
Fig. 3-19
Drive axle 3-14 B15/18/20T, B18/20TL, B16/18/20X-7

Each of planetary gears (5) has a pin (7) inserted in its
center. As pins (7) are connected to planetary carrier (8),
planetary carrier (8) also revolves when planetary gears
(5) make a circular movement. Planetary carrier (8) is
splined to drive shaft (9) at its center, and thus its turning
leads to the revolving of the shaft and ultimately the drive
wheel.
In this way, power from the drive motor is transmitted to

the drive wheel via motor shaft (1), pinion gear (2), helical
gear (3), sun gear (4), planetary gears (5), planetary
carrier (8), and drive shaft (9) so as to drive the vehicle
forward or backward.
Why drive axle is needed
Why isn’t the drive motor connected to the drive wheel to

directly transfer its power to the wheel? It is because the
combination of gears of the drive axle is needed to
reduce the speed and multiply the torque through their
gear ratio (24.25) so that the drive wheel can drive stably
and suitably. 3
Drive/brake system

B. Braking function
Lever plate
Neutral
Acruated
(11) Helical gear

(10) Friction disc
(7) Lever plate
(7) Lever plate

(8) Ball
(9) Steel plate
(5) Hook (4) Chamber

(6) Piston
(1) Master cylinder

(3) Brake cylinder
(2) Brake line
Fig. 3-20
When the brake is applied, pressurized oil flows from

master cylinder (1) through brake lines (2) to brake
cylinder (3) located at each drive axle. Once oil has
entered the brake cylinder, it fills chamber (4), causing
piston (6) and hook (5) to move forward.
The forward movement of the hook (5) moves lever plate

(7) slightly to the right, lifting it on its balls (8). As lever
plate (7) is lifted, it compresses rotating friction discs (10)
in between stationary steel plates (9).
Because friction discs (10) are splined to helical gear (11),

once their rotation is stopped, so is the motion/rotation of
the drive axle shaft and drive wheel.

3-3-3 Adjustment
To determine the shim pack thickness required to
achieve the correct rolling torque of the drive axle ass’y,
use the formula D=B-C-(0 to 0.05mm, 0 to 0.002in)) and
refer to Fig. 3-21.
Example:
B = 2.58 mm (0.1 in) measured at the carrier and drive
shaft
C = 2.05 mm (0.08 in) measured at the lock nut B Distance between the surface of carrier
and the surface of drive shaft.
D = 2.58 mm - 2.05 mm (0–0.05) = 0.48 mm (0–0.53)
C Height of step in lock nut
Then 0.5 mm (0.02 in) thickness of shim pack can be
D Required thickness of shim pack
applied.
Fig. 3-21
Procedure
1. Tighten lock nut (1) to a torque of 80–110 N·m

(59–81 lb·ft) by hand in order to ensure the taper
roller bearing fitted to the drive shaft ass’y is in
3
the proper position.
Drive/brake system
2. Make the necessary measurements using the
formula:
 D = B - C (0–0.05 mm, 0-0.002 in)
Fig. 3-22
3. Remove locknut (1).
4. Install shims as required and then install locknut

(1), tightening it to a torque of 150-220 N·m (110-
162 lb·ft).
5. Check to see if the drive axle meets the rolling

torque specification of 4.5–6.5 N·m (3.3–4.8 lb·ft).
 Add or remove shims as required until you
have the correct rolling torque.
6. Remove locknut (1).
Fig. 3-23

3-3-4 Disassembly and assembly
Tools needed
Names Figures Tool no.
DOOSAN tool
Nut installer
no. T126
DOOSAN tool
Bearing installer
no. T127
DOOSAN tool
Oil seal installer
no. T128
DOOSAN tool
Gamma seal installer
no. T129

Names Figures Tool no.
Needle bearing DOOSAN tool

installer no. T130
Flat head bolt DOOSAN tool

installer no. T131
NOTICE: The disassembly and assembly procedure for

3
the drive axle is the same for both left and right sides.
Drive/brake system
Preliminary steps
1. Remove the drive axle (see Section 3-2-3). (2) Bolt

(1) Bolt
2. Remove hex socket bolts (1).
 Installation sealant: Loctite #277 to the threads
3. Remove socket M8X25 bolts (2).

 Installation sealant: Loctite #277 to the threads
Fig. 3-24
4. Separate the housing ass’y from the housing
cover ass’y using M8 bolts.
 The housing cover areas must be cleaned and
degreased.
 Adhesive: Three Bond #1215 to the coat of
one side.

(12) Lever plate
(11) Washer
(10) Steel plate

(9) Friction disc
(7) Washer
(4) Helical gear ass’y (6) End plate
(4-1) Retaining ring

(4-2) Retaining ring (8) Spring
(20) Breather
(4-4) Bearing (3-2) Bearing
(5) Bolt
(3-3) Pinion gear
(4-3) Sun gear
(17) Pin
(3) Piston gear ass’y
(16) Bearing
(22) Spring
(24) Shim (21) Plug
(15) Pin
(14) Steel ball (18) O-ring
(19) Plug
(23-1) Wear ring

(23-2) Back up ring
(23-3) Quad ring
(23-4) Quad ring
(13) Hook Piston rod
(23-5) Back up ring
(23-6) Wear ring
(23) Piston Rod ass’y
Fig. 3-25
Cover ass’y
1. Remove and disassembly pinion gear ass’y (3) in
the following order:
 Retaining ring (3-1)
 Ball bearings (3-2)
 Pinion gear (3-3)
 Grease: Total Multis EP2 to thrust bearing.
2. Remove and disassemble helical gear ass’y (4)
in the following order:
 Retaining ring (4-2). The opening directions of
two snap rings opposite.
 Sun gear (4-3)
 Ball bearing (4-4)
 When assembling, make sure the teeth of the
friction discs are aligned before installing it.

3. Remove bolts (5) using bolt installer.
 Installation torque: 8±3 N·m (5.9±2.2 lb·ft)
4. Lift out end plate (6) carefully.
 At installation, put pressure on end plate (6) L (6) End plate
and check if the distance between the surface
of it and the housing cover’s bolting surface (L)
meets the specified measurement of 1.03–1.63
mm (0.041–0.064 in).
5. Remove washers (7).
Fig. 3-26
6. Pull out springs (8).
7. Lift out five friction discs (9) and four steel plates (10).
8. Remove washers (11) located on top of the first
steel plate and then remove it, too.
 Before installing the friction discs, soak them in
transmission oil for a minimum of 12 hours.
9. Lift out lever plate (12) and hook (13).
 The split pin of hook (13) should be facing up if
installed correctly.
10. Remove steel balls (14)
 Grease: Total MULTIS EP2
11. Remove pins (15)
3
12. Remove ball bearing (16)
Drive/brake system
13. Remove parallel pin (17)
14. Remove and inspect O-ring (18).
15. Remove drain plug (19).
16. Remove breather (20) and washer.
 Installation torque: 70±10 N·m (52±7 lb·ft).
17. Remove plug (21)
18. Pull out spring (22).
19. Remove piston rod ass’y (23) and disassemble it.
 Wear ring (23-1)
 Back up ring (23-2)
 Quad ring (23-3)
 Quad ring (23-4)
 Back up ring (23-5)
 Wear ring (23-6)
 Lubricant: Total Azolla ZS 10 to all rings
 Grease: Total MULTIS EP2 to the protruding
end of the piston rod
 Ensure the backup rings are installed in the
correct position.
20. Remove shim (24).

(31) Bearing
(36) Plug
(30) Bearing cup

(32) Drive shaft ass’y (35) Oil seal
(34) Bearing cup
(33) Seal
(25-1) Bolt
(32-1) Bearing cone

(32-2) Bolt
(25-7) Bolt
(25-2) Carrier cover
(25-8) Lock nut
(25-3) Ring
(25-9) Shim (25-4) Bearing
(25-5) Planetary gear
(25-6) Ring
(25-10) Parallel pin
(26) Bolt (25-11) Pin
(25-12) Spring pin
(25-13) Carrier housing
(25-14) Taper bearing
(25) Carrier ass’y
(27) Ring gear

(29) Plate
(28) Retaining ring
Housing ass’y Fig. 3-27
1. Disassemble carrier ass’y (25) in the following

order:
 Socket head bolts (25-1) Apply Loctite #277 to
the threads of bolts (22-1) and then tighten
them to a torque of 30±7 N·m (22±5 lb·ft).
 Carrier cover (25-2)
 Rings (25-3)
 Needle rollers (25-4)
 Planetary gears (25-5)
 Rings (25-6)
 Stopping socket head bolt (25-7) Apply Loctite
#277 to the thread of bolt (22-7) and then
tighten it to a torque of 8±3 N·m (59±2.2 lb·ft).
 Lock nut (25-8) If the slot/bolt hole is not well
aligned with tap in carrier, rotate by one or two
splines until it is. Apply Loctite #277 to the
thread of lock nut (22-7) and then tighten it to a
torque of 150–220 N·m (110–162 lb·ft) using
the nut installer.
 Shims (25-9). See Section 3-3-3 before installing.
 Parallel pins (25-10)
 Pins (25-11)
 Spring pins (25-12)

 Carrier housing (25-13) with taper bearing
cone (25-14).
 When assembling, ensure the marks on the
carrier and carrier cover are aligned.
2. Separate the bearing cone (25-14) from the
carrier housing using the two armed
puller/bearing installer. Install the taper bearing
cone using the bearing installer and apply Total
MULTIS EP2 grease to the inner ring and the
space between the rollers.
3. Remove bolts (26) from ring gear (27)
 Installation torque: 55±10 N·m (40.6–7.4 lb·ft).
4. Remove retaining ring (28).
5. Remove plate (29).
6. Remove taper bearing cup (30).
7. Remove needle roller bearing (31). Install using
the needle bearing installer
8. Pull out drive shaft ass’y (32) and disassemble it
in the following order:
9. Taper bearing cone (32-1). Apply Total Multis
EP2 grease to the inner ring and the space
between the rollers and then install bearing cone
using the bearing installer.
10. Wheel bolts (32-2).
11. Remove gamma seal (33) Apply Three Bond
#1102 to the inner race, and then apply grease
to the rib.
3
12. Remove taper bearing cup (34),
Drive/brake system
13. Remove oil seal (35), Apply Three Bond #1102
to the outer race.
14. Remove oil level plug (36). Apply Loctite #572 on
the thread of the plug and tighten it to a torque:
70 ± 10 N·m (52 ± 7 lb·ft).
assemble the drive axle.
During assembly
• Thoroughly clean all parts and remove all residual
Loctite.
• Check all the parts for wear and damage and
replace any if necessary.
• Finish sealing’s mating surface with an oil stone or
a fine finishing file.
• Lubricate the cleaned antifriction bearings before
installing.
• Be sure to replace all the sealing elements.
• Be sure to use mastic sealants (such as Loctite)
only.
DANGER
Corrosive detergents will cause
serious skin burns or even death if
inhaled or consumed.
Wear protective gloves, goggles, and a
mask.

3-4 Accelerator
Fig. 3-28
Item Spec.
Part number A401077
Initial pedal load 1 kgf (2.2 lbf)
Full stroke pedal load 3.0±0.5 kgf (6.6±1.1 lbf)
Input voltage 5 V±0.5%
Rated current 20 mA
Power 100 mW
Wire width 20 AWG
SIGNAL “A” 0.4±0.1 V
Voltage output at start point
SIGNAL “B” 4.5±0.1 V
SIGNAL “A” 3.60±0.15 V
Voltage output at end point
SIGNAL “B” 1.39±0.15 V
Insulation 10 mΩ @ 500 VDC
Operating temperature -40 to +85 ℃ (-104 to +185 ℉)
Storate temperature -40 to +100 ℃ (-104 to +212 ℉)
Accelerator 3-24 B15/18/20T, B18/20TL, B16/18/20X-7

3-4-2 How it works
Fig. 3-29
Electric vehicles such as the models B15/18/20T-7 and
B15/18/20T-7 run on power generated by the drive motor.
Therefore the accelerator that determines the travel
speed of the vehicle is connected to drive motor
controllers.
Only the left motor controller is connected directly to the

accelerator, but it transmits inputs received from the
3
accelerator via the CAN protocol to the right motor
Drive/brake system
controller so that both motors may respond to those
inputs.
As shown in the circuit diagram, the accelerator is

powered at 5 V from the left drive motor controller (at
Terminal 3, 26/RD/BK) and produces Signal A (at
Terminal 2, 16/VO/BK). This output determines the
vehicle’s speed in proportion to the angle at which the
accelerator pedal is pressed.
The accelerator is also powered at 5 V from the pump HALL IC output charateristics
motor controller (at Terminal 6, 64/RD) and produces SIGNAL “B”(+) SIGNAL “A”(-)
6
Signal B as a reference (at Terminal 6, 58/BK). These
4
Output (V)
Signals A and B transmitted by two different controllers, 2
as shown in the above, are shared by CAN

0 1 3 5 7 9 11 13 15 17 19 21
communication. In principle the values of these two Accelerator pedal angle
signals should be the same. If their difference exceeds
Fig. 3-30
the tolerance, it will be recognized as a problem in the
electrical system or accelerator and error code F2 will
appear on the display.
B15/18/20T, B18/20TL, B16/18/20X-7 3-25 Accelerator

(2) Front floor plate
(5) Accelerator pedal
(4) Screw
(1) Rear floor plate (3) Connector

Fig. 3-31
Preliminary Steps
2. Remove the floor mat that covers floor plates
Procedure
1. Raise front floor plate (1) and disconnect the

connector of accelerator pedal (5) from main
harness connector (2).
2. Remove front floor plate (1)
3. Loosen three sets bolts (3) and nuts (4), and

remove accelerator pedal (5).

reinstall the accelerator pedal.
5. Perform accelerator initial setting using the

EasyView application (See the Pedal Set menu
in Section 2-6-4).
Accelerator 3-26 B15/18/20T, B18/20TL, B16/18/20X-7

3-5 F/R unit
Drive/brake system
Fig. 3-32
Items Spec.
Rated voltage 48 VDC/80 VDC
Operating voltage 24 to 90 VDC
Output current comsumption 1.5 A Max
FWD: close to common (BAT +)
Output (at input battery voltage)
REV: close to common (BAT +)
Operating temperature -40 to +75 ℃ (-104 to +167 ℉)
Storage temperature -40 to +100 ℃ (-104 to +212 ℉)
Protection grade IP65
B15/18/20T, B18/20TL, B16/18/20X-7 3-27 F/R unit

3-5-2 How it works
Fig. 3-33
Like the accelerator, the F/R unit that determines the

travel direction of the vehicle is connected to the left drive
motor directly and to the right drive motor via the CAN
communications.
As shown in the circuit diagram, you can control the F/R

(forward/reverse) unit using the F/R switch attached to
the lift lever. Once the F/R switch is shifted to “Forward”
(Terminal 3) or “Reverse” (Terminal 4), the signal is
transferred to the F/R drive unit, and this unit then
transfers the signal to the drive motor controller (Forward:
Terminal 3, 20/YL/GN; Reverse: Terminal 1, 21/BR).
In the power supply line to the F/R drive unit (Terminal 2,

3/OR) is a key switch, and when this switch is off the F/R
drive unit does not work.
Furthermore, the unit is also connected to a backup

option (Terminal 5, 85/RD/GN), which turns on a backup
lamp and sounds a backup horn during reverse drive. To
prevent overcurrent while using this option, a fuse is
connected to the unit (Terminal 4, 84/RD/YL).
F/R unit 3-28 B15/18/20T, B18/20TL, B16/18/20X-7

3-5-3 Removal/Installation
Preliminary steps
1. Lift up the seat and the hood.
F/R unit removal/installation
1. Disconnect main harness cable (2) and F/R

switch cable (3).
2. Remove bolts (4) and washers in both sides and

then remove F/R unit (1). (1) F/R unit
3. Follow the steps above in the opposite order to (4) Bolt and washer
reinstall the F/R unit.

(3) Cable to F/R switch
NOTICE: The F/R switch is attached onto the lift lever (2) Cable to harness
and cannot be removed separately. Fig. 3-34
Drive/brake system
B15/18/20T, B18/20TL, B16/18/20X-7 3-29 F/R unit

3-6 Service brake pedal ass’y
Fig. 3-35
Compoents Items Spec.

Part no. A501502
Max. use pressure 100 kg/cm2 (102 psi) or over
Master
Effective stroke 25 mm (1 in)
cylinder
Valve activating pressure 7 kg/cm2 (100 psi)
Cylinder pressure efficiency 90% or over
Part no. A159136
Rated voltage Up to DC 200 V
Brake oil
Switching current 1A
reservoir
Using temperature -40 to +150 ℃ (-104 to +302 ℉)
Ploater Gauss 570±60 G
Service brake pedal ass’y 3-30 B15/18/20T, B18/20TL, B16/18/20X-7

3-6-2 How it works
A. Brake pedal
(1) Pedal (3) Reservoir
Once brake pedal (1) is pressed, the rod of master
cylinder (2) connected to the pedal is pushed to activate (2) Master cylinder
the cylinder. The activation of master cylinder (2) supplies
oil in reservoir (3) through tube (4) to the service brake in
drive axle (5) to generate a braking power. In this way,
pressing pedal (1) causes the immediate activation of the
brake by a hydraulic power through a process. For a
detailed explanation of the braking process in drive axle
(5), see Section 3-3-2.
(5) Drive axle
(4) Tube
Fig. 3-36
B. Master cylinder
(1) Reservoir
Drive/brake system
(2) Inlet port
(B) Secondary chamber (A) Primary chamber

(6) Residual pressure valve
Fig. 3-37
Neutral position
When the pedal is in the neutral position, oil flows back

and forth between reservoir (1) and primary chamber (A)
via inlet port (2). This is necessary to ensure that the
master cylinder’s oil level is always kept completely full
so that air cannot enter the system.
The outlet at secondary chamber (B) is equipped with

residual pressure valve (6) to prevent air inflow from the
disc brake and oil outflow from the cylinder.
B15/18/20T, B18/20TL, B16/18/20X-7 3-31 Service brake pedal ass’y

High pressure
Low pressure
(2) Inlet port
(4-1) Primary piston cup seal
(6-1) Rod
(6) Residual
pressure valve
(B) Secondary chamber (A) Primary chamber (3) Push rod
(5) Secondary piston (4) Primary piston
Fig. 3-38
First depressed position
When the pedal is depressed, push rod (3) pushes

primary piston (4) forward until primary piston cup seal
(4-1) seals inlet port (2), trapping the oil in primary
chamber (A). The trapped oil then pushes secondary
piston (5) for the oil in secondary chamber (B) to flow in
the disc brake through residual pressure valve (6),
consequently engaging the service brake.
Rod (6-1) of residual pressure valve (6), when

pressurized, is pushed as indicated by the arrows so that
oil is allowed to flow out.

High pressure
Low pressure
(2) Inlet port

(C) Return chamber
(5-4) Adjusting bolt

(B) Secondary chamber (5-3) Joint spring
(5) Secondary piston (4) Primary piston
(5-2) Hole
(5-1) Joint rod
Fig. 3-39
Second depressed position
As the pedal is depressed even further, the oil pressure

in secondary chamber (B) increasingly overcomes the
pressure of joint spring (5-3) to push joint rod (5-1). The
move of joint rod (5-1) then forms a passage through 3
which the oil inflow through hole (5-2) can pass as
Drive/brake system
indicated by the arrows. Thus, oil in primary chamber (A)
returns to return chamber (C), on which inlet (2) is
installed, and subsequently goes back to the oil reservoir.
From then on, primary piston (4) is no longer pressurized,
and only the oil in secondary chamber (B) conveys its
pressure to the disc brake. This causes a great increase
in the braking power increment by a further pedal effort.
The pressure to push joint spring (5-3) determines the

pedal effort to enter this stage, it can be adjusted by
adjusting bolt (5-4).

(1) Reservoir
(2) Inlet port
(7) Orifice
(B) Secondary chamber (A) Primary chamber

(6) Residual pressure valve (5) Secondary piston (4) Primary piston
Fig. 3-40
Released position
Once the pedal is released, two springs that have

pressed by primary and secondary pistons (4, 5) in
primary and secondary chambers (A, B) respectively are
relieved. Primary chamber (A) again face inlet (2),
allowing the oil in it to flow back and forth between the
chamber and reservoir again.
Because the pistons (4, 5) return much quicker than the

oil, a low pressure area is created in primary chamber (A),
which could potentially allow air to enter the system.
Small orifices (7) are drilled into the back of both pistons
to allow the oil at the back of them to travel forward and
fill the low pressure area as a means to prevent this
problem from happening.
When the oil in the lines has returned to normal, the

master cylinder is kept at an atmospheric pressure by
residual pressure valve (6). The residual pressure helps
prevent air from entering at the wheel cylinder and it
keeps fluid from leaking out.

3-6-3 Brake pedal adjustment
The brake pedal must have enough free play to let the master
cylinder piston return to the release positon and open the relief
outlet. The master cylinder push rod must be adjusted so the
brake pedal has 3.0 to 8.0 mm (0.118 ± 0.315 in) of free play from
the pedals stop to the push rod contact point with the master
cylinder piston.
Hydraulic pressure in the brake lines travels back through

the relief opening and releases the brakes. If there is no
pedal free play, the pressure cannot go back through the
relief opening, and the brakes will tighten and not release.
If there is too much free play, the brake pedal will be low
even with the correct brake adjustment.
1. Pull back rubber boot (1) to expose the

adjustment nuts.
2. Loosen nut (3).
3. Adjust rod (2) until there is 3.0 to 8.0mm (0.118 ±

0.315in.) of free play from the pedals stop to the
3
point where the push rod makes contact with the
Drive/brake system
master cylinder piston.
(1) Cover
(3) Nut (2) Rod
4. Hold rod (2) and tighten nut (3).
Fig. 3-41

3-6-4 Air removal in brake oil
(4) Brake pedal
(1) Bleed screw
(2) Bleeder hose
(5) Master cylinder
(3) Bottle
Axle housing
Fig. 3-42
If you depress the brake pedal and it feels spongy, this is

an indication that air has entered the brake’s hydraulic
system.
Bleeder wrench/appropriate
wrench
Tools needed:
Flexible hosing
Plastic bottle
Preliminary steps
1. Remove the carriage.

Procedure
1. Find bleeder screw (1) located at the back of the

drive axle housing.
2. Loosen the screw using the bleeder wrench (do

not force it), and then tighten it again moderately
3. Fit one end of a piece of clear tubing (2) over the

bleed screw and place the other in a plastic
bottle.
4. Have a partner pump the brake pedal and signal

to you “up” or “down”.
5. When your partner signals “down”, loosen the

bleed screw; allow the brake oil to flow into the
plastic bottle (3) and then tighten the screw again.
6. Have your partner release the pedal (4).
7. Repeat steps 7–8 until the brake oil is free of air.
8. Refill the master cylinder (5) to the “Full” line and

then repeat steps 3–9 to bleed the brakes on the
3
opposite side of the drive axle.
Drive/brake system
9. Take the vehicle for a short drive and test the
brakes to see if they still feel spongy. If they do:
 Check the oil level in the master cylinder is
sufficient.
 Bleed the brakes once more.

(1) Port
(2) Bolt Fig. 3-43
Preliminary steps
1. Remove floor plate.
2. Drain the reservoir.
3. Prepare an oil pan.
Procedure
1. Mark ports (1) and their corresponding hoses as

a reference for assembly.
2. Have the oil pan ready to catch any oil that will
come out of the hoses and cylinder ports.
3. Disconnect hoses from ports (1).
4. Remove bolts (2) and remove the brake ass’y

install the brake ass’y.

(12) Bracket
(5) Pin
(11) Washer
(10-1) Pad
(16) Tube connector ass’y
(4) Washer
(3) Snap pin
(13) Washer
(14) Bolt
(15) Master cylinder (9) Spring

(8) Bearing
(10) Pedal ass’y
(7) Hard washer
(6) Bolt
Fig. 3-44
Brake pedal removal/installation
1. After removing snap pin (3), remove washer (4)

and pin (5).
3
Drive/brake system
2. Remove spring (9) if needed.
3. Unscrew bolt (6) and remove hard washer (7),

bearing (8), pedal assembly (10), and washer
(11) from bracket (12).
4. To assemble the brake pedal, perform the

procedure above in the reverse sequence.
Master cylinder removal/installation
1. After removing washers (13) and bolts (14),

remove master cylinder (15).
2. Remove/disassemble tube connector assembly

(16) if needed.
3. To assemble the master cylinder, perform the

procedure above in the reverse sequence.

3-6-6 Master cylinder disassembly/assembly
(4-1) Large spring
(4-2) Primary cup
(4-3) Large spacer
(4) primary piston ass’y
(5) secondary piston ass’y
(5-5) Small spacer

(5-4) Primary cup 1 (3) Retaining ring (2) boot (1) head pin
(5-3) Spring seat

(5-1) Small spring
Fig. 3-45
Toos needed Vise
Preliminary steps
1. Remove the master cylinder (See Section 3-6-2)
Procedure
1. Position the cylinder in a vise
2. Remove head pin (1)
3. Remove boot (2)
4. Retaining ring (3)
5. Pull out primary piston ass’y (4) and secondary

piston ass’y (5) together and separate them.
6. Disassemble primary piston ass’y (4) in the

following order.
 Large spring (4-1)
 Primary cup 2 (4-2)
 Large spacer (4-3)

7. Disassemble secondary piston ass’y (5) in the
following order.
 Small spring (5-1)
 Spring seat (5-3)
 Primary cup 1 (5-4)
 Small spacer (5-5)

assemble the master cylinder
Drive/brake system

3-7 EM parking brake
Fig. 3-46
Components 36 V spec. 48 V spec.

Part no. 130104-00300 130104-00301
Operating voltage 36 V 48 V
Power 30.9 W @ 20 ℃ (68 ℉) 34.5 W @ 20 ℃ (68 ℉)
Current 0.858 A @ 20 ℃ (68 ℉) 0.718 A @ 20 ℃ (68 ℉)
Resistance 41.9 Ω ± 5% 66.8 Ω ± 5%
Braking torque 42 N·m (31 lb·ft) 42 N·m (31 lb·ft)
Max. inclination at which
15° 15°
braking is effective
EM parking brake 3-42 B15/18/20T, B18/20TL, B16/18/20X-7

3-7-2 How it works
Models B15/18/20T and B16/18/20X-7 are a parking
brake that uses an EM (electromagnetic) brake. (5) Flange (2) Spring
The EM brake is connected to the shafts in the backs of

(1) Inductor
the drive motors in both sides. The shafts in both sides
(6) Hub
are ultimately connected to the drive wheels and make
(7) Motor shaft
the entire drive system of the vehicle immovable when
(3) Armature
the EM brake is activated.
(4) Friction disc
If the operator stops the vehicle, spring (2) pushes
armature (3) and friction disc (4) so that flange (5) and
armature (3) contact both sides of friction disc (4), which
brings friction disc (4) and motor shaft (7) to a halt. If the
motor shaft (7) does not revolve, then the drive axle and
the wheel also will not revolve.
When the vehicle moves, electric current flows in inductor

(1) and generates magnetism to pull armature (3). Then a Fig. 3-47
3
free space is made among flange (5), friction disc (4),
and armature (3) so that friction disc (4) can rotates freely
without touching the front and rear sides, and thus motor
shaft (7), drive axle, and wheels connected to the friction
Drive/brake system
disc can revolves freely.
B15/18/20T, B18/20TL, B16/18/20X-7 3-43 EM parking brake

3-7-3 Parking brake test
WARNING
The vehicle will roll if the parking
brake is not adjusted correctly,
causing a hazardous circumstance:
Be prepared to operate the service
brake if the parking brake fails during
this procedure.
1. Put a rated load capacity on the forks
2. Drive the vehicle up a 15% incline.
3. Half way up the incline, stop the lift truck using

15 %
the service brake, and the EM brake will be
automatically engaged as the parking brake.
4. If the parking brake has been adjusted properly,

the vehicle should remain stationary (If the Fig. 3-48
vehicle descends see Section 3-8-3 EM parking

brake troubleshooting).
EM parking brake 3-44 B15/18/20T, B18/20TL, B16/18/20X-7

3-7-4 Manual release of braking
The EM parking brake is automatically engaged three
seconds after the vehicle stops driving and disengaged
again once the accelerator pedal is pushed. Though this
gives convenience to the operator, in some cases such
as towing the vehicle you need to manually disengage
the brake when the vehicle is parked.
DANGER
Once you disengage the EM parking
brake, the vehicle may move as
unmanned.
Before you start the procedure below,
make sure to park the vehicle on a flat
ground and support the wheels with
wooden blocks.
Preliminary steps
1. Remove the top counterweight cover (See

Section 7-4).
3
Drive/brake system
Procedure
1. Disconnect the cables of EM CONN A and EM

CONN B beside the fuse box.
 The fault code 80 (L-EM Brake Fault) will be
displayed on the instrument panel and the
warning buzzer will sound.
2. Connect the cable of EM CONN B to the cable of

EMERGENCY C to release the EM parking
brake. < Location of cables > Fig. 3-49
< Cables zoomed in > Fig. 3-50
B15/18/20T, B18/20TL, B16/18/20X-7 3-45 EM parking brake

3-8 Troubleshooting
3-8-1 Driving
Problems Probable causes
Switch not closed (battery connector, key switch, seat switch,

F/R switch or parking brake switch):
 Close the switch. If it still does not operate, test for
power to the control panel and power flow through each
switch with a voltmeter.
 But the service brake switch should be opened.
Bad connection. Fuse blown:
 Check battery connections. Check connections at battery
connector. Check fuses, drive and logics. Replace fuse if
blown.
 Check the Drive motor and control panel for possible
reasons for a blown fuse. Some causes are:
a. Operation under excessive MOSFET load, too high
current limit (C/L).
b. Possible short circuit in power unit.
Drive motor does not operate. Low battery voltage:
 Check battery terminal voltage. If too low, charge the
battery.
 Check all the cells for one or more that have defects.
 Check the specific gravity of each cell. The maximum
density difference from the highest to the lowest cell
must not be more than .020 SG (specific gravity).
Control panel operation not correct:
 See “Section 2-3-4 Motor controller test” and “2-7
Diagnosis/calibration/handling faults.”
Static return to off circuit (S.R.O.) actuated:
 If the static return to off is activated, the control will not
start again until the accelerator is released and the
directional control lever is returned to neutral.
Encoder is breakdown.
Brakes have a defect, cause a resistance (lack of free
movement). Heat increases, which causes the motor to stall:
 Check the brake adjustment.
Traction does not operate through a Too much heat in the control panel because:
normal work period, but hydraulic a. Extra heavy traction loads.: Decrease the duty cycle
load.
operation is normal.
b. Faulty thermal sensor: See “Section 2-7-3 Handling
faults on instrument panel/EasyView.” These can
cause MOSFETS to become defective, control panel
failure or drive fuse to go bad.
Troubleshooting 3-46 B15/18/20T, B18/20TL, B16/18/20X-7

Too small a battery equipped in the lift truck:
 Use a larger battery for the complete work cycle and
normal work period.
Battery not being fully charged or equalized during the
battery charging operation:
 Check the battery cells for an equalization charge (a
charge to make the specific gravity the same in all cells).
 Check the battery charger for defects.
Battery change interval is too long or changed battery cooling
time is too short. This decreases the capacity and the ability
of the battery:
 Decrease the battery work duration before a change.
 Increase the battery cooling time after a charge before it
is put to use.
Battery has one or more defective cells which results in less
than the rated capacity and ability of the battery:
 Replace the battery.
Neither traction nor hydraulic does Traction system draws (makes a consumption of) too much
last through a complete normal battery power because of traction system faults. Operation of
work period. the duty cycle (complete working cycle) condition is not
correct:
 Check the brake adjustment. Check the mechanical
components such as wheel bearings, axles, etc., for
corrections to eliminate the faults. Change to a tire with
less friction.
3
Hydraulic system draws too much battery power because of
Drive/brake system
lifting and tilting arrangements, or hydraulic conditions are not
correct for the duty cycle:
 Decrease hydraulic relief valve setting to the capacity
that only will be used.
 Change to a smaller hydraulic pump.
 Check the mast for restriction during operation.
Lift truck working more than the capacity of its design with no
available power after one work shift:
 Have available an extra (exchange) battery. Decrease
the speed and work load required to complete the work
shift.
Dirty battery, electrolyte on top of cells and is in contact with
the frame. Current flows through battery box, which places a
voltage on the truck frame:
 Clean the battery with baking soda and water solution.
Low resistance to ground [battery Battery or control panel wire connections in contact with truck
polarity either positive (+) or frame:
negative (–) or a medium voltage is  Make a continuity test and move the wire from contact.
in direct contact with truck frame  Remove wires in sequence until the fault is cleared.
 The fault will be in the wire last disconnected.
(body) or drive motor body].
Dirty motor:
 Remove metallic or carbon dust with air pressure.
Wet motor:
 To dry the motor, heat it to 90°C (194°F).
B15/18/20T, B18/20TL, B16/18/20X-7 3-47 Troubleshooting

Battery not fully charged or battery has bad cells:
 Charge the battery. Check for bad cells. Replace the
battery if necessary.
A fault either in the drive motor, control panel or drive train:
Lift truck does not get to top speed.
 Check lift truck speed in both directions. If the control
panel needs to be tuned up, make adjustments as shown
in the respective part of “Section 2 electrical system."
 If the drive motor is at fault, make tests of the motor components.
Unpolished or improperly positioned forks:
Lift truck does not have enough  Install tapered and polished forks. Position forks
correctly for load being lifted.
power to position itself under a
Lift truck equipped with tires that have poor traction:
load. Lift truck does not have
 Install tires that have good traction per recommendation
enough power on ramps or towing from DOOSAN Inc.
trailers. Lift truck work load is too heavy or the duty cycle too long:
 Decrease the work load and/or duty cycle.
Drive control overheated and the thermal switch opens.
Lift truck has slow acceleration. NOTE: The thermal switch will warning if the temperature is
145 °C (293 °F).
3-8-2 Service brake

Leakage or low fluid level.
Pedal resistance is not solid
Air in the brake hydraulic system.
(spongy).
Master cylinder is loose.
Mechanical resistance on the brake pedal.
Extra (excessive) pedal pressure Restriction in the brake line.
needed for braking action. Bad master cylinder.
Discs look like glass (glazed) or are worn.
Pedal gradually goes to the floor.
Bad master cylinder.
Pedal adjustment is not correct.
Extra (excessive) pedal travel. Air in the brake hydraulic system.
Discs are worn.
Air in the brake hydraulic system.
Linkage is not in correct adjustment or is bent.
Brakes does not apply.
Discs look like glass (glazed) or worn.
Oil or brake fluid is on the lining.
Discs look like glass (glazed) or worn.
Oil or brake fluid is on the lining.
Not braking evenly or rough feeling Bad contact between the steel discs and friction discs.
during braking (chatter). Brake discs uneven (out of flat).
Loose pressure plate bearing.
Bad disc and friction disc assembly.

3-8-3 EM parking brake
Problems Possible causes

Power supply is too low.
Brake is not properly Power supply is too interrupted.
released. Disc is worn
Coil is damaged
Voltage is present afther the switch turned off.
Brake is not engaged.
Grease on the friction disc
Drive/brake system

4 Hydraulic system
4-1 Overview........................................................2
4-1-1 Components............................................................2
4-1-2 Oil flow ....................................................................4
4-2 Pump motor ..................................................6

4-2-2 How it works............................................................8
4-2-3 Pump motor and main hydraulic pump
removal/installation ...............................................10
4-2-4 Pump motor disassembly/assembly .....................12
4-3 Main hydraulic pump .................................14

4-3-2 How it works..........................................................15
4-4 Priority valve ...............................................18
4
4-4-2 How it works..........................................................19
Hydraulic system
4-4-4 Disassembly and assembly ..................................21
4-5 Hydraulic tank and filter ............................22

4-5-1 How it works..........................................................22

4-1 Overview
4-1-1 Components
Fig. 4-1

The hydraulic system operates a number of actuators by
pressurized oil from the main hydraulic pump and
withdraws oil drained from those actuators.
• Pump motor, regulated by the controller, drives

the main hydraulic pump. [Section 4-2]
• Main hydraulic pump pressurizes oil in the

hydraulic tank using the rotatory force delivered
from the motor and sends the oil to the priority
valve. [Section 4-3]
• Priority valve determines to which device between

the steering unit and control valve it gives priority,
and then supplies the prioritized one with a
majority of pump oil. [Section 4-4]
• Hydraulic tank stores hydraulic oil that returns

from actuators. The stored oil is suctioned by the
main hydraulic pump for reuse. [Section 4-5]
Hydraulic system

4-1-2 Oil flow
Fig. 4-2

Hydraulic oil circulation
Hydraulic tank (1) stores hydraulic oil, which is to be

supplied to main hydraulic pump (3) through suction
strainer (2). Main hydraulic pump (3) pressurizes the
supplied oil and distributes it to different systems
throughout the vehicle via priority valve (4). Upon
receiving hydraulic oil, these systems perform their
functions and then discharge the used oil to tank (1)
through return filter (7).
Hydraulically operated systems
The following systems are operated by the circulation of

hydraulic oil:
• Lift/tilt/auxiliary system: Control valve (5)

controls this system using a supply of hydraulic oil.
See Section 5 for more information.
• Steering system: Steering unit (6) controls this

system using a supply of hydraulic oil. See Section
6 for more information.
To ensure an efficient and safe use of the limited

hydraulic pressure, priority valve (4) determines which of
these two systems the majority of hydraulic oil will be
4
supplied to. When the steering mechanism is not being
Hydraulic system
operated, steering unit (6) is supplied with only little
hydraulic oil that passes through an orifice, and control
valve (5) is supplied with the rest.
However, once the operator turns the steering wheel,

priority valve (4) receives a pilot signal from steering unit
(6) through the load sensing line that shifts its spool,
increasing the hydraulic oil supply to steering unit (6).
For more information on the operations of individual

components that are involved in hydraulic oil circulation,
refer to the following sections.

4-2 Pump motor
A. Pump motor
Fig. 4-3
Items Spec.
Voltage 48 VAC
Power 14.0 kW
Voltage 30 V
Current 352 A
Speed 2140 rpm
Max. speed 4500 rpm
Frequency 74 Hz
Protection degree IP43
Weight 41.5 kg(91.5 lb)
Pump motor 4-6 B15/18/20T, B18/20TL, B16/18/20X-7

B. Pump motor controller
Fig. 4-4
4
Items Spec.
Voltage 36/48 V
Hydraulic system
Drive maximum current 450 A
Pump maximum current -40 to +50°C(-104 to +122 ℉)
Operating ambient temperature range -40 to +95°C(-104 to +203 ℉)
Maximum temperature +95°C (+203 ℉)
B15/18/20T, B18/20TL, B16/18/20X-7 4-7 Pump motor

4-2-2 How it works
PUMP MOTOR
CONTROLLER
GND
60/WH/BU P1-7
THM1
61/GN/RD P1-8
B1
63/BR P1-32
A1
62/GN/BK P1-31
60/WH/BU P1-9 65/BU 65/BU 2
63/BR +5V 1
64/RD P1-26
64/RD MAST TILT SW2 (OPT)
61/GN/RD
PUMP MOTOR 68/WH/GN 2
62/GN/BK P1-4 68/WH/GN
+
69/BU/WH 69/BU/WH 1
P1-13
ENCODER
GND A B
MR TILT SOLENOID (OPT)

P1-19 78/YL/GN 78/YL/GN 2
1
Auto tilt SW3 (OPT)
P1-20 79/YL/BU 79/YL/BU 2
1
THERMAL THERMAL
60/WH/BU TILT LEVER (OPT)
SENSOR SENDER
1
1 47/RD/GN P1-25 P1-25 47/RD/GN 47/RD/GN 2
2 117/YL/WH P1-6 44/VO 44/VO TILT
P1-10 4
45/YL 45/YL AUX1
PRESSURE SENSOR(OPT) P1-22 6
46/BK/WH
AUX2
P1-33 46/BK/WH 8
P1-7 60/WH/BU 60/WH/BU 5 GND+12V
P1-24 67/GN/YL 67/GN/YL 7 OUT
LIFT SENSOR
1
P1-14 24/WH/BK 24/WH/BK 2
HEIGHT SW1 (OPT)
Fig. 4-5
The pump motor transmits power to the main hydraulic
pump so that it can pump hydraulic oil for operating the
hydraulic system.
Controlling by controllers
As shown in the schematic diagram, the pump motor is

connected to a controller through an encoder. The
controller controls the pump motor based on the input
from different switches.
The conditions for the pump to work are as follows:
• Key switch is closed.
• Operator is seated, closing the seat switch.
• One of the hydraulic control switches, F/R switch,

or accelerator switch is signaling the controller.
Turning the F/R switch to Forward or Reverse triggers the

pump motor to run at idle for six seconds. And then it
enters PP mode to stop running unless signaled from the
accelerator in the six seconds. To restart up the pump
motor, the operator should return the F/R switch to
neutral and then shift it to Forward or Reverse again, or
move one of the hydraulic control levers to turn on the
respective switch.

Unlike in tilting or other auxiliary operations, speed
matters when it comes to lifting. Therefore, via the lift
sensor, the input signal for lifting varies with the angle of
the lever; receiving this variable signal, the controller
regulates the pump motor’s speed in rpm. The motor’s
speed determines the pressure of the hydraulic oil sent to
the lift cylinders and consequently the lifting speed.
Motor speed detection (encoder operation)
An encoder is equipped with two hole sensors, and has a

gear installed on the drive shaft of the motor to interact with
these two hole sensors. This gear’s turning along with the
drive shaft causes the gear’s teeth periodically to pass the
magnetic field of each hole sensor. When a top land of the
gear passes the magnetic field, it comes closer to the hole
Mechanical profile
sensor and thus the magnetic flux increases. On the other
hand, when a bottom land passes the magnetic field, the
Magnetic profile
distance increases and the magnetic flux decreases
accordingly.
Sensor electrical output profile
This cycle recurs and the magnetic flux has a waveform

Fig. 4-6
to produce a voltage pulse. The controller analyses the
4
amplitude of this pulse to compute the rpm of the motor.
A smaller amplitude means a higher rpm of the motor.
Like other sensors, the encoder too produces both a main
Hydraulic system
signal (signal A) and a reference signal (signal B) through the
two hole sensors. As shown in Fig. 4-7, the order of the signals
Clockwise rotation
produced changes depending on the direction of revolution.
Overheat protection (thermal sensor operation)
Each drive motor is equipped with a thermal sensor to

protect it from overheating. Once the motor reaches a Counterclockwise rotation
heat of 145 °C (293 °F), an overheat alarm is activated
Fig. 4-7
and the working performance of the motors is limited.

4-2-3 Pump motor and main hydraulic pump removal/installation
(4) Cable
(5) Encoder cable

(6) Thermal sensor cable
(3) Brake pedal ass’y
(1) Brake line
(10) Suction hose
(2) Brake line

(7) Suction hose
(8) Bulk hose
(9) Tube ass’y
(12) Bolt
(11) Strap Fig. 4-8
NOTICE: When assembling and disassembling the

hydraulic pump, do not apply any pressure on the motor
nor damage the encoder (sensor bearing) cable.
Preliminary steps
1. Remove the floor plates in the compartment so

that you may see the pump motor as shown in
Fig. 4-9.
2. Prepare and oil pan.
Fig. 4-9

Procedure
1. Use a tie wrap or something similar to prevent

the brake oil from draining to the reservoir via
brake line (1).
 Have the oil pan ready to catch any brake fluid
that will come out of the lines and cylinder
ports.
2. Disconnect brake line (2) from the master

cylinder.
3. Dismount brake pedal ass’y (3) (See Section 3-

6-5).
4. Disconnect cables (4) from the UVW terminal.
5. Disconnect encoder cable (5) and thermal

sensor cable (6) from the main harness.
6. Disconnect suction hose (7) which connects the

priority valve to the control valve.
7. Disconnect bulk hose (8) from the hydraulic

pump.
8. Disconnect tube ass’y (9).
9. Disconnect suction hose (10) that runs from the

4
hydraulic pump to the priority valve.
Hydraulic system
10. Support the pump motor with straps (11) and
remove the motor and pump ass’y.
11. Remove bolts (12), washers, and hydraulic pump

from the hydraulic motor.
 Installation torque: 55±10 N·m(40±7 lb·ft).

install the pump motor.

4-2-4 Pump motor disassembly/assembly and test
(8-1) Nut (11) Encoder
(8) Terminal block
(8-2) Screw (11-1) Bolt
(10) End bell

(9) Bearing
(4) Bearing
(2) End bell
(3) Washer (7) Stator assembly
(6) Bolt
(5) Rotor assembly
(1) Nut Fig. 4-10
Disassembly/assembly
1. After removing the terminal protector, loosen nut

(8-1) and remove the terminals from terminal
block (8).
2. Loosen screw (8-2) and remove terminal block

(8).
3. Loosen bolts (11-1) and remove encoder (11).
4. Loosen nuts (1) and remove bolts (6).
5. Remove end bell (4).
6. Remove stator assembly (7) by hand or using a

tool.
7. Remove washer (3) and bearing (4) from rotor

assembly (5).

8. Remove bearing (9) and rotor assembly (5) from
end bell (10).
 It is recommended to use a hand puller as
shown in Fig. 4-11.

assemble the pump motor.
NOTICE: Before you reassemble the motor, you may test

its parts as follows.
Fig. 4-11
Rotor Test
1. Remove contaminants on the surface of the rotor

using compressed air and a soft cloth.
2. Measure the outer diameter of the rotor using a

vernier caliper.
 Specification: ø 123.1mm ± 0.05(ø 4.8in ± 0.05)
Stator Test
1. Carefully wipe contaminants from the surface of
4
the stator using a clean cloth dampened with
alcohol.
NOTICE: Contaminants in the stator may cause damage Fig. 4-12
Hydraulic system
to the coil and consequently to the stator itself.
2. Measure resistance for each phase (U-V, V-W,

W-U) using a milli-ohmmeter.
 Rated resistance: 3.50 mΩ
Fig. 4-13
3. Test insulation at 1000 Vac and Min. 10 MΩ
using an insulation tester.
 If insulation is faulty, replace the stator with a
new one.
Fig. 4-14

4-3 Main hydraulic pump
Fig. 4-15
Items Spec.
Displacement 16.5 cc/rev
Rotation direction Counterclockwise
Rated pressure 21,000 kPa(3,046 psi)
Velocity at the maximum pressure 500 to 3000 rpm
Main hydraulic pump 4-14 B15/18/20T, B18/20TL, B16/18/20X-7

4-3-2 How it works
Fig. 4-16
This model uses a circumscribed gear pump as its main
hydraulic pump.
Gear operation
As shown in Fig. 4-16, driving gear (1) receives power

from the pump motor through drive shaft (2) and
transmits this power to engaged driven gear (3). These
two interlocked gears then revolve in the opposite
direction to each other.
4
Hydraulic system
Hydraulic oil flow
If the two gears revolve in the opposite direction to each

other, then the hydraulic oil in area A will be carried to
area D via areas B and C. Although the hydraulic oil in
area D tries to circulate by flowing between the two gears
back to area A, it remains in area D because there is no
space between the two gears for it to travel. Therefore, a
low pressure area is created in area A as the hydraulic oil
flows out, while a high pressure area is created in area D
as the oil is accumulated.
As a result, the low pressure area in area A causes

hydraulic oil in the tank to flow into the pump while the
high pressure area in area D causes its pressurized oil to
flow out of the pump via the outlet.
B15/18/20T, B18/20TL, B16/18/20X-7 4-15 Main hydraulic pump

Preliminary steps
1. Remove hydraulic pump.
Procedure
NOTICE: Identify and mark all sections of the hydraulic
pump for purposes of reassembly.
1. Remove four bolts (1) and washers (2) to remove

pump cover (3).
 Installation torque: 39–41 N·m(29-30 lb·ft)
Fig. 4-17
2. Remove O-ring seal (4) from the pump body
Fig. 4-18
3. Remove seal (5), back up-ring (6) and bushes (7)
from the pump gears.
4. Remove two gears (8) from the pump body and

Fig. 4-19
then separate the pump’s sections.
Fig. 4-20
Main hydraulic pump 4-16 B15/18/20T, B18/20TL, B16/18/20X-7

5. Remove O-ring (9), seal (10), back up-ring (11)
and bush (12) from the pump body. Replace
seals, back up-ring, O-ring with new ones if
needed
Fig. 4-21
6. Remove seal (13) from the flange (14).
 When installing seal (13), make sure the lip of
the seal is positioned toward the inside of the
pump housing.
7. To assemble the main hydraulic pump, perform

the procedure in the reverse sequence.
Fig. 4-22
Hydraulic system
B15/18/20T, B18/20TL, B16/18/20X-7 4-17 Main hydraulic pump

4-4 Priority valve
Fig. 4-23
Items Spec.
Part number D518223
Max. flow at “P” port 50 LPM
Max. pressure of excessive flow (EF) 21.6 MPa (3,129 psi)
Control pressure 0.46±0.05 MPa (67±7 psi)
Steering system Internal pilot dynamic signal type
Priority valve 4-18 B15/18/20T, B18/20TL, B16/18/20X-7

4-4-2 How it works
As shown in Fig. 4-24 and 4-25, the priority valve meters
hydraulic oil to the control valve and the steering unit
after receiving oil from the main hydraulic pump so as to
always give priority to the steering system when
demanded for steering. It is because the steering speed
is more closely related to safety than the mast and
carriage speed.
A portion of the hydraulic oil that travels along the

steering unit line is distributed to lines A and B. Hydraulic
oil in line A has a higher pressure than spring (2) to push
spool (1) toward the opposite side of spring (2), but
pressure in line B varies depending on conditions of the
load sensing line.
When steering wheel is not turned
When the steering wheel is not being turned, there is no

hydraulic oil (pilot pressure) sent from the steering unit
through the load sensing line. Therefore, as shown in Fig.
4-24, the hydraulic oil sent through line B flows out to the
4
load sensing line and gives nearly no pressure to spool
(1). Accordingly, spool (1) is pushed by the pressure from
line A, and the majority of pump oil is sent to the control
valve while the steering unit is supplied with only a small
Hydraulic system
amount of oil that has passed orifice (1-1). This helps the
mast assembly operate at full performance.
Fig. 4-24
When steering wheel is turned
When the steering wheel is being turned, a certain

pressure of hydraulic oil (pilot pressure) is sent from the
steering unit through the load sensing line and pushes
spool (1) together with the hydraulic oil in line B in the
opposite direction to the pressure of line A. As spring (2)
adds pressure, the pressure in line B exceeds the
pressure in line A, pushing spool (1) in the direction
shown in Fig. 4-25. As a result, the steering unit is
supplied with a greater amount of hydraulic oil sent
through the unrestraint passage in spool (1).
Fig. 4-25
B15/18/20T, B18/20TL, B16/18/20X-7 4-19 Priority valve

DANGER
Pressurized hydraulic oil will cause
severe burns, and infection that may
even result in amputation.
Release the pressure from the system
before you perform the following
procedure (See 5-2-3).
(1) Floor plate

Preliminary steps
1. Remove the floor plate (1)
2. Drain the hydraulic tank.
Procedure
Fig. 4-26
1. Mark connections (3) and their corresponding
hoses as a reference for assembly.
(4) Bolt
2. Have the oil pan ready to catch any oil that will
(5) Bracket
come out of the hoses and the priority valve’s
ports.
3. Disconnect the hoses at the connections and

(3) Connection
then plug and cap them.
4. Supporting the priority valve, remove bolts (4)

and washers and then lift out the priority valve Fig. 4-27
ass’y together with mounting bracket (5).

install the priority valve.
6. Refill the tank with hydraulic oil according to the

specifications given in the Operation and
Maintenance Manual.
Priority valve 4-20 B15/18/20T, B18/20TL, B16/18/20X-7

4-4-4 Disassembly and assembly
(1) Plug
(2) Bushing
(3) Spool
(4) Spring
(5) Check valve
4
Fig. 4-28
Hydraulic system
Preliminary steps
1. Remove priority valve (See Section 4-4-3)
Procedure
1. Remove plug (1)
2. Remove bushing (2).

 Check the condition of the bushing and replace
it with a new one if worn or damaged.
3. Remove spool (3).
4. Remove spring (4).
5. Remove check valve (5).
6. Clean all the parts.

assemble the priority valve
B15/18/20T, B18/20TL, B16/18/20X-7 4-21 Priority valve

4-5 Hydraulic tank and filter
4-5-1 How it works
Fig. 4-29
The hydraulic tank and the filter that is installed in the
tank perform the following functions:
Storing hydraulic oil
The hydraulic tank retrieves and stores hydraulic oil

discharged from different components of the hydraulic
system in order that those discharges might be reused by
the main hydraulic pump. As shown in Fig. 4-29, the two
lines connected to the tank are responsible for receiving
and supplying hydraulic oil respectively.
Hydraulic tank and filter 4-22 B15/18/20T, B18/20TL, B16/18/20X-7

The oil height (H) in the tank varies depending on the
contraction/expansion of various cylinders and the
opening/closing of different valves, and the remaining
space (R) changes accordingly. Air breather (2) is
installed to let external air flow into/out of this space so
that oil in the tank remains under constant atmospheric
pressure, and to prevent dust from entering the system a
filtering element is also installed.
You can open oil cap (1) and refill the tank with hydraulic
oil when needed.
Filtering impurities from hydraulic oil
As oil passes through the different components in the

hydraulic system, it collects various contaminants such
as moisture and air, which may lower the system
performance and cause component malfunction or failure.
For this reason, various devices have been installed in
the oil tank to filter these materials and protect the
system from failure.
Large, solid particles are the first of the contaminants to

be filtered by return filter (3) while the remaining particles
are separated into the lighter than oil, which float on the
surface, and the heavier, which settle at the bottom. Plug
4
(5), which is installed at the bottom of the oil tank,
Hydraulic system
facilitates the precipitation of the impurities.
And suction strainer (4) is installed in the discharge line

to the pump so that oil is filtered once more before it
flows back to the hydraulic system.
B15/18/20T, B18/20TL, B16/18/20X-7 4-23 Hydraulic tank and filter

4-6 Troubleshooting
The oil level is low.

The oil is thick (viscosity too high).
The pump inlet line has a restriction in it.
Noise in the pump.
Worn parts in the pump.
Oil is dirty.
Air leaks into the inlet line.
The oil level is low.
There is a restriction in an oil passage.
The relief valve setting is too low.
The oil is too thin.
There is air leakage in the system.
The oil temperature is too high.
The pump has too much wear.
The system operates at too high a pressure.
a. Relief valve setting too high.
b. Attachment components cause a restriction during
movement.
c. Restrictions in flow control valve, check valve and in
oil lines.
The shaft seal is worn.
The inner parts of the pump body are worn.
Operation with too low oil level in tank causes suction on the
Leakage at the pump shaft seal.
seal.
Seal cut on shoulder of pump or keyway during installation.
Seal lips are dry and hardened from heat.
Low level of the oil in the tank.
There is a restriction in the pump inlet line.
There is air leakage in the pump inlet line.
a. Loose bolts.
There is failure of the pump to b. Defects in suction line.
deliver fluid.
The viscosity of the oil is wrong.
The pump has too much wear.
Failure of the pump shaft.
The bolts of the pump do not have the correct torque.

5 Lift/tilt/auxiliary system
5-1 Overview........................................................2
5-1-1 Components............................................................2
5-1-2 Oil flow ....................................................................4
5-2 Control valve .................................................6

5-2-2 How it works............................................................7
5-2-3 Pressure removal in the hydraulic system ............18
5-2-4 Relief valve adjustment.........................................19
5-2-5 Needle valve for emergent lowering .....................21
5-2-6 Levers and switch group
adjustment/removal/installation ............................22
5-2-7 Control valve removal/installation .........................24
5-2-8 Control valve disassembly/assembly ....................26
5-3 Mast assembly ............................................28

5-3-2 How it works..........................................................30
5-3-3 Forks service.........................................................38
5-3-4
5-3-5
Sideshifter .............................................................40
Chains service ......................................................46
5
5-3-6 Tilt cylinders service .............................................52
Lift/tilt/ auxiliary system

5-3-7 Primary lift cylinders service .................................60
5-3-8 Standard/secondary cylinders service ..................64
5-3-9 Carriage service ....................................................74
5-3-10 Mast service ..........................................................78

5-1 Overview
5-1-1 Components
Fig. 5-1

The lift/tilt/auxiliary system is powered by the main
hydraulic pump, which consists of the following
components:
• Control valve, connecting the main hydraulic

pump and a number of actuator cylinders, supplies
to or returns pump oil from those cylinders. The
positions of the valve’s spools determine whether
cylinders are supplied with or drained of hydraulic
oil; and their positions are shifted by their
respectively corresponding levers. [Section 5-2]
• Mast ass’y is a group of devices that lift, lower, tilt

back and forward, and handle other operations
with loads. This ass’y is equipped with lift, tilt, and
auxiliary cylinders that the operator controls. These
cylinders are connected to the LIFT, TILT, and
AUX sections of the control valve.
 Forks: Two prong-shaped objects to support a
load [Section 5-3-3]
 Sideshifter: An attachment that moves the
forks and the loads on them to the left and
right [Section 5-3-4]
 Chains: Parts that lift the carriage and mast
[Section 5-3-5]
 Tilt cylinders: Double-acting cylinders that
pull or push the mast [Section 5-3-6]
 Primary lift cylinder: A single-acting cylinder
that pulls back the carriage’s chains [Section
5-3-7] 5
 Standard lift cylinders: Single-acting
cylinders that extend the inner mast [Section 5-

3-8]
 Carriage: A support structure to which the
forks are mounted [Section 5-3-9]
 Mast: A vertical structure at the front of the
forklift that extends and retracts to lift and
lower a load [Section 5-3-10]

5-1-2 Oil flow
(3-2) Auxiliary relief valve (3) Control valve (8) Auxiliary cylinder
OUTLET block
AUX2 block (7) Tilt cylinder
AUX1 block
(B) Rear (A) Front
TILT block [Primary]
[Secondary/STD] [Secondary/STD]
(4) Lift cylinder
STEERING UNIT
LIFT block
(3-1) Main relief valve

INLET block (5) Flow protector
(6) Flow regulator

Load sensing line
(2) Priority valve
Hydraulic line
Pilot line
(1) Main hydraulic pump Drain line
Fig. 5-2
Priority valve operation
Priority valve (2) receives hydraulic oil from main
hydraulic pump (1) and distributes it to the steering unit
and control valve (3). When the steering wheel is not
operated, as shown in the circuit diagram priority valve (2)
moves the spool, and the steering unit receives low-
pressure oil that passes through the valve’s orifice, while
control valve (3) receives all the rest pump oil of a high
pressure. Accordingly, the mast, carriage, sideshifter, and
other attachments become able to work with the high
pressure oil required for their full performance.
Lifting/lowering
Lift cylinders (4) are connected to the LIFT block of
control valve (3) with hydraulic lines for one of the
following jobs, depending on the movement of the spool
that is mechanically connected to the lift lever.

• Lift is achieved as the cylinders receive hydraulic
oil to push their rods upward and consequently the
mast/carriage fastened to them.
• Lowering is achieved as the cylinders discharge
oil in their heads to retract the rods and
consequently the mast/carriage fastened to them
by gravitational force.
• Neutral is maintained as the cylinders neither
receive nor discharge oil so that their rods and the
mast/carriage fastened to them may stay in place.
Sudden lowering may lower work efficiency and threaten
safety. To control this there are many devices including
flow protectors (5) and flow regulator (6).
Tilt forward/backward
Tilt cylinders (4) are connected to the TILT block of
control valve (3) with hydraulic lines for one of the
following jobs depending on the movement of the spool
that is mechanically connected to the tilt lever.
• Tilt forward: is achieved as the cylinders receive
hydraulic oil at the pistons’ rear (B), which results
in the discharge of oil from the front (A), to extend
the cylinder rods and consequently to push the
mast fastened to them.
• Tilt backward is achieved as the cylinders receive
hydraulic oil at the pistons’ front (A), which results
in the discharge of oil from the rear (B), to retract
the cylinder rods and consequently to pull the mast
fastened to them.
5
• Neutral is maintained as the cylinders neither
receive nor discharge oil so that their rods and the
mast fastened to them may stay in place.
Anti-cavitation valve (3-6) is responsible for reducing

cavitation (forming of air bubbles) in tilt cylinders (7).
Attachment
Sideshifter and various other attachments’ operations are
controlled by auxiliary cylinder (8) and can be made in
both directions depending on the spool’s position as with
tilt cylinders (7).
Pressure relief
If the hydraulic pressure sent to cylinders exceeds a set
limit, the excess portion of the oil will be discharged for
the purpose of safety. Overpressure in lift cylinder (4) is
controlled by main relief valve (3-1) while overpressure in
tilt cylinder (7) and auxiliary cylinder (8) is controlled by
auxiliary relief valve (3-2).
For detailed explanations of the control valve and mast
assembly, see Sections 5-2-2 and 5-3-2 respectively.

5-2 Control valve
Fig. 5-3
Items Spec.
A158140 (2-section)
Part no. A158141 (3-section)
A158142 (4-section)
Hydraulic oil -35 to 3100 ℃(-95 to 212 ℉)
Rated flow 53 L/min
Spool stroke 7 mm (0.28 in)
Main relief valve: 19.9±0.25 MPa (2,887±35.6 psi) at 4033 L/min
Relief valve settings
Aux. relief valve: 13.8±0.25 MPa (2,005±35.6 psi) at 2333 L/min
Spool operating force Max. 27 kgf (60 lbf)
LIFT spool: max. 5 cc/min at 19.6 MPa (2,845 psi)
TILT spool: max. 17.5 cc/min at 9.8 MPa (1,422 psi)
Leakage Other spools: max. 12.3 cc/min at 68.6 MPa (9,956 psi)
Load check leakage: max. 61.4 cc/min at 6.9 MPa (996 psi) (common to all ports)
Tilt lock leakage: max. 246 cc/min at 6.9 MPa (996 psi)
Coil type: 12 VDC / 14 W, male packard connector
Solenoid valve “B”
Solenoid valve B: normally colsed
performance
Internal leakage: 0.6 L/min at 20.6 MPa (2,987 psi)
Control valve 5-6 B15/18/20T, B18/20TL, B16/18/20X-7

5-2-2 How it works
A. INLET section
INLET
P
(1-1) Spring
(1) Main relief valve Main relief valve
Fig. 5-4
Hydraulic oil inflow
The pump oil that flows in the control valve through the
priority valve reaches the INLET section first.
Pressure relief
Once the oil pressure in the LIFT section has exceeded

the set limit, spring (1-1) is pushed to open main relief
5
valve (1), allowing the hydraulic oil to exit to the tank until

the pressure returns to below the set limit.
B15/18/20T, B18/20TL, B16/18/20X-7 5-7 Control valve

B. LIFT section
(1) Spool
LIFT
(2) Lift cylinder
P TILT section
Fig. 5-5
Neutral
When the lift lever in the neutral position, the oil from the
pump flows to the TILT section, and the mast does not
rise since the pump oil supply line and lift cylinder line are
disconnected to one another.
The mast does not lower either because the oil remaining
in lift cylinders (2) is blocked from returning to the tank.

LIFT (1) Spool
(2) Lift cylinder
Fig. 5-6
Lift
Moving the lift lever to the lift position shifts spool (1) to
allow the oil from the pump to pass through spool (1) to
the line to lift cylinders (2), pushing their pistons up and
raising the mast.

Lift lock solenoid
(1) Spool
Needle valve
LIFT
Lift lock valve
(2) Lift cylinder
A B
(7) Protector
(6) Flow regulator
(4) Lift lock valve
(3) Lift lock solenoid
(5) Needle valve Fig. 5-7
Lowering
Moving the lift lever to the lowering position shifts spool

(1) to allow the oil from the pump to pass through spool
(1) to the TILT section. At the same time, the oil in lift
cylinders (2) is pushed by the pistons under gravitational
force to return to the control valve and be drained
through spool (1) to the tank.
In the normal condition where the operator is seated, lift

lock solenoid valve (3) stays open, allowing the hydraulic
oil that reaches this valve to pass itself through.
Consequently the oil that has flowed out of lift cylinders (2)
through line A can hardly apply pressure to lift lock valve
(4), while the oil that reaches this valve through line B
retains a pressure to push on the valve and opens it.
Thus the oil from lift cylinders (2) could pass through
spool (1) and exit to the tank.
As the hydraulic oil that has supported the pistons of lift

cylinders (2) flows out, the mast is lowered. Through its
built-in orifice, flow regulator (6) never allows a large
amount of oil to exit lift cylinders (2) at once, preventing a
sudden drop of the mast.
If the line from the control valve to a lift cylinder (2) is

broken, the valve of protector (7) will be shifted to make
the oil in the cylinder pass through its orifice, preventing a
sudden drop of the mast.

(1) Spool
LIFT
Needle valve
(2) Lift cylinder
A B
(4) Lift lock valve
(3) Lift lock solenoid Fig. 5-8
(5) Needle valve
Limitation of lowering and manual lowering

For the purpose of safety, when the operator leaves the
seat, this forklift model stops the oil supply from the main
hydraulic pump in order to prevent the actuators from
working even when the levers are moved. However, there
needs to be another device to limit the lowering function
in this situation because lowering is not actuated by oil
but by gravitational force.
5
Once the operator leaves the seat, lift lock solenoid valve
(3) is signaled by the left drive motor controller to close.

Then, the oil flow that has exited lift cylinders (2) and
passed through this valve starts to remain along line A to
be pressurized. The pressurized oil plus the spring of lift
lock valve (4) consequently overcomes the oil in line B to
close it. As a result, all the paths through which the
hydraulic oil in lift cylinders (2) can reach spool (1) are
blocked. It is in this way that moving the lift lever cannot
drain oil from cylinders (2) to lower the mast.
In this situation, if you were to manually lower the mast,

you should use needle valve (5). Open this valve and
move the lift lever to the lowering position to allow the
hydraulic oil that has held the pistons in place to be
drained with the mast being lowered.
NOTICE: When you use the needle valve, make sure to

follow the appropriate procedure in Section 5-2-5.

C. TILT section
TILT (1) Spool
AUX1 section
(2) Tilt cylinder

T
Fig. 5-9
Neutral
When the tilt lever is in the neutral position, the oil from
the pump flows to the AUX1 section and the mast neither
tilts forward nor back since the pump oil supply line and
tilt cylinder line are disconnected to one another.

TILT
(1) Spool
(3) Tilt lock valve
(3-1) Spring
B A
(2) Tilt cylinder
(4) Anti-cavitation valve Fig. 5-10
Tilt-forward
Once you push the tilt lever forward, spool (1) is shifted to
allow pump oil to flow in head chamber (A) of tilt cylinders
(2), and to allow oil in cylinder rod chamber (B) to be
drained through spool (1) to the tank. As a result, the
mast is pushed forward.
Tilt spool (1) is equipped with tilt lock valve (3) and thus
hydraulic oil in tilt cylinders (2) is not drained until pump
oil pushes this valve to open. Thus this valve keeps 5
closed, blocking the return passage of the oil in chamber

B when pump oil is not supplied due to the operator’s
absence from the seat. As a result the tilt-forward
function is unavailable even when the lever is moved by
mistake or accident, preventing the load from
unexpectedly dropping.
Also, there is cavitation valve (4) in the TILT section,

preventing cavitation in tilt cylinders (2), which might
occur during a forward tilt of the mast.

TILT (1) Spool
B A
P
(2) Tilt cylinder
Fig. 5-11
Tilt-backward
Once you pull the tilt lever back, spool (1) is shifted to
allow pump oil to flow in rod chamber (B) of tilt cylinders
(2) and to allow oil in cylinder head chamber (A) to be
drained through spool (1) to tank, pulling the mast back.

D. AUX section
Fig. 5-12
Fig. 5-13 Lift/tilt/ auxiliary system
Attachment movement
The movement of auxiliary cylinder (2) is similar to that of

the tilt cylinders. Depending on the position of spool (1),
the chamber to be supplied with hydraulic oil and the
chamber to be drained are switched within cylinder (2). In
this way any attachment mounted to the cylinder rod will
move with it together.

E. OUTLET section
OUTLET
P
Auxiliary relief valve
140k
(1-1) Spring
P
(1) Auxiliary relief valve
T
T
Fig. 5-14
Hydraulic oil outflow
The oil to be drained from the control valve passes

through the OUTLET section.
Pressure relief
Once the oil pressure in the TILT, AUX1, or AUX2 section

exceeds the set limit, spring (1-1) is pushed to open
auxiliary relief valve (1), allowing the hydraulic oil to exit
to the tank until the pressure decreases to the set limit.

F. Valve control board
KEY SWITCH AUX1 AUX2
LIFT sensor TILT
PUMP MOTOR
CONTROLLER
3/OR 1
P1-25 47/RD/GN 47/RD/GN 2
TILT
P1-10 44/VO 44/VO 4
AUX1
P1-22 45/YL 45/YL 6
AUX2
P1-33 46/BK/WH 46/BK/WH 8
P1-7 60/WH/BU 60/WH/BU 5 GND +12V
P1-24 67/GN/YL 67/GN/YL 7 OUT
LIFT SENSOR
Fig. 5-15
In an electronic vehicle like this model, a switch is
installed in each hydraulic lever, which when pushed or
pulled signals the pump motor controller. These signals
enable hydraulic operations by activating the pump motor
and the main hydraulic pump.
Unlike other lever switches that can only perform

switching functions, the lift lever has a sensor that signals
with a voltage in proportion to the angle of the lift lever
after receiving 12 V of power from the controller. The
further you pull the lever, the higher the output from the
pump motor becomes, achieving a faster lift operation.
The valve board is connected to the key switch so that it

can respond immediately to the opening/closing of the
5
switch by moving a hydraulic lever when the key switch is
on.

5-2-3 Pressure removal in the hydraulic system
To remove a number of hydraulic devices safely, you
should remove the pressure in the hydraulic system as
follows:
Cylinder Pressure removal
1. Start the vehicle.
2. Move the controllers back and forward.
3. Stop the vehicle.
4. Slowly loosen the cap of the hydraulic tank to

release pressure.
Hydraulic system pressure removal
1. Lower the carriage to the ground.
2. Turn the key switch off.
3. Move the control levers to release pressure.

5-2-4 Relief valve adjustment
DANGER
Make sure the pressure is released from
the system before you perform the
following procedure (See Section 5-2-3).
Pressure-checking adapter <Pressure-checking adapter>

Tools needed Pressure tube
28,000 kPa (4061 psi) gauge
<Pressure tube>
Preliminary steps
1. Move the vehicle to a level surface where you

can fully extend the mast.
2. Take out floor plates (See Section 7-3).

<Pressure gauge>
3. With the key off, remove hose from pump port (1). Fig. 5-16
4. Connect the 28,000 kPa (4061 psi) gauge to port

(1).
5
Lift relief valve check and adjustment
1. Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating

temperature.
2. Without a load on the forks, extend the mast to

its maximum height.
3. Holding the control lever in position, watch the

gauge.
 The value the gauge indicates is the current
Fig. 5-17
pressure at which the relief valve is opened at
the end of a cylinder stroke.

4. Check whether the reading on the gauge
matches the corresponding figure for your
vehicle model in the table.
Main relief pressure

Models
kPa psi
B16X-7, B15T-7 19,900 2,886
B18X-7, B18T-7 19,900 2,886
B20X-7, B20T-7 21,600 3,133
5. If it does not, loosen jam nut (2) and then turn

setscrew (3) either clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve according to your need.
Auxiliary relief valve check and adjustment
1. Key the vehicle on and activate the hydraulics

until the hydraulic oil is at the normal operating
temperature.
2. Tilt the mast fully backward.

Fig. 5-18
3. Holding the control lever in position, watch the
gauge.
 The gauge indicates is the current pressure at
which the relief valve is opened at the end of a
cylinder stroke.
4. Check whether the reading on the gauge

matches the corresponding figure for your
vehicle model in the table.
Auxiliary relief
Models pressure
kPa psi
B16X-7, B15T-7
B18X-7, B18T-7 14,000 2,031
B20X-7, B20T-7
5. If it does not, loosen jam nut (4) and then turn

setscrew (5) either clockwise to increase or
counterclockwise to decrease the pressure
setting of the relief valve according to your need.
Fig. 5-19

5-2-5 Needle valve for emergent lowering
The needle valve is used to manually lower the mast
when the regular lowering operation by the lever is
disabled.
DANGER
A sudden drop of the mast can cause
a serious accident.
Turn the needle valve slowly, looking at
the lowering of the mast.
1. Turn the key switch off and open the control

lever cover.
2. With the lift lever moved to the lowering position,

turn needle valve (1) 2–3 times counterclockwise
very slowly.
3. Once the carriage reaches the ground, lock

needle valve (1) again.
Fig. 5-20

5-2-6 Levers and switch group adjustment/removal/installation
(14) Cam
(15) Switch roller (18) Lever
(1) Bolt
(16) Switch
(13) Screw
X
(17) Screw
(6) Lift sensor
(12) Connector
(11) Switch ass’y
(10) Screw (2) Lift sensor
(3) Screw
Y
(4) Setscrew
(5) Magnet
(7) Screw
(9) Board ass’y
(8) Connector
Fig. 5-21
Lift sensor adjustment
1. Disconnect the battery and discharge the head
capacitor.
2. Loosen setscrew (4).
3. Adjust screw (3) so there is 1.0mm (0.039 in)

clearance (Y) between lift sensor (2) and magnet
(5) when the lift lever pulled all the way back.
NOTICE: If the magnet (5) makes contact with the plastic bracket
when the lift lever is activated, the lift sensor may be damaged.
4. Tighten setscrew (4).

 Check the lift sensor circuit to see if the valve
control card needs adjusting.
5. Set lift sensor initial setting using the EasyView

application (See the Lift Set menu in Section 2-6-4).

Tilt and auxiliary switches adjustment
1. Disconnect the battery and discharge the head

capacitor.
2. Disconnect all but connector (12) of the micro

switch that you wish to adjust.
3. With the corresponding spool for the connected

micro switch ass’y in neutral, loosen screws (13)
and adjust screw (17) to align switch roller (15)
with cam (14).
4. After obtaining the correct alignment, tighten

screws (13) and (17) to secure the micro switch
ass’y’s position.
5. Connect the battery, close the seat switch, and

then turn the key on.
 If needed, readjust the micro switch ass’y
being tested so the pump motor turns on
before the control valve spool opens. This
must be adjusted for each lever direction
(forward/back/neutral).
 A gap of at least 3mm (X) should always be
left between switch (16) and screw (17).
Levers and switch group removal/installation
1. Remove knob ass’y (1) from the top of levers

(18). 5
2. Disconnect connector (8).

3. Loosen screws (7) and then remove board ass’y
(9).
4. Remove screws (10), and then remove micro

switch ass’ies (11) and lift sensor (2).

install the levers and switch group
6. Perform the sensor and switch adjustment

procedures above.

5-2-7 Control valve removal/installation
(2) Pin ass’y

(1) Yoke
(3) Bolt
(25) Cam
(24) Split pin (4) Bracket
(26) Pin
(5) Pin
(6) Split pin
(10) Bolt
(7) Bracket
(8) Bolt
(9) Pivot ass’y
(11) Split pin

(18) Clip ass’y
(12) Nut
(17) Pin
(16) Screw
(13) Bolt
(15) Guide
(14) Bracket
A
Rear view
(19) Nut
(23) Bolt
(20) Stopper
(21) Bolt
(22) Bracket
Fig. 5-22
DANGER

Preliminary steps
2. Lift the hood.
Procedure
1. Give each port and its connection, adaptor or

plug a corresponding mark as a reference for
assembly.
2. Referring to circle A, disconnect the connections,

adaptors or plugs and then plug and cap those
that are connected to hydraulic hoses.
 Have the oil pan ready to catch any oil that will
3. Pull out split pins (24) and pins (26) from the
AUX2, AUX1, and TILT spool’s cams (25) and
then remove them.
4. Pull out split pins (11) and pin (17), and then
loosen nut (12) from screw (16) to remove clip
ass’y (18).
5. Pull out split pins (6) and pins (5), remove

stopper (20) and nut (19), and then dismount the
valve ass’y bracket (4).
6. Loosen bolts (10) and bolt (3) from valve 5

mounting bracket (6).

7. Carefully remove pivot ass’y (9) while catching
yokes (1) as they slide off pin ass’y (2).
8. Remove bolts (8) from the valve mounting

bracket (7) and remove it
9. Remove bolts (13) from bracket (14) and remove

it along with guide (15)
10. Supporting the control valve, remove bolts (23)

from the front of main mounting bracket (22) and
bolts (21) from the back.

install the control valve.

specifications given in Section 1-6-2.

5-2-8 Control valve disassembly/assembly
AUX2 AUX1 TILT LIFT
(3) Auxilirary relief valve ass’y
(1) Bolt
(2) Main relief valve ass’y
(4) Lift lock valve ass’y
(5) Solenoid valve ass’y
Fig. 5-23
Preliminary steps
1. Remove the control valve (See Section 5-2-7).
2. Mark the blocks according to their type.
3. Remove bolts (1) and separate the blocks.
4. Remove main relief valve ass’y (2) and auxiliary

relief valve ass’y (3).
5. Remove lift lock valve ass’y (4) and solenoid

valve ass’y (5) from the LIFT section.

The different section blocks of the control valve all have similar disassembly and assembly
procedures. The illustration used for this section is of the tilt section block.
(6) Bolt
Seal plate (11) Anti-cavitation valve
(9) Dust wiper

(10) O-ring
(15) O-ring
(14) Check valve ass’y
(13) O-ring
(12) Plug
(8) Spool ass’y
(7) Return cap
5
(6) Bolt
Procedure Fig. 5-24
1. Remove four bolts (6).

2. Remove return cap (7).
3. Pull out spool ass’y (8).
4. Remove dust wiper seal (9) and O-ring (10) at

both sides of the section block.
5. Unscrew the top of anti-cavitation valve (11) and

remove it.
 This step applies to the TILT section only
6. Remove plug (12) and O-ring (13).
7. Unscrew the top of check valve ass’y (14) and

remove it.
8. Remove O-ring (15).

assemble the control valve.
 Inspect the condition of O-rings and install new
ones at assembly if worn or cracked

5-3 Mast assembly
Fig. 5-25
Mast assembly 5-28 B15/18/20T, B18/20TL, B16/18/20X-7

The mast ass’y is comprised of various components and options. See the following part numbers to
check the specifications and information you need.
Items STD FFL FFT

Mast-vehicle joint parts A156562 A156634 A156562
Lift cylinder joint parts D583418 D583524 A156569
Attachment hydraulic D583426 (3-way) D583428 (3-way) A156571 (3-way)
hoses (mounted on mast) D583427 (4-way) D583429 (4-way) A156572 (4-way)
D583432 (3-way, LH) D583435 (3-way, LH) A156573 (3-way, LH)
Attachment tubes
D583433 (3-way, RH) D583436 (3-way, RH) A156574 (3-way, RH)
(mounted on carriage)
D583434 (4-way) D583437 (4-way) A156575 (4-way)
Sideshifter hydraulic lines D584018 D584019
Tilt cylinder groups A252107
Mast body D583572 D583573
Outer mast group 230218-02030 230218-02031 230218-02032
Inner mast group D583620 D583622 D583623
Intermediate mast group - - A156524
Chains D583413 D583414 A156560
Standard/secondary lift
D512374 D512388 D512394
cylinder group
Primary lift cylinder group - D501865 400321-00037
Carriage joint parts 160626-00451
Carriage body 230216-00432 230216-00433 230216-00434
Sideshifter body A156229
5
Sideshift cylinder D144202
Load backrest D580046
Sideshifter-integrated
D800461 D800598 D801337
carriage

Fork positioner-integrated
D800721 D801373 D801336
carriage
B15/18/20T, B18/20TL, B16/18/20X-7 5-29 Mast assembly

5-3-2 How it works
A. Mast tilt
Mast tilt operation is made by two double-acting cylinders.

In the case of each cylinder, one end is connected to the
vehicle’s chassis, while the other to the side of the mast.
Tilt forward
Pushing the tilt lever to shift the TILT spool of the control
valve will send hydraulic oil to the opposite chamber to
each cylinder rod (1-2), withdrawing oil from the rod’s
(1) Tilt cylinder
chamber. This leads piston (1-1) to be pushed forward,
tilting forward mast (2) mounted to cylinder rods (1-2) on
the axis of the connection to the vehicle (3). (2) Mast
(3) Connection to the vehicle
(1-2) Cylinder rod

(1-1) Cylinder piston
TILT CYLINDER
Fig. 5-26
Tilt backward
Pulling the tilt lever to shift the TILT spool of the control
valve will send hydraulic oil to the chamber of each
cylinder rod (1-2), withdrawing oil from the opposite
chamber. This leads piston (1-1) to be pushed backward,
tilting back mast (2) mounted to cylinder rods (1-2) on the (1) Tilt cylinder
axis of the connection to the vehicle (3).

(2) Mast
(3) Connection to the vehicle
(1-2) Cylinder rod

(1-1) Cylinder piston
TILT CYLINDER
Fig. 5-27

B. Standard mast lift
Standard (STD) mast assemblies use two masts and two

single-acting cylinders to lift a load.
(4) Inner mast (3) Lift chain
Rollers (6) respectively installed inside and outside the (2) Outer mast
carriage and the mast facilitate these up/down
movements.
(1) STD cylinder [L/R]
(5) Carriage
(6) Roller
STD CYLINDER
CONTROL VALVE
Fig. 5-28
Lift
Upon receiving hydraulic oil from the control valve’s LIFT (5) Carriage
section, standard cylinder (1) rod is extended, pushing up (4) Inner mast
inner mast (4) as shown in the Fig. 5-29.
At the same time carriage (5) is also pulled by lift chain (3) (3) Lift chain
that is connected to outer mast (2) to be lifted up together

with the chain.
(6) Roller
(2) Outer mast 5

Lowering
(1) STD cylinder [L/R]
If the operator controls the lever to open the oil outlet in
the lift block of the control valve, the oil sent in standard
cylinder (1) will start to flow out by gravitational force.
STD CYLINDER
When the oil is discharged, the cylinder rod and the
attached inner mast (4) will retract.
When inner mast (4) is lowered, the tension of the lift

chain (3) will be loosened and carriage (5) will also be
lowered.
CONTROL VALVE
Fig. 5-29

C. FFL mast lift
Full Free Lift (FFL) mast assemblies use two masts and
two single-acting cylinders to lift a load. Primary cylinder
(5) is responsible for the lifting/lowering of carriage (7)
while two secondary cylinders (1) are responsible for
lifting/lowering of inner mast (4).
Rollers (8), installed inside and outside the carriage and

the mast respectively, facilitate their up/down movements.
Fig. 5-30
Carriage lifted
The schematic diagram shows that primary cylinder (5)

and secondary cylinders (1) are connected with each
other. Because the diameter of primary cylinder (5) is
larger than that of the secondary cylinder, upon
recieveing hydraulic oil from the control valve’s LIFT
section, the primary cylinder’s rod is extended first as
shown in Fig. 5-31.
When the rod of primary cylinder (5) is lifted, free lift

chain (6) hung over the upper pulley is pulled, raising
carriage (7).
In this way, once the operator starts the lift operation,

carriage (7) is raised first while the mast remains in a
lowered position.
Fig. 5-31

Mast lifted
If the operator keeps pulling the lift lever, thereby sending

oil even after primary cylinder (5) rod has been fully
extended, then secondary cylinder (1) will begin to
extend. As shown in Fig. 5-32, as secondary cylinder (1)
rod pushes the chain pulley attached to the upper part,
the inner mast (5) is pulled and lifted by secondary lift
chain (3) fastened to outer mast (2).
Lowering

the lift block of the control valve, the oil sent in the lift
cylinder will start to flow out by gravitational force.
Contrary to the lift function, oil in secondary cylinder (1) is
discharged first, followed by the oil in primary cylinder (5).
Therefore, the carriage remains in a raised position until
the mast is fully lowered.
Fig. 5-32

D. FFT mast lift
Full Free Triple (FFT) mast assemblies use three masts

and two single-acting cylinders to lift load. Primary
cylinder (6) is responsible for the lifting/lowering of
carriage (8) while secondary cylinders (1) are responsible
for the lifting/lowering of inner mast (5) and intermediate
mast (6).
Rollers (9), installed inside and outside the carriage and

the mast respectively, facilitate their up/down movements.
Fig. 5-33
Carriage lifted
The schematic diagram shows that primary cylinder (6)

and secondary cylinder (1) are connected with each other.
Because the diameter of primary cylinder (6) is larger
than that of secondary cylinder (1), upon receiving
hydraulic oil from the control valve LIFT section, the
primary cylinder rod is extended first as shown in Fig. 5-
34.
When primary cylinder (6) rod is extended, free lift chain

(7) hung over the upper pulley is pulled and thus raises
carriage (8).
In this way, once the operator starts the lift operation,

carriage (8) is lifted first up while the mast stays in
lowered position.
Fig. 5-34

Mast lifted
If the operator keeps pulling the lift lever, sending oil

even after primary cylinder (6) rod has been fully
extended, then secondary cylinder (1) will start to extend.
As shown in Fig. 5-35, as secondary cylinder (1) rod
pushes intermediate mast (4) upward, inner mast (5) is
pulled upward and extended by secondary lift chain (3)
fastened to outer mast (2).
As mentioned above, when intermediate mast (4) is lifted

by secondary cylinder (1) rod, inner mast (5) connected
to outer mast (2) via a chain is lifted together.
Lowering

the lift block of the control valve, the oil sent in the lift
cylinder will start to flow out by gravitational force. On the
contrary to lift, oil in secondary cylinder (1) is discharged
first, and then followed by the oil in primary cylinder (6).
Therefore, the carriage remains in a raised position until
the mast is fully lowered.
Fig. 5-35
5

E. Sideshifter and other attachments
Various attachments can be mounted to the carriage, and

using the auxiliary cylinder (double acting cylinder),
operations can be carried out in accordance with the
characteristics of the corresponding attachment.
Sideshifter
The most basic attachment is the “sideshifter” that moves

the forks mounted to it left and right as shown in Fig. 5-36
and 5-26. For this purpose an auxiliary operation cylinder
called “sideshift cylinder” is used.
Move to the right
Pushing the sideshift lever to shift the AUX1 spool of the

control valve will send hydraulic oil to the left chamber of
cylinder piston (1-1), taking back the oil in the right
chamber. This leads piston (1-1) to be pushed forward
along with sideshifter (2) mounted to cylinder rod (1-2),
moving the forks attached thereto to the right also.
Fig. 5-36
Move to the left
Pulling the sideshift lever to shift the AUX1 spool of the

control valve will send hydraulic oil to the right chamber
of cylinder piston (1-1), taking back the oil in the left
chamber. This leads piston (1-1) to be pushed backward
along with sideshifter (2) mounted to cylinder rod (1-2),
moving the forks attached thereto to the left also.
Fig. 5-37

Other attachments
There are various other attachments than the sideshifter

that may be used with. All attachments are operated by
the auxiliary cylinders that are connected to the AUX1
and AUX2 section blocks of the control valve. The
number and type of the auxiliary cylinders used for each
attachment may vary.

5-3-3 Forks service
A. Forks alignment
After you make sure the carriage is correctly adjusted

(See Section 5-3-9 C), adjust the forks as follows:
1. Fully lower the carraige, and then use the tilt

lever to make the top surface of the forks parallel
with the ground.
2. Measure the distance from the forks’ heels to the

ground.
 The heels must be within 7 mm (0.28 in) of a
level surface.
Fig. 5-38
3. Raise the carriage to a good height and lay a
straight bar on the higher fork as shown in Fig. 5-
39.
4. Measure the vetical distance from the surface of

the lower fork to the straight bar.
 The measurement should fall within 3 mm
(0.12 in) if the forks are 1,500 mm (59 in) or
shorter, and 4 mm if they are longer than 1,500
mm (59 in). Replace damaged forks. Fig. 5-39
NOTICE: Since the forks are made from a strong elastic

material, forcing them into position will only yield
temporary results before they return to their original
position.

B. Forks removal and installation
(1) Latch ass’y
Forks
(2) Sideshifter
Fig. 5-40 5

1. Disassemble latch ass’y (1) or pin.
2. Slide the fork to the center of the sideshifter and

remove it.
3. Repeat the steps above for the other fork.

install the forks.
NOTICE: During disassembly, inspect the forks and fork

mounts and replace any components that may be
damaged, cracked, or excessively rusty.

5-3-4 Sideshifter service
A. Sideshifter and cylinder removal/installation

(4) Sideshift cylinder
(3) Bracket
(1) Bolt
(2) Shim
(5) Pin
(6) Pin
(4-1) Port
(9) Washer
(10) Bolt
(8) Shim
(7) Bar
Fig. 5-41
DANGER
Preliminary steps
1. Raise the carriage and position a wooden block

underneath it.
2. Lower the carriage onto the wooden block and

fasten a hoist to the load backrest.
3. Remove the forks (See Section 5-3-3 B).
Fig. 5-42

Sideshifter body removal
1. Give hoses and ports (1) a corresponding mark

as a reference for assembly.
2. Disconnect hoses from ports (4-1) and then plug

and cap them.
3. Remove shim (2) bracket ass’y (3) after

unscrewing bolts (1).
4. Remove bolts (10) and washers (9), and then

shim (8) and bar (7).
5. Remove the sideshifter from the carriage.
Sideshift cylinder removal
1. After removing two pins (5), pull out pin (6) and,
supporting sideshift cylinder (4), remove it.
Reassembly

install the sideshifter body and sideshift cylinder.

B. Attachment hydraulic lines removal/installation
(1) Bolt
(2) Hose sheave
(3) Bracket
(4) Bracket ass’y

Hose A
(4) Bracket ass’y
(5) Hose sheave
(4-1) Bolt
View A
Hose B
(6) Bracket
(7) Connector
(8) Bracket
(11) Sideshift cylinder

(9) Pipe ass’y
Hose C
Hose D
(10) Regulator
(10) Regulator
Fig. 5-43

DANGER
Preliminary steps
1. Prepare an oil pan
Procedure
1. Remove brackets (3) from the side of the mast.
2. Disconnect hose A at connector (7) and pipe

ass’y (9) and drain the oil into the pan.
 After removing hose A, plug its ends to prevent
debris and foreign material from entering the
hydraulic system.
3. Unscrew bolt (1), dismount hose sheave (2), and

lay hose A to one side.
4. Remove brackets (7) and (6).
5. Disconnect hose B at pipe ass’y (9) and

regulator (10) and drain the oil into the pan.
5
 After removing hose B, plug its ends to prevent

hydraulic system.
6. Remove pipe ass’y (9).
7. Unscrew bolts (4-1), dismount bracket ass’y (4)

with hose sheave (5) and hose B intact.
8. Disconnect hoses C and D at regulator (10) and

at sideshift cylinder (11) and drain the oil into the
pan.
9. Dismount regulator (10).

install the attachment hoses.

Maintenance Manual.

C. Sideshift cylinder disassembly/assembly
Tube
Piston ass’y
(5) Nut
(6) Seal
Piston
(3) O-ring Rod

(4) Back up ring
Head
(2) Seal
(1) Seal
Head ass’y
Fig. 5-44

Vise
Tools needed
Claw-type spanner wrench
Preliminary steps
1. Remove the sideshift cylinder (See Section 5-3-4

A).
Procedure
1. Position the sideshift cylinder in a vise and

remove the rod ass’y using a claw-type spanner
wrench.
2. Remove head ass’y.
3. Remove wiper seal (1).

 Install with lip facing outside head.
4. Remove U-cup (2).
5. Remove O-ring (3)

 Install so curved side of back up ring contacts.
6. Remove back up ring (4).
7. Remove bolt (5)..
8. Remove piston ass’y.

5
9. Remove seal (6).

assemble the sideshift cylinder.
NOTICE: Once you have completely assembled the

cylinder, make sure you reseal the ports with the dust cap
and plugs.

5-3-5 Chains service
A. Chain wear check
Tools needed Chain wear gauge
Finding chain pitch
To check chain wear, the chain pitch must be found first:
1. Lift the carriage enough to put tension on the lift

chains.
2. Put the stationary pointer of gauge (1) against

the upper pin of chain link (2).
3. Put the sliding pointer against the lower pin of

chain link (2).
4. Make sure to line the two pointers at the same

position on both pins to get an exact reading.
5. Hold the sliding pointer in position and read the Fig. 5-45
scale on gauge (1) to find out the chain pitch.

Checking chain wear
Once you have found the chain pitch, start wear check:
1. Put the sliding pointer over one of the three

boxes at the bottom of the scale of gauge (1).
2. Put the window of the pointer over the square

that contains the chain pitch found above.
3. Hold gauge (1) against the other side of the lift

chain again with the stationary pointer against
the upper pin of one of the chain links.
Fig. 5-46
4. With the full length of gauge (1) against lift chain
(2), move the sliding pointer until it is aligned with
the upper pin of another chain link, keeping the
window of the pointer over the correct square
found in step 2.
 The colored line next to the white line on the
sliding pointer is the chain wear indication.
Each color stands for a degree in chain wear:
Green is 1%, orange 2%, red 3%, and blue 4%.
5. If the chain wear indication is 2% or greater,

replace the lift chain.
WARNING
An indication of 2% chain wear or
higher can lead to serious injury.
Do not operate the forklift if this reading
5
is higher than 2%.

B. Chain tension check
(2-1) Locknut
(2-3) Locknut
(1-1) Lift chain
(1-3) Secondary lift chain
(1-2) Free lift chain
(2-3) Locknut
[ STD ] [ FFL / FFT ]

Fig. 5-47

For safe operation, the tension of each pair of chains on
the mast should be the same.
Chains for STD
1. Raise the carriage to put weight on lift chains (1-1).
2. Push lightly on both of lift chains (1-1) with your

hand to check the tension.
 If their tensions are uneven, follow the
adjustment procedure below.
3. With the carriage raised, position blocks

underneath.
4. Lower the carriage onto the blocks so that

Fig. 5-48
tension is released from the chains.
5. Tighten or untighten locknuts (2-1) at both sides

of the carriage to increase or decrease the chain
tensions as needed.
6. Put Loctite #242 on the threads of locknut (2-1)

after the adjustment is completed.
Chains for FFL/FFT
1. Perform the same precedure for STD on free lift chains

(1-2) and make adjustments with locknuts (2-2).
2. After fully raising the carriage, raise the mast 5

even further to apply tension to secondary lift

chains (1-3).
3. Push lightly on both of secondary lift chains (1-3)

with your hand to check the tension.
 If their tensions are uneven, follow the
adjustment procedure below.
4. With the inner mast raised, position blocks

underneath.
5. Lower the inner mast onto the blocks so that

tension is released from the chains.
6. Tighten or untighten locknuts (2-3) at both sides

of the carriage to increase or decrease the chain
tensions as needed.
7. Put Loctite #242 on the threads of locknut (2-1)

after the adjustment is completed.

C. Chain removal/installation
(1) Chain sheave ass’y
(2) Retaining ring
(3) Nut
(6) Chain sheave ass’y

(5) Retaining ring
(7) Nut
(4) Split pin

[Secondary lift chains]
(8) Split pin
[Free lift chains]

Fig. 5-49

Tools needed Pliers
Free lift chain removal
1. Unscrew chain anchor nuts (7) and then remove

the chain anchor from the free lift chain sheave
together with the chains and put them all to one
side.
 Installation torque: 270 ± 40 N·m (200 ± 30
lb·ft)
2. Remove split pin (5) from the behind of the lower

panel of the carriage using the pair of pliers.
3. Remove retaining ring (5) and then dismount

chain sheave ass’y (6).
4. Perform the steps above for the other side.
Secondary lift chain removal
1. Unscrew chain anchor nuts (3) and then remove

the chain anchor from the secondary lift chain
sheave together with chains and put them all to
one side.
 Installation torque: 270±40 N·m (200 ± 30 lb·ft)
5
2. Remove split pin (4) from the inner mast using
the pair of pliers.
3. Remove retaining ring (2) and then dismount

chain sheave ass’y (1).
4. Perform the steps above for the other side.
Free/secondary lift chain installation

install the chains.
2. Check that the chains have the correct tension

(See Section 5-3-5 B).

5-3-6 Tilt cylinders service
A. Tilt cylinder alignment
WARNING
Mast can fall and crush, causing
serious injury.
After you have finished adjusting,
ensure the cylinder rod is installed
securely in the clevis.
NOTICE: Cylinders which are out of alignment will cause

extra stress in the mast assembly and the mast hinge
area. To ensure the cylinders are aligned, follow the
steps below:
Preliminary steps
Before you start the adjustment, check if:
• Both cylinders stop evenly at the end of the tilt

back and tilt forward strokes;
• Both cylinders extend and retract evenly;
• Both sides of the mast are not twisted;
• The tilt angles of the mast when tilted fully forward

and backward fall within the specifications stamped
on the truck’s identification plate (To measure them,
use a tilt indicator or protractor); and
• The difference in length between the cylinder rods

when fully extended is within 3.18 mm (0.125 in).
 If any of the conditions are not met, follow the
steps bellow to adjust the alignment of your tilt
cylinders.

Procedure
1. Tilt the mast fully forward.
2. Loosen nut (2) that holds the cylinder rod in

clevis (1).
3. Twist the rod out of or into the clevis to achieve

the correct length for both cylinders.
 For tilt cylinders that include the tilt back
limiting group option, you will need to move Fig. 5-50
spacer (5) back before you can adjust the rod.
4. Install nut (2) and tighten it to a torque of 95±15

N·m (70±10 lb·ft).
 Perform the following steps only if the tilt
cylinders on your vehicle include the tilt back
limiting group option.
5. Tilt the mast fully back.
6. Install shims (4) so there is no gap left between

spacer (5) and head (6).

B. Tilt cylinder drift test
WARNING
Unexpected movement of the mast or
carriage can crush and cause
serious injury.
Use wood blocks and clamps to hold the mast in
position, and keep your hands and feet clear of
any moving parts.
Preliminary steps
1. Ensure that the chains tension is equal and that

the tilt cylinders are properly aligned.
2. Raise the mast 762 mm (30 in) and use blocks

and clamps to hold the mast in this position.
3. Check the mast hinge bolts to make sure they

are tight.
4. Remove the blocks and clamps and lower the

762 mm (30 in)
mast
Fig. 5-51

Procedure
1. Position a load equal to the vehicle’s rated load

capacity on the forks
2. Run the forklift through a complete lift and tilt

cycle until the oil is at normal temperature for
operation 45 to 55 °C (113 to 131 °F).
3. Put the mast in a vertical position.
4. Raise a rated load capacity to a height of 2.5 m

(8.2 ft).
 In the case of vehicles with less than 2.5 m
(8.2 ft) height extension, raise the load as high
as the vehicle is capable.
5. Place a tape measure between the cylinder tube Measurement
and head and measure how far the rod extends

(cylinder stroke) as the mast drifts forward over a
ten minute period. Fig. 5-52
 Drift should not exceed 35.5 mm (1.40 in). If
drifting exceeds this amount, it is possible that
you have a hydraulic leak at the cylinders or
control valve.

C. Tilt cylinder removal/installation
(1) Port
(5) Bearing
(4) Pin
(3) Grease nipple
(2) Bolt
(4)
(6) Bushing (2)
(3)
Fig. 5-53

DANGER
CAUTION
The tilt cylinders can drop and crush
causing injury.
Support the tilt cylinder before you
perform the following procedure.
Preliminary steps
1. Prepare a hoist and tie straps to both sides of the
top of the mast ass’y.
Procedure
1. Mark hoses and ports (1) as a reference for
assembly.
2. Disconnect hoses from ports and plug and cap
them.
5

3. Remove bolt (2) and washer from the chassis
end of the cylinder.
 Installation torque: 105 N·m (77 lb·ft)
4. Remove grease nipple (3).
5. Remove pin (4).
6. Remove bearing (5).
7. Repeat steps 2–6 for the mast end of the cylinder,
and remove bushing (6) that covers the pin
8. Remove the tilt cylinder.
install the tilt cylinder.
Maintenance Manual.

D. Tilt cylinder disassembly/assembly
Fig. 5-54

Vise
Tools needed
NOTICE: During disassembly, be careful not to damage
the highly finished surface of the cylinder rod and the
bore of the cylinder body.
1. Position the tilt cylinder in a vise and remove the

rod ass’y using a claw-type spanner wrench.
2. Remove eye (1) by loosening nut (2) and bolt (3).

3. Remove head ass’y.
4. Remove DU bushing (4).

5. Remove seal (5).

9. Remove seal (9).
5
 Install with lip facing inside head.
10. Remove nut (10).


11. Remove piston ass’y
12. Remove slipper seal (11).
NOTICE: Once you have completely assembled the tilt

cylinder, make sure you reseal the ports with dust cap.

5-3-7 Primary lift cylinders service
A. Primary lift cylinder removal/installation
The FTL/FFT primary lift cylinders have a similar removal and installation procedure. The illustration
used for this section is the FFT.
(1) Hose sheave ass’y
(1-1) Bolt
(2) Clamp
(3) Hose
(4) Primary cylinder
(5) Clamp
(2) Hose
(6) Flow protector
Fig. 5-55

DANGER
Preliminary steps
1. Remove the carriage (See Section 5-3-9 B).
2. Fasten a hoist to the primary cylinder.
Procedure
1. Remove clamp (5).
2. Lean primary cylinder (4) forward using the hoist

and then disconnect it from flow protector (6),
draining the oil from primary cylinder (4) and
hose (3) to the pan.
3. Once you have drained the oil, plug and cap
5
primary cylinder (4) and hose (3) to prevent
hydraulic system.

4. Disconnect hose (3) from the hose that connects
with the control valve.
5. Remove clamp (2).
6. Unscrew bolts (1-1) and remove hose sheave

ass’y (1) together with hose (3) and flow
protector (6) intact.

install the primary cylinder.

Maintenance Manual.

B. Primary lift cylinder disassembly/assembly
The FFL and FFT primary cylinders have similar disassembly and assembly procedures. The
illustration used for this section is of the FFL primary cylinder.
Fig. 5-56

Vise
Tools needed
1. Position cylinder tube in a vise.
2. Remove rod ass’y using a claw-type spanner

wrench.
 Sealant: Loctite #262
3. Remove cover ass’y.

 Before you install the cover ass’y, inject 100 cc
of hydraulic oil into the tube at the rod cover
end.
4. Remove stopper (1).
5. Remove wiper (2).
6. Remove packing (3).
9. Remove piston ass’y
10. Remove check valve (6).
11. Remove retaining ring (7). 5

12. Remove slipper seal (8).

13. Remove wear ring (9).

assemble the primary cylinder.

cylinder, make sure you reseal the ports with dust cap.

5-3-8 Standard/secondary cylinders service
A. STD/SEC lift cylinder air removal
DANGER
procedure, and never remove bleed
screws completely (See Section 5-2-3).
WARNING
Forks will fall and can crush when
the bleed screws are loosened.
Keep your body away from the mast,
carriage and forks.
After the standard lift cylinder has been disassembled

and assembled, it may be necessary to remove the air
(bleed) from the cylinder.
1. Run the lift cylinders through one complete cycle

without any load.
2. With the forks on the floor, check the oil level in

the hydraulic tank and fill it to the full mark if not
full already.
3. Run the lift cylinders through four complete

cycles without any load.
4. Lift the forks high enough that weight is applied

all stages of the lift cylinders.
5. Locate the setscrew on each lift cylinder and

slowly open them no more than one turn.
6. Repeat Steps 4 and 5 until there are no air

bubbles at the setscrews.
7. Tighten the setscrews to a torque of 5 to 7 N·m

(4 to 5 lb·ft) once all the air is removed.
8. Fill the hydraulic tank to the full mark.

Fig. 5-57
9. Run lift cylinders through one last cycle.
10. Repeat steps 3 through 9 if the mast does not

operate smoothly.

B. Kick adjustment
To adjust the lift cylinder kick:
1. Adjust the outer chains so their tensions are

equal.
2. Raise the mast fully.

 If the mast does not kick to either side, no
shims are required. If the mast does kick to
one side, follow the steps below to shim the lift
cylinder.
3. Remove bolt (2) and, tilting the cylinder Fig. 5-58

forward,.add shims (1) as needed.
 The total number of shims must not exceed
three.
4. Reinstall the cylinder.
5. Adjust the outer chains so their tensions are

equal.
6. Raise the mast and check if either side of the

mast still kicks.
7. Repeat the procedure until the mast does not

kick, adding 3 mm (0.12 in) of shims (1) at the
most.

C. STD/SEC lift cylinder drift test
WARNING
Unexpected movement of the mast or
carriage can crush and cause
serious injury.
Use wood blocks and clamps to hold
the mast in position, and keep your
hands and feet clear of any moving
parts.
Preliminary steps
1. Ensure that the chain’s tension is equal and the

tilt cylinders are properly aligned.
2. Raise the mast 762 mm (30 in) and use blocks

and clamps to hold the mast in this position.
3. Check the mast hinge bolts to make sure they

are tight.
4. Remove the blocks and clamps and lower the 762 mm (30 in)
mast.
Fig. 5-59

Procedure
1. Position a load equal to the vehicle’s rated load

capacity on the forks.
2. Run the forklift through a complete lift and tilt

cycle until the oil is at the normal temperature for
operation (45–55 °C, 113–131 °F).
4. Raise a rated load capacity to a height of 2.5 m

Measurement
(98.4 in).
 In the case of vehicles with less than 2.5 m
(98.4 in) height extension, raise the load as
high as the vehicle is capable.
5. Place a tape measure on the lift cylinder and

measure how far the rod retracts (cylinder stroke)
as the carriage drifts downward over a ten
minute period. Fig. 5-60
 Drift should not exceed 100.0 mm (3.94 in). If

drifting exceeds this amount, it is possible that
you have a hydraulic leak at the cylinders or
control valve.

D. STD/SEC lift cylinder removal/installation
The illustration below is of the STD mast; the procedure is similar for all STD/FFL/FFT mast types.
(1) Plate ass’y
(2) U bolt ass’y
(3) Secondary/standard lift cylinder

LH RH
[Mounting Gp Lift - STD]
(4) Hose ass’y
Fig. 5-61

DANGER
Preliminary steps
1. Remove the chains (See Section 5-3-5 C).
3. Remove the primary lift cylinder (See Section 5-

3-7 A).
4. Remove the mast (See Section 5-3-10 A).
5. Lay the mast on a flat ground
Procedure
1. Disconnect hose ass’y (4) from the cylinder port

at one side and then drain the oil to the pan.
2. After removing hoses ass’y (4), plug each port to

prevent debris and foreign material from entering 5
the hydraulic system

3. Remove U bolt ass’y (2).
4. Remove plate ass’y (1) and dismount lift cylinder

(3).
5. Repeat the steps above for the other lift cylinder.

install the lift cylinders.

Maintenance Manual.

E. STD/SEC lift cylinder disassembly/assembly
STD lift cylinder
Fig. 5-62

Vise
Tools needed Hex wrench

1. Position standard lift cylinder in a vise.
2. Remove screws (1) and steel balls using a hex

wrench.
 At installation, inject 100 cc hydraulic oil into
the head before mounting the steel balls.
 Installation torque: 6±1 N·m (4±0.7 lb·ft)
3. Remove head ass’y using a claw-type spanner

wrench.
4. Remove U-packing (2).

 Install with lip facing outside.
5. Remove dust wiper seal (3).
7. Remove glyd ring (5). 5


10. Remove rings (8).

assembly the STD lift cylinder.
NOTICE: Once you have completely assembled the lift

and plugs.

FFL/FFT secondary lift cylinder
The FFL and FFT lift cylinders have a similar disassembly and assembly procedure. The illustration
used for this section is of the FFT.
Tube
Rod
Piston ass’y
(12) Snap ring
(11) Ring cushion
Piston Head ass’y
(8) Wear ring

(9) Snap ring
(6) Back up ring
(10) Ring
(7) O-ring
(1) Screw
Head
(5) Glyd ring
(4) U-packing
(3) Back up ring
(2) Dust wiper
Fig. 5-63

Vise
Tools needed
1. Position the secondary cylinder in a vise.
2. Remove screws (1) and steel balls using a hex

wrench.
 At installation, inject 100 cc hydraulic oil into
the head before mounting the steel balls.
 Installation torque: 6±1 N·m (4±0.7 lb·ft)
3. Remove cylinder rod ass’y with a claw-type

spanner wrench.
4. Remove dust wiper seal (2)

6. Remove U-packing (4).
7. Remove glyd ring (5).
8. Remove back up ring (6)

5
10. Remove the piston ass’y.

11. Remove wear rings (8).
13. Remove ring (10).
14. Remove ring cushion (11).

assembly the secondary FFL/FFT cylinders.

and plugs.

5-3-9 Carriage service
A. Carriage and mast height adjustment
2. Lower the carriage fully.

 The bottom of the inner mast on FFL and FFT
lift models must be even with the bottom of the
outer mast.
3. Measure the distance from the bottom of the

inner upright to the bottom of carriage bearing
(A).
 If your measurement of (A) does not match
those in the table below, adjust the chains
(See Section 5-3-5 B) and repeat this Fig. 5-64
procedure.
Height of carriage roller extrusion

STD FFL FFT
-6 mm 8 mm 8 mm
(-0.2 in) (0.3 in) (0.3 in)
B. Carriage removal/installation
DANGER
Preliminary steps
1. Remove bolts (1) and washers, and then remove

load backrest.

(1) Bolt
Fig. 5-65

3. Raise the carriage and position a wooden block
underneath it.
4. Lower the carriage onto the wooden block and

fasten a hoist to it
5. Remove the sideshifter (See Section 5-3-4 A).
7. Disconnect the chains connected tha carriage

from the inner mast.
Fig. 5-66
Procedure
1. Disconnect all hoses from the carriage ports (2),

and cap and plug them together
come out of the hoses and ports.
Fig. 5-67
2. Remove stop bolt (3) and the retainers under the
bolt.
[Clearance a] (3) Stop bolt [STD]
 As shown in Fig. 5-68, for the STD mast, stop
bolt (3) is installed on the foreside of the inner Carriage stopper [STD]
mast; for the FFL and FFT masts, it is on the
5
Inner mast upper stay [FFL/FFT]
rear side of the carriage.
[Clearance a]
 If stop bolt (3) is worn or damaged, replace it. (3) Stop bolt [FFL/FFT]
 At installation, adjust the number of the
retainers to obtain a 4.0 to 6.0 mm (0.16 to

0.24 in) overlap between bolt (3) and carriage Fig. 5-68
stopper [STD] or inner mast upper stay
[FFL/FFT].
3. Raise inner mast high and slide out carriage (5)

downwards.
4. Follow the opposite steps above to install the

carriage.
Fig. 5-69

C. Carriage roller bearings adjustment
(3) Shims
(4) Bearing
(2) Retainer
(1) Screw
Roller bearing ass’y
(5) Bolt
(6) Thrust washer
(7) Pin
(11) Roller
(10) Bushing (8) Shims

(9) Washer
Side roller bearing ass’y

Fig. 5-70
You can adjust the clearance between the mast channel
and carriage rollers by adding or removing shims. All six
carriage roller bearings can be shimmed using the same
procedure.
Before and during adjustment:
• Make sure all parts are clean
• Check all parts for wear and replace those that are
worn.
• Perform the procedure one roller bearing set at a

time.
Preliminary steps
Upper and lower roller bearing adjustment
1. Remove screw (1).

2. Remove retainer (2).
3. Remove roller bearing ass’y (3 to 4).

4. Separate shims (3) from roller bearing (4).
5. If you are installing new roller bearings, refer to

the table below to choose those roller bearings
(4) which will help achieve “minimum clearance”
(clearance b) between the bearing and channel
leg for the full length of the mast; make sure you
use the same bearing in all six locations.
Part no. Bearing size Bearing O.D.*

D580006 Undersize 98.5mm (3.88 in)
D580007 Standard 99.0mm (3.90 in)
D580008 Oversize 99.5mm (3.92 in) (3) Shims (4) Upper/lower roller bearing
* Permissible tolerance ± 0.08 mm (0.003 in)
6. Measure across the width of the inner mast with

a ruler to find the narrowest point.
7. At this point, install shims (3) behind the [Clearance b]
upper/lower carriage roller bearings (4) at both (2) Retainer (1) Screw
sides until there is “zero clearance” between the
A-A Section
inner mast and the bearings.
 Make sure an equal amount of shims is Fig. 5-71
installed for each corresponding side.
 Torque for screw (1): 34±7 N·m (25±5 lb·ft)
Side roller bearing adjustment
1. Unscrew bolts (5) and remove side roller bearing

ass’y (6 to 11).
5

2. Install shims (8) on bolt connections at both ends
of pin (7) to achieve “minimum clearance”
(clearance c) between side roller bearings (11)
and the inner mast.
3. Reinstall side roller bearing ass’y (6 to 11). (8) Shims
(7) Pin [Clearance c]
(11) Side roller

bearing (5) Bolt
(9) Washer (9) Washer
B-B Section
Fig. 5-72

5-3-10 Mast service
A. Mast removal/installation
The STD, FFL and FFT mast ass’ies have a similar disassembly and assembly procedure. The
illustration used for this section is the FFT.
(3) Pin ass’y

(2) Bolt
(1) Hose
Bushing
Grease nipple
(4) Bolts
Fig. 5-73

DANGER
WARNING
The tilt cylinders can drop and crush
causing injury.
Support the tilt cylinder before you
perform the following procedure.
Preliminary steps
2. Remove the carriage (See Section 5-3-9 B)
3. Remove primary lift cylinder (See Section 5-3-7
A).
Procedure
5
1. Disconnect hose (1), and cap and plug it.
come out of the hoses
2. Remove bolt (2) and washer.

3. Remove pin ass’y (3).
4. Lean the mast assembly forward 8° using the
hoist
NOTICE: Loosen the tension of the straps connected to
the hoist when you tilt the mast forward. Straps that are
too tight can cause the mast assembly to slide off when
bolts (4) are removed.
5. Remove bolts (4)
6. Remove the mast assembly using the hoist
install the mast.
Maintenance Manual.

B. Mast disassembly/assembly and roller bearing adjustment
(4) Shim
(3) Pad
(2) Bushing
(1) Pin
(7) Shim
(6) Bearing
(5) Snap ring
Fig. 5-74
Preliminary steps
1. Remove mast ass’y (See Section 5-3-10 A).
2. Remove priamry and secondary (standard) lift

cylinders and their hydraulic hoses (See
Sections 5-3-7 A and 5-3-8 D).

Disassembly
1. Hammer out mounting pins (1) on both sides of

the outer mast.
2. Check the condition of the bushings (2) inside

the mounting pin bore and replace them if too
worn.
3. Spread the masts apart so that all the roller

bearings are visible.
4. Remove all pads (3) and shims (4) and mark

them as a reference for assembly
5. Give each mast roller bearing ass’y a mark that

corresponds to its location on its mast.
6. Remove snap rings (5) and then remove mast

roller bearings (6) along with shims (7).
 Disassemble the mast roller bearings and
inspect the condition of mast roller bearings (6),
replacing any that are worn or damaged as
explained in the assembly procedure.
 For those bearings in good condition, clean
their parts, reassemble them, and then put
them to one side until installation.
7. Separate and mark shims (7) as a reference for
5
assembly.
8. Separate the masts from each other using a

hoist.

(4) Shim
(3) Pad
(2) Bushing
(1) Pin
(7) Shim
(6) Bearing
(5) Snap ring
Fig. 5-75
Assembly and roller bearing adjustment
For STD and FFL you need to perform the following steps
once with the inner and outer masts; and twice for FFT—
firstly with the intermediate and outer masts and secondly
with the inner and intermediate masts.
Before and during adjustment:
• Make sure all parts are clean
• Check all parts for wear and replace those that are
worn.
• Perform the procedure one roller bearing set at a

time.
1. Joint all the masts from each other using a hoist.

2. If you are installing new roller bearings, refer to
(7) Shims
the table below to choose those roller bearings [Clearance b]
(6) which will help achieve “minimum clearance”
(clearance a) between the bearing and channel (6) Bearing
[Clearance a]
leg for the full length of the mast; make sure you
use the same bearing for the right and left side of
the mast location you are adjusting. [Clearance a]
[Clearance b]
Part no. Bearing size Bearing O.D.* [Clearance a]
D580006 Undersize 98.5 mm (3.878 in) [Clearance b]
D580007 Standard 99.0 mm (3.898 in) (6) Bearing (7) Shims

D580008 Oversize 99.5 mm (3.917 in) [Clearance a]
[Clearance b]
* Permissible tolerance ± 0.08 mm (0.003 in) Fig. 5-76

3. Within the section from the bottom of the wider
mast to the bottom of the channel lap (the area
where the masts overlap when fully extended),
measure across the width of the wider mast with
a ruler to find the narrowest point.
4. At this point, install 0.5 mm (0.02 in) or 1.0 mm (0.04

in) shims behind each roller bearing on both lower
outside ends of the narrower mast until they have
“zero clearance” (clearance b), securing bearing (6)
with snap ring (5). Fig. 5-77
NOTICE: Make sure the bearings are installed at the
correct locations by checking the marks you them, with
an equal amount of shims for each corresponding side.
5. Shim bearings (6) at both inside ends of the

(4) Shims / (3) Pad [Clearance c]
wider mast in the same way to ensure “zero
clearance” (clearance b) there as well.
6. Use a hoist to fit the narrower mast inside the

(7) Shims [Clearance b ]
[Clearance b]
5
wider mast.

7. Make sure all roller bearings (6) are properly
shimmed by rolling the narrower mast inside of (6) Bearing
the wider mast and moving it from side to side.
8. If clearance is detected or if the roller bearings (6) (6) Bearing

are shimmed too tight, pull out the narrower mast
from the wider mast with a hoist, adding or (7) Shims [Clearance b]
removing 0.5 mm or 1.0 mm shims as needed. (4) Shims / (3) Pad [Clearance c]
When the bearings have been shimmed correctly, Fig. 5-78
move on to the next step.
9. Install shims behind each pad (6) until there is “a

maximum of 0.80 mm (0.031 in) clearance” (clearance
c) between the pad and the narrower mast with the
mast ass’y at full extension. When the pads have been
shimmed correctly, move on to the next step.
NOTICE: Make sure an equal amount of shims is

installed for each side.
10. Install mounting pins (1) on both sides of the

wider mast.

5-4 Troubleshooting
[Hydraulic cause]
There is an air leak, which lets air into the hydraulic system
on the inlet side of the hydraulic pump.
The relief valve opens at low oil pressure.
The hydraulic pump has too much wear.
The hydraulic system does not lift The load is not correct (too heavy).
the load.
[Mechanical cause]
The mast is not in alignment with the other lifting components
and does not move freely.
Not enough lubricant on the parts of the mast that move.
The carriage or mast rollers (bearings) are worn and do not
move (seized).
[Hydraulic cause]
Not enough oil supply to lift cylinder.
Defective lift cylinder seals.
[Mechanical cause]
Lift cylinder extends too slowly. The mast is not in alignment with the other lifting components
Not enough lubricant on the parts of the mast that move.
move (seized)
[Hydraulic cause]
Air in the hydraulic system.
Relief valve sticks or defective.
Mast does not move smoothly
[Mechanical cause]
Not enough lubricant on the parts of the mast that move
Load rollers (bearings) defective or not adjusted correctly.
[Electrical cause]
Nor to supply the electric power to solenoid valve in lift
section of control valve.
A broken solenoid valve in lift section of control valve.
Mast does not lower completely or [Hydraulic cause]

Lift poppet (lift lock) damaged and contaminated
does not lower at all.
[Mechanical cause]
Lift cylinder damaged or bent.
Load roller defective (bearing) or not adjusted correctly.
Not enough lubricant on the parts of mast which that moves.

[Electrical cause]
The electric switch (on-off) below a seat damaged.
The electric parts (relay and controller) related to a solenoid
Safety lift lock doesn’t work. valve in lift section of control valve damaged.
[Hydraulic cause]
Lift poppet (lift lock) damaged and contaminated.
Needle valve is loosened.
[Hydraulic cause]
There is an air leak, which lets air into the hydraulic system
on the inlet side of the hydraulic pump.
The relief valve opens at low oil pressure.
The mast does not tilt correctly or The hydraulic pump has too much wear.
moves too slowly.
The internal valve of the tilt spool is stuck.
Control valve tilt spool has a restriction
[Mechanical cause]
Damage or failure of the piston rods on the tilt cylinders.
[Hydraulic cause]
There are restrictions in the lift line.
The lift spool in the control valve has a restriction caused by
foreign material and does not operate freely.
The lift cylinder flow control valve has a restriction.
Lift cylinders excess flow protectors have a restriction.
The carriage does not lower
correctly.
Air in the hydraulic system. 5
[Mechanical cause]
The mast is not in alignment with the other lifting components

Carriage chains need an adjustment.
Not enough lubricant on the part of the mast that moves.
move (seized).
The valve spools do not hold their positions because the
springs for the valve spools are weak or broken.
Control valve leakage caused by worn valve spools.
The lift or tilt cylinders do not hold
their position with the valve control The check valve or flow control valves in the control valve are
levers in neutral position. bad.
Leakage of the cylinder lines or piston seals.
There is foreign material in the control valve.

6 Steering System
6-1 Overview........................................................2
6-1-1 Components............................................................2
6-1-2 Oil flow ....................................................................4
6-2 Steering control group .................................6

6-2-2 How it works............................................................8
6-2-3 Steering system air removal .................................15
6-2-4 Steering system pressure check...........................16
6-2-5 Steering wheel cover removal/installation ............18
6-2-6 Steering wheel removal/installation ......................19
6-2-7 Steering wheel column removal/installation .........20
6-2-8 Steering unit disassembly/assembly ....................22
6-3 Steering operation group [B15/18/20T (TL)] ...

...........................................................24
6-3-2 How It works .........................................................26
6-3-3 Steer angle sensor removal/installation................28
6-3-4 Rear wheel and hub
6-3-5 Steer axle spindle
6
removal/installation/disassembly/assembly .............32
6-3-6 Steer axle housing ass’y disassembly/assembly..34
6-4 Steering operation group [B16/18/20X] ....36

6-4-1 Exterior and specifications ....................................36 Steering system
6-4-2 How it works..........................................................38
6-4-3 Steer angle sensor ................................................40
6-4-4 Rear wheel and hub
6-4-5 Steer axle removal/installation ..............................44
6-4-6 Link ass’y removal/installation ..............................46
6-4-7 Steering knuckle, king pin, and bearing
removal/installation ...............................................47
6-4-8 Steering cylinder
removal/installation/disassembly/assembly ...........48

6-1 Overview
6-1-1 Components
CONTROLLING GROUP
Steering wheel
Steering cylinder
Steering column
Steer axle
Steering unit
Load-sensing line
Rear wheel
ACTUATOR GROUP [ B15/18/20T, B18/20TL ]

Pump motor
Priority valve Hydraulic tank
Main hydraulic pump
Steer axle
Steering cylinder
Rear wheel
ACTUATOR GROUP [ B16/18/20X ]

Fig. 6-1

The steering system is a group of devices to steer the
vehicle to the left or right. In this model, the steering
system is hydraulically operated, consisting of a control
group and an actuator group:
• Control group determines the speed and direction

of steering and accordingly supplies hydraulic oil to
the operation group. This group includes a steering
wheel and a steering unit. [Section 6-2]
• Operation group converts hydraulic power

transmitted from the control section via hydraulic
oil into a mechanical power to steer the rear
wheels. This group includes a steering cylinder,
steer axle, and two rear wheel assemblies.
[Section 6-3]
Unlike automobiles, forklifts use their rear wheels as

steer wheels because their priority lies not in driving
speed but in securing a wider steering angle in a narrow
place. For models B15/18/20T-7 and B18/20TL-7, the
rear wheels are positioned at very close distance to each
other at the center of the vehicle’s rear to achieve an
even wider steering.
6
Steering system

6-1-2 Oil flow
Fig. 6-2

Main pump (1) sends oil through priority valve (3) to
steering unit (2) in proportion to the speed at which the
steering wheel is turned. This valve is defaulted to supply
oil to steering unit (3) first, and then main control valve (5).
Steering unit (3) uses a built-in spool splined to the

steering wheel to regulate the oil within the unit according
to the movement of the steering wheel.
Neutral position
When the steering wheel is in the neutral position,

steering unit (3) sends less pressure via the load sensing
line, and the spool of priority valve (2) is moved to the
neutral position, allowing a substantial amount of oil from
main pump (1) to travel to main control valve (5).
Turning
When the steering wheel is in a right or left position, an

increased load sensing pressure shifts the spool of
priority valve (2) to send oil to steering unit (3). During a
right turn, steering unit (3) sends the supplied oil to the
left side of steering cylinder (4). Once the oil reaches this
cylinder, it acts on the cylinder and moves its piston to
the right. The return oil from this cylinder drains back to
hydraulic tank through steering unit (3).
During a left turn, the same process takes place, only the
oil acts on the right side of steering cylinder (5) instead of
6
the left.
Pressure relief
Steering system
The relief valve in steering unit (3) opens when the
steering pressure rises above 10,3 MPa (1,493 psi).

6-2 Steering control group
Fig. 6-3
Steering control group 6-6 B15/18/20T, B18/20TL, B16/18/20X-7

Steering wheel Part no. 900141-00836
Part no. D512926
Max. impact pressure 17.2 MPa (2,489 psi)
Rated flow 22.7 l/min

Steering unit
Displacement 50 cc/rev
12.7–13.7 kPa (0.9–1 lb·ft)

Input torque
at 60 rpm
Relief valve pressure 10.3–10.8 MPa (1,493–1,564 psi)
6
Steering system
B15/18/20T, B18/20TL, B16/18/20X-7 6-7 Steering control group

6-2-2 How it works
A. Steering control mechanism
Fig. 6-4
Once steering wheel (1) is turned, the spool inside

steering unit (2) also turns via the steering wheel column
that is splined between them. Turning the spool leads to
the steering unit regulating the amount of oil discharged
to the steering cylinder in the following ways:
• Control section (A), depending on the direction to

which the steering wheel is turned, this section
determines which side of the steering chamber the oil
will be assigned to and then delivers the oil supplied
from the hydraulic pump to metering section (B).
Once it passed metering section (B), the oil returns
back to control section (A) to exit through either left
turn port (2-1) or right turn port (2-2) according to the
turning direction of the steering wheel.
• Metering section (B) works as a small pump,

controlling the amount of oil the unit sends to the
steering cylinder. The turning angle of the vehicle
increases in proportion to the amount of oil sent to
the steering cylinder, which is determined by the
steering wheel’s rotational speed.
Oil discharged from left turn port (2-1) flows to the right of
steering cylinder (3), pushes the cylinder to the left, and
turns rear wheels (5) to the left. Oil discharged from right
turn port (2-2) flows the other way round and turns rear
wheels (5) to the right. For more information on the
cylinder and wheel’s different operations, see Section 6-
3-2 [BT model] and Section 6-4-2 [BX model].

B. Neutral position
Steering cylinder
(A) Control section (B) Metering section
(3) Outlet
(2) Sleeve (4) Check valve (5) Inlet
(7) Stator
Steering unit
(1) Spool (6) Rotor
10.3 MPa
(8) Centering spring
(13) Drive
(9) Pin (11) Right turn port
(10) Left turn port (12) Housing T
Priority valve
P
Fig. 6-5
When the steering wheel is in neutral, oil grooves (21) of

spool (1) and oil holes (20) of sleeve (2) are not aligned
to each other and thus oil that reaches sleeve (2) is not
able to enter spool (1), or the steering cylinder as a result.
Therefore, as the rear wheels can neither make a left nor 6
right turn, the vehicle drives straight.
Steering system
Fig. 6-6
In addition, low pressure oil fed from the priority valve
results in a weakened push of the check valve in inlet (6)
and thus only a small amount of the pumped oil passes
through this valve to the steering unit. This amount fills
the inside of the steering unit and enables it to respond
quickly to the steering wheel’s demands.

C. Left turn
Steering cylinder
PUMP OIL
METERED OIL:
RETURN OIL
(11) Right turn port
(10) Left turn port
(3) Outlet (5) Inlet Steering unit
(14) Passage
(15) Passage
(16) Gerotor
(1) Spool
10.3 MPa
(9) Pin (2) Sleeve (17) Passage

T
Priority valve
P
Fig. 6-7
When the steering wheel is turning
As spool (1) is splined to the steering wheel, turning the

steering wheel makes spool (1) and its engaged pin (9)
and drive (13) turn also. Sleeve (2) is also engaged with
pin (9), but pin hole (19) in sleeve (2) has a larger diameter
than pin (9) itself; so for some time after spool (1) starts
rotating, sleeve (2) does not spin as shown in Fig. 6-8.
Accordingly oil holes (20) and oil grooves (21) that were
not aligned with each other in neutral now are, and the
Fig. 6-8
pumped oil outside sleeve (2) flows into spool (1). Then
this oil flows out through the following two paths:
• Load sensing line  priority valve: The

pressurized oil gives a pilot signal to the priority
valve to supply more highly pressurized oil to the
steering unit. Then this highly pressurized oil
overcomes the resistance of the check valve’s
Fig. 6-9
spring inside inlet (5) and flows into the steering unit.

• Passage (15)  metering section (B): Except for
the small amount of pilot pressure oil travelling in
the load sensing line, all pressurized oil flows
through passage (15) to metering section (B).
Splined to drive (13), gerotor (16) in metering
section (B) turns together with the steering wheel
to pump the oil inflow. This pumped oil is
discharged through oil passage (17) to left turn port
(10) and then to the right chamber of the steering
cylinder. The oil that enters the right chamber
pushes the piston to the left, turning the vehicle to
the left. Steering speed increases in proportion to
the amount of oil discharged and the rate at which
it is pumped, which is determined by the steering
wheel’s rotational speed. Because of the
pressurized oil supply from the priority valve as
mentioned above, the pressurized oil keeps flowing
in via this passage as long as the steering wheel is
turning, increasing the steering angle until the
steering cylinder reaches its limit.
When the steering wheel stands still
Once the operator stops turning the steering wheel, spool

(1), pin (9), drive (13), and stator (7) also stop turning,
and centering spring (8) returns spool (1) and sleeve (2)
back to their original positions. The pilot signal that was
sent to the priority valve through the load sensing line
then stops and only a small amount of pressurized oil is
supplied. Even this small amount is not able to enter
spool (1) nor can the oil inside spool (1) enter into
metering section (B) through passage (15). The oil in
6
metering section (B) is not pumped out to left turn port
Steering system
(10) either, because the steering wheel no longer turns. Fig. 6-10
Thus all oil flow stops and the steering angle of the
wheels is maintained.

D. Right turn
Steering cylinder
PUMP OIL
METERED OIL
RETURN OIL
(10) Left turn port (5) Inlet
(3) Outlet (11) Right turn port Steering unit
(14) Passage
(15) Passage
(16) Gerotor
(1) Spool
10.3 MPa
(8) Centering
spring (9) Pin (2) Sleeve (13) Drive (17) Passage
T
(4) Check valve
Priority valve
P
Fig. 6-11
When the steering wheel is turning
As spool (1) is splined to the steering wheel, turning the

steering wheel makes spool (1) and its engaged pin (9)
and drive (13) turn also. Sleeve (2) is also engaged with
pin (9), but pin hole (19) in sleeve (2) has a larger diameter
than pin (9) itself; so for some time after spool (1) starts
rotating, sleeve (2) does not spin as shown in Fig. 6-12.
Accordingly oil holes (20) and oil grooves (21) that were
not aligned each other in neutral now are, and the pumped
oil outside sleeve (2) flows into spool (1). Then this oil Fig. 6-12
flows out through the following two paths:
• Load sensing line  priority valve: The

pressurized oil gives a pilot signal to the priority
valve to supply more highly pressurized oil to the
steering unit. Then this highly pressurized oil
overcomes the resistance of the check valve’s
spring inside inlet (5) and flows into the steering
unit. Fig. 6-13

• Passage (17)  metering section (B): Except for
the small amount of pilot pressure oil travelling in
the load sensing line, all the pressurized oil enters
flows through passage (17) to metering section (B).
Splined to drive (13), gerotor (16) in metering
section (B) turns together with the steering wheel
to pump the oil inflow. This pumped oil is then
discharged through oil passage (15) to right turn
port (11) and then to the right chamber of the
steering cylinder. The oil that enters the right
chamber pushes the piston to the left, turning the
vehicle to the right. Steering speed increases in
proportion to the amount of oil discharged and the
rate at which it is pumped, which is determined by
the steering wheel’s rotational speed. Because of
the pressurized oil supply from the priority valve as
mentioned above, the pressurized oil keeps flowing
in via this passage as long as the steering wheel is
turning, increasing the steering angle until the
steering cylinder reaches its limit.
When the steering wheel stands still
Once the operator stops turning the steering wheel, spool

(1), pin (9), drive (13), and stator (7) also stop turning,
and centering spring (8) returns spool (1) and sleeve (2)
to their original positions. The pilot signal that was sent to
the priority valve through the load sensing line then stops
and only a small amount of pressurized oil is supplied.
Even this small amount is not able to enter spool (1) nor
can the oil inside spool (1) enter into metering section (B)
through passage (17). The oil in metering section (B) is
6
not pumped out to right turn port (11) either because the
Steering system
steering wheel no longer turns. Thus all oil flow stops and Fig. 6-14
the steering angle of the wheels is maintained .

E. Relief
Steering cylinder
Steering unit
Spool
To relieve excessive pressure
10.3 MPa
Spool Priority valve

P
Fig. 6-15
Once the hydraulic oil fed to the steering cylinder reaches
the set pressure (10.3 MPa, 1,493 psi), a relief function is
triggered to lower the pressure to ensure safety.
As shown in Fig. 6-15, when the pumped oil pressure

exceeds the force of the spring, the spool is pushed
against the spring to allow the pressurized oil to exit the
steering unit to the hydraulic tank until its pressure falls
below the spring’s pressure setting.

6-2-3 Steering system air removal
WARNING
Driving the vehicle when there is air
in the steering system may result in a
crash.
Make sure air has been completely
removed from the system before driving
the vehicle.
If you have recently replaced a steering component or if
any part of the steering system has been opened, it may
be necessary to bleed the system.
Preliminary steps
1. Turn the motor off and wait for the vehicle to cool
2. Put a rated load capacity on the forks shift the

weight on the steer axle to the front of the vehicle.
3. Turn the steering wheel full lock to the left.
4. Fill the hydraulic tank to the full mark with the

appropriate oil (for details, see Section 1-6-2 Oil
specifications).
5. Check the hosing connections, hoses, and seal

fittings for openings where air might be let in to
the system, and replace those faulty parts.
Procedure
1. Have a partner keep an eye on the oil level in the
6
reservoir while you turn the steering wheel slowly
from lock to lock.
NOTICE: Do not turn the steering wheel too quickly as
Steering system
this will overflow the reservoir.
2. As you turn the steering wheel, have your
partner replenish the hydraulic tank with
hydraulic oil as the level drops.
NOTICE: Do not let the oil level in the hydraulic tank fall
below the pump outlet port.
 If the level does not drop immediately, this
could mean there is a large bubble in the
system; oil will not pass through until the
bubble passes.
3. Repeat the previous step 15–20 times until the

oil level remains consistent, and the oil is clear
(i.e. not cloudy) and free of bubbles.
 If you perform the steps above and you are still
able to see bubbles, repeat the procedure.

6-2-4 Steering system pressure check
DANGER
severe burns and infection, which
may even result in amputation.
Release the pressure from the steering
system by turning the wheels back and
forth before you perform the following
procedure.
If the steering system does not work correctly, check the

hydraulic tank for the correct oil level and the hoses and
connections for leakage. If all these items are correct,
use the pressure gauge to check the steering hydraulic
system and its relief pressure setting.
Preliminary steps
1. Check the hydraulic tank is at the full mark.
2. Check hosing connections, hoses, and seal

fittings for opening
DANGER
Checking the lines for pressurized
hydraulic oil leaks by hand can lead
to serve infection, which may even
result in amputation.
and check for leaks using a piece of
cardboard.
3. Turn the motor and the disconnect off.
Procedure
1. Remove plug from port (1) and connect a 28,000
kPa (4,000 psi) gauge as shown in Fig.6-16.
2. Turn the key switch to the ON position and

activate the hydraulic controls until the oil is at
the temperature for normal operation. (1) Port
3. Turn the rear wheels left or right against the stops

and record the indication on the pressure gauge.
 The indication on the pressure gauge is the
pressure at which the priority valve’s relief valve is Fig. 6-16
opened—10.340–10.840 kPa (1,500–1,570 psi).

4. Use the flowchart below to find out the
appropriate action for your pressure reading.
5. After making the necessary adjustments, repairs,

or replacements repeat steps 1–6 again to
ensure you have the correct pressure reading.
Pressure level check
Yes Are you still Yes

Is the Pressure
experiencing
value correct?
problems?
Check the steering system’s

No mechanical connections for
No failure and make the necessary
repairs and adjustments.
See step 2
Is the pressure
value
Yes See step 2
approximately
correct?
Check the steering unit for

hydraulic failure and make the
necessary repairs and
adjustments.
No
Is the pressure
value
Yes
See step 2
6
excessively
Steering system
high or low?
Replace the priority valve and its

components.
No
Check the steering cylinder for

hydraulic failure and make the See step 2
necessary repairs and
adjustments.
See step 5

6-2-5 Steering wheel cover removal/installation
Fig. 6-17
1. Loosen 10 screws (1) and remove the washer,
cover (2-1 to 2-4), and key switch (3).

install the cover.

6-2-6 Steering wheel removal/installation
(1) Cap
(2) Nut
(3) Washer
(4) Steering wheel ass’y
(5) Horn switch
Fig. 6-18
1. Remove cap (1) from the steering wheel.
2. Remove nut (2) and washer (3) from the steering 6

wheel.
Steering system
3. Remove knob (4).
4. Remove horn switch (5).
5. Remove the steering wheel ass’y using a

suitable puller.

install the steering wheel cover.

6-2-7 Steering wheel column removal/installation
Fig. 6-19
Danger
procedure (See Section 6-2-4).
1. Remove four hose assemblies (1) and load

sensing line (2) from steering unit (8).
NOTICE: As a reference for assembly mark the hoses

and then plug and cap each port to prevent debris and
foreign material from entering the hydraulic system.

2. Loosen four bolts (4) and four washers (5) from
the steering column ass’y and remove the
steering unit (8).
NOTICE: If you do not hold the steering unit when

loosening bolts (4), steering unit (8) may fall to the floor
and be damaged.
3. Pull out cotter pin (6) and then remove steering

column ass’y (9–12) while removing pin (8).
4. Remove retaining ring (10), and then remove

yoke (11) and gas spring (9).

install the steering column.
6
Steering system

6-2-8 Steering unit disassembly/assembly
(31) Plug
(30) Washer
(29) Fixed plug
(28) Spring
(25) Spring seat and ball assembly
(24) Ball seat
(23) Retaining ring
(22) Seal gland bushing
(21) Dust seal
(27) Spool (20) O-ring
(1) Housing
(26) Bushing
(17) Check valve ball

(16) Check valve pin
(15) Cap seal
(14) Bearing set
(13) Spool
(12) O-ring
(19) Check valve ball
(11) Distributor
(18) Threaded bush
(10) O-ring
(9) Shaft
(8) Spacer
(7) Inner gear
(6) Outer gear
(5) O-ring
(4) End cover

(3) Washer
(2) Bolt
Body disassembly/assembly Fig. 6-20
1. Mark housing (1) as a reference for assembly,

and then remove fittings and lines
2. Remove seven bolts (2) and washers (3).

 One of the bolts is a special bolt. Mark off its
position with a pin.
 At assembly, tighten bolts (2) in the sequence
shown in Fig. 6-21 to a first torque of 14.1±2.8 2nd 7th
N·m (3.0±2.1 lb·ft), and then tighten them to a
second torque of 28.2±2.8 N·m (20.8±2.1 lb·ft). 4th 5th
3. Remove end cover (4), O-ring (5), outer gear (6), 6th
inner gear (7), and spacer (8).

1st 3rd
4. Remove shaft (9), O-ring (10), and distributor

plate (11). Fig. 6-21
 At assembly, make sure to engage the groove

of shaft (9) with the pin of spool assembly (13).

6. Remove spool assembly (13), and remove

bearing set (14) and cap seal (15) from the
assembly.
7. Remove check valve pins (16) and balls (17).
8. Remove threaded bush (18) and check valve ball

(19).
9. Pry retaining ring (23).
10. Remove seal gland bushing (22) and O-ring (20),

and remove dust ring (21) from the bushing.
11. Remove three sets of plugs (31), washers (30),

fixed plugs (29), and springs (28).
12. Remove spools (27) and bushing (26).
13. Remove spring seat and ball assemblies (25)

and ball seats (24).

assemble the steering unit.
Spool ass’y (13) disassembly/assembly
1. Remove the pin from the spool ass’y.
2. Pull the spool partially from the control end of the

sleeve, then remove the centering springs
6
carefully.
3. Push the spool back out of sleeve by rotating it

slowly.
4. Follow the steps above in the opposite order to Steering system

Fig. 6-22
assemble the spool ass’y.

6-3 Steering operation group [B15/18/20T (TL)]
A. Steer axle ass’y
Fig. 6-23
Items Spec.
190104-00126 (Solid Soft)
Part no. 190104-00128 (Cushion)
190104-001230 (Wide)
Output torqe 688.6 N·m at 7,400 kPa (507.9 lb·ft at 1,073 psi)
Piston area 28.27 cm2 (4.38 in2)
Pitch radius 33.02 mm (1.3 in)
Piston stroke (90°turn) 51.82 mm (2.04 in)
Volume (180°turn) 292.9 ml
Steering operation group [B15/18/20T (TL)] 6-24 B15/18/20T, B18/20TL, B16/18/20X-7

B. Steer sensor
Fig. 6-24
Characteristics Items Spec.

Part no. 301308-00553
Input voltage
Current consume
DC 12±0.2 V
10 mA
6
Electrical and Independent linearity ±3%
Steering system
mechanical Electrical angle 300±1°
Mechanical angle 360°
Service life 3 million cycles min (1 cycle = ±90°
)
Operating temp. -30 to +80 ℃(-86 to +176 ℉)
High temp. exposure 100 ℃(212 ℉) 96 Hr
Low temp. exposure -40 ℃(104 ℉) 96 Hr
Water resistance JIS D0203 S1
Environmental
Humidity 60 ℃(140 ℉), 90–95% RH, 500 Hr
10G, 50–250 Hz, 12 Hr
Vibration
each direction of X, Y, and Z
Shock 30G
B15/18/20T, B18/20TL, B16/18/20X-7 6-25 Steering operation group [B15/18/20T (TL)]

6-3-2 How It works
A. Steer axle operation
Neutral position
When steering wheel (1) is in neutral, steering unit (2)

discharges oil neither to left turn port (2-1) nor to right
turn port (2-2). Therefore pistons (3-1) stay at the center
to keep the wheels straight.
Fig. 6-25
Left turn
When you are turning steering wheel (1) to the left,

steering unit (2) discharges oil through left turn port (2-1).
Accordingly, as oil fills the right chamber of steering
cylinder (3), the oil in the left chamber is discharged to
steering unit (2), and thus both pistons (3-1) and rack
gear (3-2) are pushed to the left. The shift of rack gear (3-
2) to the left causes pinion gear (4), which it is engaged
with, to spin together with steering wheel (5) in the
direction shown in Fig. 6-26, turning the vehicle to the left.
Fig. 6-26
Right turn
When you are turning steering wheel (1) to the right,

steering unit (2) discharges oil through the right turn port
(2-2). Accordingly, as oil fills the left chamber of the
steering cylinder (3), the oil in the right chamber is
discharged to steering unit (2), and thus both pistons (3-1)
and rack gear (3-2) are pushed to the right. The shift of
rack gear (3-2) to the right causes pinion gear (4), which
it is engaged with, to spin together with steering wheel (5)
in the direction shown in Fig. 6-27, turning the vehicle to
the right.
Fig. 6-27

B. Steer sensor operation
Fig. 6-28
The steer sensor monitors the angle at which the rear
wheels are turned and report it to the controller in real
time.
Powered from the left motor controller at 12 V, this

sensor signals with a voltage which ranges from 9 V to 0
V in inverse proportion to the rear wheels’ turning angle (-
150° to 150°).
6
The controller then converts this analog signal into angle
data and shares the converted data across the CAN
network: this data is then displayed on the instrument
panel and also used to control the electrical system in
Steering system
accordance with the settings of a number of parameters.

6-3-3 Steer angle sensor removal/installation
Preliminary steps
1. Open the counterweight top cover (See Section

7-4).
Removal
1. Disconnect the cable of steer angle sensor (5).

remove sensor-bracket ass’y (5 to 6), clip (7),
hose (8), and clip (9).
3. Remove screw (1), washer (2), and then detach

sensor (5) from bracket (6).
Installation
1. Turn the rear wheels to make them straight.
2. Measure the resistance between P1 and P2, or

Fig. 6-29
P2 and P3 of the steer angle sensor connector.
 The resistance should read 2.6 ± 0.1 kΩ.
3. If the resistance meets specification, then follow

the steps above in the opposite order to install
the steer angle sensor.
4. Perform sensor initial setting using the EasyView

application (See the Steering Set menu in
Section 2-6-4).

6-3-4 Rear wheel and hub adjustment/removal/installation
A. Rear wheel bearing adjustment
Tools needed: Torque wrench
Procedure (single wheel)
1. Slowly tighten nut (1) to a torque of 100 N·m (74 (2) Bearing
lb·ft).
(1) Nut
2. Turn the wheel at least one full rotation to secure
bearing (2) in the correct position.
3. Loosen nut (1) completely and then tighten it (3) Loco washer
again to a torque of 45 ± 3 N·m (33 ± 2 lb·ft).

Fig. 6-30
4. Bend forward the tabs of lock washer (3) to

secure it.
Procedure (double wheel)
1. Slowly tighten nut (1) to a torque of 133 N·m (98

lb·ft).
2. Turn the wheel at least one full rotation to secure

bearing (2) in the correct position.
3. Loosen nut (1) completely and then tighten again

to a torque of 45 to 55 N·m (33 to 41 lb·ft).
6
4. Bend forward the tabs of lock washer (3) to
secure it.
Steering system

B. Rear wheel and hub removal/installation
(9) Bolt
(8) Hub
(11) Seal (7) Bearing

(10) Bearing (6) Tongue washer
(5) Lock washer
(4) Nut
(3) Wheel cap
(2) Rear wheel

(1) Nut
Fig. 6-31
Floor jack
Tools needed
Torque wrench
Preliminary steps
1. Raise the rear of the vehicle using a floor jack

and support it with wooden blocks.
2. Turn the rear wheels as much as 90 degrees as

shown in Fig. 6-31..
Rear wheel removal/installation
1. Remove nuts (1) that are connected with bolts

(9).
2. Remove rear wheel (2).

install the wheel.
Rear wheel hub removal/installation
1. Remove wheel cap (3).
2. Clean hub ass’y (8) and make sure it is free of

grease.
 At installation, fully lubricate the inside of hub
ass’y (8).
3. Bend the tabs of lock washer (5) and then

remove nut (4) using a torque wrench.

4. Remove lock washer (5).
 At installation, perform the wheel bearing
adjustment procedure in the previous section.
5. Remove tongue washer (6) and the cone of

bearing (7) from hub (8).
6. Remove hub (8).
7. Remove the cups of bearing (7) and bearing (10)

from both sides of hub (8).
 At installation, lubricate the cups’ contact
surfaces with Multipurpose Grease.
8. Remove the cone of bearing (10) from the

vehicle.

install the wheel hub.
6
Steering system

6-3-5 Steer axle spindle removal/installation/disassembly/assembly
Fig. 6-32

Tools needed Floor jack
Preliminary steps
1. Remove both rear wheels and keep the rear of

the vehicle supported with wooden blocks (See
Section 6-3-4 B).
Procedure
1. Loosen bolts (1) and remove washers (2).

2. Remove spindle ass’y (3).

install the spindle ass’y.
6
Steering system

6-3-6 Steer axle housing ass’y disassembly/assembly
Fig. 6-33
Preliminary steps
1. Remove the steer sensor (See Section 6-3-3).
2. Remove the steer axle spindle (See Section 6-3-5).
Housing ass’y removal/installation
1. Disconnect overflow hose (7) and two steer

hoses (16).
2. Remove three pairs of bolts (8) and washers (9)

fastened to the front/back of the housing ass’y.
 Installation sealing: Loctite #262
3. Remove housing ass’y (10).

reinstall the housing ass’y.
Top plate and shim removal
1. Loosen bolt (1) and remove top plate (3).
2. You may loosen bolt (4) and remove shaft (2)

from plate (3) if needed.
3. Remove shim pack (22) from pinion gear (23).

Top plate and shim installation
1. Install top plate (3), and tighten bolts (1) to a
torque of 55 ± 10 N·m (41 ± 7 lb·ft) and then
loosen them again.
2. Measure distance (Y) from the surface of
housing (10) to the top of pinion gear (23) and
distance (X) from the surface of housing (10) to
the top of bearing (6). After you’ve recorded your
measurement, calculate the difference between
the two distances (X - Y).
3. Referring to the table below, determine the
required thickness of shims (22) according to the
value of (X – Y), and install them.
No. of shims 1 2 3 4
Thickness 0.05 0.125 0.35 0.75
mm, (in) (0.002) (0.005) (0.014) (0.030)
4. Reinstall top plate (1) and fasten bolt (1) to a
torque of 45±7 N·m (33 ± 5 lb·ft).
Main body disassembly/assembly
1. With the housing upside down, remove pinion gear (23).
 At assembly, with the rack gear (11) in the
center, install pinion gear (23) so that the “TOP”
hole is in the position shown in Fig. 6-34.
2. Remove the cone of bearing (20) from pinion
gear (23).
remove cap (17) and O-ring seal (15) at each side.
 Installation torque: 55 ± 10 N·m (40 ± 7 lb·ft).
Fig. 6-34
4. Remove rack gear piston ass’y (11 to 14).
5. Remove seal (9) and the cone and cup of bearing (6).
6. Remove seal (21) and the cup of bearing (20)
6
from housing (10).
Steering system
assemble the body of the housing ass’y.
Piston-rack gear disassembly/assembly
1. Remove friction ring (12-3) from each piston (12-4).
remove both piston ass’ies and rack gear (11).
 Installation torque: 55 ± 10 N·m (40 ± 7 lb·ft)
 Apply lubricant NLGI #2 to rack gear (11).
3. Remove O-ring seal (12-1) and seal (12-2).
 At assembly, lightly apply Loctite #592 to
where the two seals touch in the piston.
assemble the piston rack gear ass’y.

6-4 Steering operation group [B16/18/20X]
A. Steer axle ass’y
Fig. 6-35

Part no. 190104-00093
Steer axle
Cramp angle 86°
Part no. A165090
Steering Use pressure 7.8 MPa (1,138 psi)
cylinder Test pressure 15.7 MPa (2,276 psi)
Allowable stroke 87±1.0
Steering operation group [B16/18/20X] 6-36 B15/18/20T, B18/20TL, B16/18/20X-7

B. Steer sensor
Fig. 6-36
Characteristics Items Spec.

Part no. 301308-00553
Input voltage
Current consume
DC 12±0.2 V
10 mA
6
Electrical and Independent linearity ±3%
Steering system
mechanical Electrical angle 300±1°
Mechanical angle 360°
Service life 3 million cycles min (1 cycle = ±90°
)
Operating temp. -30 to +80 ℃(-86 to 176 ℉)
High temp. exposure 100 ℃(212 ℉) 96 Hr
Low temp. exposure -40 ℃(104 ℉) 96 Hr
Water resistance JIS D0203 S1
Environmental
Humidity 60 ℃(140 ℉), 90–95% RH, 500 Hr
10G, 50–250 Hz, 12 Hr
Vibration
each direction of X, Y, and Z
Shock 30G
B15/18/20T, B18/20TL, B16/18/20X-7 6-37 Steering operation group [B16/18/20X]

6-4-2 How it works
A. Steer axle operation
Neutral position
When steering wheel (1) is in neutral, steering unit (2)

discharges oil neither to left turn port (2-1) nor to right
turn port (2-2). Therefore piston (3-1) stays at the center
to keep the wheels straight.
Fig. 6-37
Left turn
When you are turning steering wheel (1) to the left,

steering unit (2) discharges oil through left turn port (2-1).
Accordingly, as oil fills the right chamber of steering
cylinder (3) the oil in the left chamber is discharged to
steering unit (2), and thus piston (3-1) and the rods in
both sides; links (4-1), which are connected to these rods;
and knuckles (4-2) are all pushed to the left. As a result,
knuckles (4-2) and rear wheels (5) turn on the axis of
both the ends of steer axle (4) as shown in Fig. 6-38,
turning the vehicle to the left.
Fig. 6-38
Right turn
When you are turning steering wheel (1) to the right, the
steering unit (2) discharges oil through right turn port (2-
2). Accordingly, as oil fills the left chamber of steering
cylinder (3) the oil in the left chamber is discharged to
steering unit (2), and thus piston (3-1) and the rods in
both sides; links (4-1), which are connected to these rods;
and knuckles (4-2) are all pushed to the right. As a result,
knuckles (4-2) and rear wheels (5) turn on the axis of
both the ends of steer axle (4) as shown in Fig. 6-39,
turning the vehicle to the right
Fig. 6-39

B. Steer sensor operation
Fig. 6-40
The steer sensor monitors the angle at which the rear
wheels are turned and reports it to the controller in real
time.
Powered from the left motor controller at 12 V, this

sensor signals with a voltage which ranges from 9 V to 0
V in inverse proportion to the rear wheels’ turning angle (-
150° to 150°).
6
The controller then converts this analog signal into angle
data and shares the converted data across the CAN
network: this data is then displayed on the instrument
panel and also used to control the electrical system in
Steering system
accordance with the settings of a number of parameters.

6-4-3 Steer angle sensor
Removal Fig. 6-41
1. Remove two screws (1) and washers (2).
2. Remove sensor (3) from the steer axle.
3. Remove plate (4).
Installation
1. Turn the rear wheels to make them straight.
2. Measure the resistance between P1 and P2, or

P2 and P3 of the steer angle sensor connector.
 The resistance should read 2.6 ± 0.1 kΩ.
3. If the resistance meets specification, then follow

the steps above in the opposite order to install
the steer angle sensor.
4. Perform sensor initial setting.
5. Perform sensor initial setting using the EasyView

application (See the Steering Set menu in
Section 2-6-4).

6-4-4 Rear wheel and hub adjustment/removal/installation
A. Wheel bearing adjustment
Tools needed Torque wrench
Procedure (2) Bearing

(3) Lock
1. Tighten nut (1) slowly to 133 N·m (98 lb·ft).
(1) Nut
2. Spin the wheel at least one full rotation to put
bearings (2) into position.
3. Loosen nut (1) completely and then tighten it

again to a torque of 45–55 N·m (33–41 lb·ft).
4. Bend lock washer (3) over nut (1) to hold it in

Fig. 6-42
position.
6
Steering system

B. Rear wheel and hub removal/installation
(9) Bolt
(8) Washer
(11) Seal (7) Bearing
(10) Bearing (6) Tongue washer
(5) Lock washer
(4) Nut
(3) Wheel cap
(2) Rear wheel (1) Nut

Fig. 6-43
Floor jack
Tools needed
Torque wrench
Preliminary steps

2. Turn the rear wheels as much as 90 degrees as

shown in Fig. 6-43.
Rear wheel removal/installation
1. Remove nuts (1) that are connected with bolts (9).
2. Remove rear wheel (2).

install the wheel.
Rear wheel hub removal/installation
1. Remove wheel cap (3).
2. Clean hub ass’y (8) and make sure it is free of

grease.
 At installation, fully lubricate the inside of hub
ass’y (8).
3. Bend the tabs of lock washer (5) and then

remove nut (4) using a torque wrench.

4. Remove lock washer (5).
 At installation, perform the wheel bearing
adjustment procedure in the previous section.
5. Remove tongue washer (6) and the cone of

bearing (7) from hub (8).
6. Remove hub (8).
7. Remove the cups of bearing (7) and bearing (10)

from both sides of hub (8).
 At installation, lubricate the cups’ contact
surfaces with Multipurpose Grease.
8. Remove the cone of bearing (10) from the

vehicle.

install the wheel hub.
6
Steering system

6-4-5 Steer axle removal/installation
(1) Steer hoses
Steer axle ass’y

(5-2) Support (rear)
(6-2) Bushing (rear)
(7-2) Shims (rear)
(3-2) Spring washer (rear)

(2-2) Mounting bolt (rear)
(4-2) Grease nipple (rear)
(6-1) Bushing (front)
(5-1) Support (front)
(7-1) Shims (front)
(4-1) Grease nipple (front)
(3-1) Spring washer (front)
(2-1) Mounting bolt (front)
Fig. 6-44

Tools needed Floor jack
Preliminary steps

 Make sure the blocks are under the vehicle
frame, not the axle, so that the vehicle may
stay raised even after the floor jack.
2. Remove both rear wheels (See section 6-4-4 B).
Procedure
1. Disconnect steer hoses (1) and plug and cap

them together with their ports.
2. Loosen rear mounting bolts (2-2) until

approximately two bolt threads are left in the
mounting boxes.
3. Lower the steer axle onto the heads of rear bolts

(2-2) with the floor jack.
4. Loosen front mounting bolts (2-1) and remove

washers (3-1) and support (5-1).
 Installation torque: 270±40 N·m (199 ± 30 lb·ft)
5. Slide the steer axle out of rear support (5-2), and

then remove the axle.
 Steer axle weight: 64 kg (141 lb)
6
6. You may remove front/rear grease nipple (4),
bushing (6), and shims (7) if needed.
 Shims (7) are to offset the gap between Steering system
front/rear supports (5) the steer axle.
 At installation, pay attention to the direction of
grease nipples (4) and pack (inject) sufficient
grease.

install the steer axle.

6-4-6 Link ass’y removal/installation
In the illustration below, the axle covers are removed in order to show necessary components. In the
actual procedure, however, you may access those components without removing the covers by
steering the rear wheels to either side.
(1) Split pin
(2) Link [top]

(4) Bearing
(3) Washer
(5) Knuckle
(6) Washer
(7) Link [bottom]
(8) Washer
(9) Nut
(10) Snap pin
Fig. 6-45
1. Pull out snap pins (10), loosen nuts (9), and then
remove washers (8), bottom link (7), and
washers (6).
2. Remove split pins (1), top link (2), washers (3),

and bearing (4).

install the link ass’y.

6-4-7 Steering knuckle, king pin, and bearing removal/installation
Fig. 6-46
Preliminary steps
1. Remove the rear wheel and hub (See Section 6-
6
4-4 B).
2. Remove the link ass’y (See Section 6-4-6).
Steering system
Procedure
1. Remove grease fittings (1), retaining rings (2),

and plugs (3) from the top and bottom.
2. Loosen nut (8) and pull out bolt (6).
3. Pull out king pin (9) and remove knuckle (7),

thrust bearing (5), and shims (10).
4. Remove needle bearings (4) from the steer axle.

install the steering knuckle, king pin, and bearing.

6-4-8 Steering cylinder removal/installation/disassembly/assembly
A. Steering cylinder removal/installation
Fig. 6-47
Preliminary steps
1. Remove the steer axle (See Section 6-4-5).
2. Remove both link ass’ies (See Section 6-4-6).
Procedure
1. Remove bolts (1) and washers.
2. Pull steering cylinder (2) to either side to remove

it.

install the steering cylinder.

B. Steering cylinder disassembly/assembly
Preliminary steps
1. Remove the steer cylinder.
Procedure
Perform the following steps for both ends of the cylinder
1. Mark the position of the rod cover on the steering

Fig. 6-48
tube as a reference for installation.
2. Remove rod cover ass’y.
3. Remove the rod from the cylinder tube.

 Plate the rod with hard chrome before
installing.
4. Remove dust wiper (1) and U-packing (2) from

the front side of the rod cover ass’y.
5. Remove O-ring (3) and DU-bushing (4) from the

6
back side
6. Remove retaining ring (6) from the piston ass’y Steering system
on the cylinder rod.
7. Remove piston ass’y from the cylinder rod.
8. Remove O-ring (5) from the front side of the

piston.
9. Remove slipper seal (7) and O-ring (8).

assemble the steering cylinder.
 Seal the port with a dust cap once you have
finished assembling.
 Adjust the rod’s stroke so that it reaches a
maximum of 87±1.0.

6-5 Troubleshooting
Priority valve (if equipped) releases pressure oil at a low

setting
Pump oil pressure is low, worn pump.
Steering gear covers are too tight.
Too much force needed to turn
steering wheel. Steering column not aligned with steering gear.
Priority valve spool is held in one position.
Steering gear without lubrication.
Low fluid level in the hydraulic supply tank.
Steering gear covers are too tight.
Steering column is not in correct alignment.
Steering wheel does not return to
center position correctly. Valve spool in the steering gear has a restriction.
Priority valve check valve permits lift and tilt hydraulic oil to
affect hydraulic circuit.
Loose hose connections.
Oil leakage at the pump.
Bad shaft seal.
Low oil level.
Priority valve (if equipped) relief valve spring weak.
Relief valve (priority valve) will not move from the open
Low oil pressure.
position.
Oil leakage inside or outside of the system.
Bad pump.
Air in the steering hydraulic circuit.
The pump has to much wear.
Pump makes noise when turning
the steering wheel and does not Loose connection of the oil line on the inlet side of the pump.
move smoothly.
The oil level in the hydraulic tank is low.
The oil level of the tank is low.
There is air in the steering system.
The pump operation is not correct.
Lift truck does not turn when
Dirt in the steering system.
steering wheel is slowly turned.
Steering gear operation is not correct.
Restriction in the steer axle linkage.
Steering cylinder has worn parts.

The temperature of the oil is too Air is mixed with the oil.
hot. The relief valve is set too high (priority valve).
There is a restriction in the return line circuit.
6
Steering system

7 Frame
7-1 Hood removal/installation ...........................2
7-2 Overhead guard removal/installation .........4
7-3 Floor plates removal/installation ................5
7-4 Top cover and counterweight

removal/installation .......................................6
7
Frame
7-1 Hood removal/installation
(5) Hoist
(4) Bolt
(2) Bolt
(3) Cylinder
(1) Harness connector
Fig. 7-1
Preliminary steps
1. Raise the hood and support it with a hoist.
Procedure
1. Disconnect harness connectors (1) for the seat.
2. Remove bolts (2) and washers from each support

cylinder (3) and then the cylinder rod from the
bracket.
WARNING
When the nuts are removed from the
support cylinder rod, the hood and
seat can fall and crush, causing
serious injury.
Support the seat and hood assembly
before removing the nut.
Hood removal/installation 7-2 B15/18/20T, B18/20TL, B16/18/20X-7

3. After closing the hood and removing the top rear
cover, remove two bolts (4) and washers on each
side.
4. Use a hoist (5) to remove the hood and seat

assembly.

install the hood.
7
Frame
B15/18/20T, B18/20TL, B16/18/20X-7 7-3 Hood removal/installation

7-2 Overhead guard removal/installation
(3) Hoist (1) Plastic cover
(5) Cap (2) Harness connector
(6) Bolt (4) Bolt
Fig. 7-2
1. After loosening the two bolts, remove plastic cover

(1) from the cowl.
2. Disconnect harness connectors (2) from the

instrument panel’s connectors.
3. Support overhead guard with lifting straps and a

hoist (3).
4. Remove bolts (4) and washer from the inside of the

front leg on each side.
5. Remove cap (5) from the rear leg on each side.
6. Remove bolts (6) and washer from the rear leg on

each side and remove the overhead guard.

install the overhead guard.
Overhead guard removal/installation 7-4 B15/18/20T, B18/20TL, B16/18/20X-7

7-3 Floor plates removal/installation
(3) Bolt (1-3) Left floor plate
(4) Washer
(1-1) Front floor plate
(1-4) right floor plate
(3) Bolt
(4) Washer
(3) Bolt
(4) Washer
(1-2) Rear floor plate

(2) Harness connector
Fig. 7-3
Many of the procedures in this manual require the
removal and installation of certain hydraulic/electrical
components. Removing the floor plates is one of the most
convenient ways to access them.
Preliminary steps
1. Remove the floor mat.
Front floor plate
1. Slightly raise front floor plate (1-1) and disconnect

the accelerator’s harness connector (2).
7
2. Remove front floor plate (1-1).
Frame

install the front floor plate.
Other floor plates
1. Remove bolt (3) and washer (4) that secure the floor
plate you wish to remove.
2. Remove the plate.

install the floor plate.
B15/18/20T, B18/20TL, B16/18/20X-7 7-5 Floor plates removal/installation

7-4 Top cover and counterweight removal/installation
Though the illustration below shows models B16/18/20X-7, models B15/18/20T-7 and B18/20TL-7
have a similar removal/installation procedure.
Fig. 7-4
WARNING
Removing the counterweight of a
loaded vehicle may cause the vehicle
to tip over to the front side.
Put the forks on a stable surface when
removing the counterweight.
Tools needed Forged eyebolts
Top cover removal/installation
1. Loosen bolts (1) and remove top cover (2).

install the top cover.
Top cover and counterweight removal/installation 7-6 B15/18/20T, B18/20TL, B16/18/20X-7

Counterweight removal/installation
1. Remove the steer axle joint parts:

 B15/18/20T and B18/20TL: Remove the steer
axle spindle (See Section 6-3-5), and
disconnect the three hoses from the steer axle
(See Section 6-3-6).
 B16/18/20X: Remove the mounting bolts and
caps from the steer axle (See Section 6-4-5).
2. Remove the battery (See Section 2-2-6).
3. Disconnect the cables from controller connectors (3).

 In the cases of models B15/18/20T and
B18/20T, you may disconnect the cable only
from the pump motor controller.
4. Loosen bolts (4) and washers.

5. Loosen bolts (6) and washers (5).
6. Install two forged eyebolts (7) at bolt holes and

attach a hoist.
7. Remove counterweight (2)

 Refer to the table below to confirm the weight
of your model’s counterweight. The weight
measurements represent the counterweight’s
net weight; you must take into consideration
the weight of other accessories.
Models Weight (kg) Weight (lb)

B15/18T-7 760 1,676
B20T-7 900 1,984
7
B18/20TL-7 750 1,653
B20T-7 588 1,296
B18X-7 671 1,479
Frame
B20X-7 850 1,874

install the counterweight.
B15/18/20T, B18/20TL, B16/18/20X-7 7-7 Top cover and counterweight removal/installation

8 Fingertip option
8-1 Overview........................................................2
8-1-1 Components and circuit ..........................................2
8-2 Fingertip extension module ........................4

8-2-2 Circuit configuration and key functions ...................5
8-2-3 Wiring ......................................................................6
8-2-4 Removal and installation.........................................7
8-3 Fingertip armrest unit ..................................8

8-3-1 Exterior view ...........................................................8
8-3-2 Circuit configuration and key functions ...................9
8-3-3 Wiring ....................................................................10
8-3-4 Hydraulic control knobs ........................................11
8-3-5 Forward/reverse switch.........................................12
8-3-6 Removal and Installation ......................................13
8-3-7 Disassembly and Assembly ..................................14
8-4 Fingertip control valve ...............................18

8-4-2 Wiring ....................................................................20
8-4-3 How it works..........................................................22
8-5 Fault diagnosis ...........................................32

8-5-1 Fault display ..........................................................32
8-5-2 Troubleshooting ....................................................33
8
Fingertip option
8-1 Overview
8-1-1 Components and circuit
To fingertip extension module
To F_CONN B of harness
To F_CONN A of harness
To control valve Solenoid A

To control valve Solenoid B
To control valve Solenoid C
To EM CONN of harness
To CAN CONN of armrest
To EM CONN of armrest
Fig. 8-1

Fig. 8-2
The fingertip option makes using the hydraulic controls
easier by replacing the levers with electronic knobs that
add a wide range of functionality, including automatic
control, diagnosis, and calibration.
For this option, the vehicle is equipped with the following

components:
• Fingertip extension module operates actuators

by sending electronic signals to the control valve
as the operator operates the knobs and carries out
various automatic controls based on parameter
settings. [Section 8-2]
8
• Fingertip arm rest unit provides electronic knobs
Fingertip option
instead of the mechanically operating hydraulic

levers, which can be operated using your fingers.
[Section 8-3]
• Fingertip control valve is an electronically

controllable hydraulic control valve that is equipped
with solenoids at both sides of the spool for each
section block. [Section 8-4]

8-2 Fingertip extension module
14 10
9 6
5 1
Fig. 8-3
Items Spec.
Item no. 300611-01010
Input Voltage 36 V/48 V
Electrical isolation to Heatsink 500VAC (minimum)
Storage Ambient Temperature Range -50 °C to +90 °C (-58 °F to +194 °F)
Operating Ambient Temperature Range -40 °C to +90 °C (-40 °F to +194 °F)
IP Degree (Dust & Water Proof) IP65
Weight 0.4 kg (0.9 lb)
Dimensions (W x L x H) 130 x 100 x 39 mm (5 x 4 x 1.5 in)
Fingertip extension module 8-4 B15/18/20T, B18/20TL, B16/18/20X-7

8-2-2 Circuit configuration and key functions
Fig. 8-4
The fingertip extension module connects the fingertip

armrest control knobs to the electrical system. Like the
three basic motor controllers, this module interacts with
several actuators to perform automatic control based on
parameter settings.
Connected to the other controllers and the instrument

panel via CAN, this module can exchange data and thus
you can perform diagnosis and calibration using the
panel or EasyView application.
8
Fingertip option
B15/18/20T, B18/20TL, B16/18/20X-7 8-5 Fingertip extension module

8-2-3 Wiring
The fingertip extension module uses a 14 pin AMP 14 10
connector (Fig 8-5).
9 6
5 1
Extension module connector

Fig. 8-5
Harness
Fig. 8-6
Fingertip extension module connector pins
Pin Wiring Pin Wiring
no. color no. color
F_CONN A (1) F_CONN A (2)
4 YL
F_CONN A (5) CAN CONN (4)
1 BK
1352 J1 (J1-2) F_CONN A (3)
5 YL/BK
CAN CONN (3) CAN CONN (1)
2 BK 1352 J1 (J1-1) 6 (N/A)
F_CONN A (6) 7 (N/A)
F_CONN A (2) 8 (N/A)
F_CONN A (3) 9 BR/YL CONN B (7)
3 RD F_CONN A (4) 10 WH CONN A (6)
F_CONN B (2) 11 BR CONN A (7)
F_CONN B (3) 12 VO CONN A (8)
F_CONN B (4) 13 OR CONN B (8)
14 WH/BK CONN B (6)
Fingertip extension module 8-6 B15/18/20T, B18/20TL, B16/18/20X-7

Preliminary steps
1. Remove the left floor plate (See Section 7-3).
Procedure
(1) Fingertip extension module
1. Disconnect connector (2) from fingertip extension
module (1).
(2) Connector
Fig. 8-7
2. Loosen bolts (3) and remove fingertip extension (1) Fingertip extension module
module (1).

install the fingertip extension module.
(3) Bolt
Fig. 8-8
8
Fingertip option
B15/18/20T, B18/20TL, B16/18/20X-7 8-7 Fingertip extension module

8-3 Fingertip armrest unit
8-3-1 Exterior view

Auto tilt leveling switch (option)
F/R switch
Knob – LIFT
Knob –TILT
Knob – AUX1
Knob – AUX2
Auto clamp switch Emergency switch
Front cover
Harness ass’y
Fig. 8-9
Fingertip armrest unit 8-8 B15/18/20T, B18/20TL, B16/18/20X-7

8-3-2 Circuit configuration and key functions
Fig. 8-10
With the fingertip option, the fingertip armrest unit
replaces the hydraulic levers, enabling you to do the
same jobs you did using the hydraulic levers more easily
by using your fingertips.
Unlike the levers, this unit is connected to the fingertip

control valve by three cables since it uses electrical
signals to control hydraulic unit operations as well as
forward/reverse drive shift.
For more details of how the knobs work, see the

followings sections:
8
Fingertip option
B15/18/20T, B18/20TL, B16/18/20X-7 8-9 Fingertip armrest unit

8-3-3 Wiring
The fingertip armrest uses a 6 pin EM connector (Fig. 8-
11) and a 4 pin CAN connector. 3 2 1
6 5 4
EM connector
Fig. 8-11
2 1
4 3
CAN connector
Fig. 8-12
EM connector pins
no. color no. color
1 BU EM SWITCH A In 4 OR EM SWITCH B Out
2 RD EM SWITCH A Out 5 GN HORN
3 WH EM SWITCH B In 6 GY HORN COM
CAN connector pins

no. color no. color
1 YL CAN HI 3 BK GND
2 RD VCC +12V 4 BU CAN LOW

8-3-4 Hydraulic control knobs
V DC out
4.6V
8° FWD
REV2 28°
Signal “B”
4 YL(SIG2) 2 BK (GND)
2.5V
Signal “A”
0.4V
3YL (SIG1) 1RD (DC5V) 0
26° 26°
NORMAL
RVS 28° FWD 28°
POSITON
Fig. 8-13
The fingertip armrest includes four identical knobs. Each

knob has two input lines (+5 V and ground) and two
output lines (phases A and B). Both phases remain
constant at 2.5 V in neutral, and vary from 0.4 V to 4.6 V,
always totaling 5 V. When their voltages do not make a
total of 5 V, the fingertip extension detects the knobs are
malfunctioning and stops the control valve.
8
Fingertip option

8-3-5 Forward/reverse switch
4 YL(SIG2) 2 BK (GND)
3YL (SIG1) 1RD (DC5V)
° RE
15 V
D
FW 15
°
FWD
NEU
REV
Fig. 8-14
The F/R (forward/reverse) knob has two input lines (+5 V

and ground) and two output lines (phases A and B).
Powered at 5 V, it signals with different analog voltages
according to the position of its angle: forward, neutral,
and reverse as shown in the graph above. The fingertip
extension module converts the signal from this knob into
a digital signal and shares it with other controllers across
the CAN network to determine the vehicle’s drive
direction.

8-3-6 Removal and Installation
Connecting harness
The manufacturers Daewon and Grammer supply seats

with differently structured joint parts, and thus they
require different installation/removal procedures.
1. Remove the EM cable and the CAN cable from CAN connector
the main harness. Main harness
EM connector
Fig. 8-15
If using a Daewon seat
1. Loosen hex bolt (4) and nut (2) and remove flat (2) Nut
(3) Flat washer
washers (3 and 5).
(1) Armrest
NOTICE: Be careful not to drop the armrest unit.
2. Remove armrest unit (1).

install the armrest unit.
If using a Grammer seat (5) Flat washer (4) Hex bolt

Fig. 8-16
1. Loosen two hex bolts (3) and the bolt (4) and
then remove the hard washer (2).
(1) Armrest
NOTICE: Be careful not to drop the armrest unit.
2. Remove armrest unit (1) and rod (6).

(6) Rod (4) Bolt
(2) Hard washer
8
3. Follow the steps above in the opposite order to (3) Hex bolt
(5) Bracket
install the armrest unit. Fig. 8-17
Fingertip option

8-3-7 Disassembly and Assembly
You don’t need to all the steps below. Perform only the steps for the part you are working on.
A. Common
1. Loosen six bolts (1) from the fingertip armrest

unit and remove bottom cover (2).
Fig. 8-18
B. Hydraulic control knob or F/R switch replacement
1. Disconnect the cables connected to front cover

(1).
 Be careful in cabling when you install them.
Fig. 8-19
2. Remove hydraulic control knob (2) or F/R switch

(3).
 At installation, check the groove and fit the
front/back sides correctly.

replace a new one.
Fig. 8-20

C. Emergency button removal/installation
1. Remove cap (1) of the emergency button using a

thin flat-head screwdriver.
Fig. 8-21
2. Remove bolt (2) and then emergency button (3).
Fig. 8-22
 Align the emergency button cap with the

groove at installation.
Fig. 8-23
8
3. Remove the pin using a plier and remove inner
cap (4).
Fingertip option
Fig. 8-24

4. Remove emergency button terminal block (5).
Disconnect the cables from the terminals by
removing the bolts.
 Cabling for installation
A – blue
B – red
C – white
D – orange

install the emergency button.
Fig. 8-25
D. CAN module removal/installation
1. Disconnect all the cables from front cover (1).
2. Loosen all screws (2) and remove CAN module

(3).

install the CAN module.
Fig. 8-26

E. Body removal/installation
1. Remove six larger bolts (1) and then six smaller

bolts (2) from the left cover.
Fig. 8-27
2. Loosen knob (3) and remove left cover (4).

 Make sure that no cables are pinched when
you reassemble.
Fig. 8-28
3. Remove bolt (5) and then bracket (6).
Fig. 8-29
8
4. Remove two sliding bars (7).
Fingertip option
Fig. 8-30

8-4 Fingertip control valve

Solenoid B1 – lowering
Fork relief valve Solenoid B2 – tilt-forward
Solenoid C1 – unloading Solenoid B3 – Sideshift to the left
Solenoid B4 – AUX2
Emergency lowering valve
INLET section
OUT LET section
LIFT
section TIFT
AUX1
section
section AUX2
section
Solenoid A4 – AUX2
Solenoid A3 – Sideshift to the right
Solenoid A2 – tilt-back
Solenoid A1 – lift
OUT LET section
INLET section
AUX2 AUX1
section section TIFT LIFT
section section
Fig. 8-32
Fingertip control valve 8-18 B15/18/20T, B18/20TL, B16/18/20X-7

Control valve
Items Spec.
410105-00973 (3 way)
Part no.
410105-00974 (4 way)
Rated flow 85 L/min
Max. pressure 23 MPa (3,336 psi)
Max. back pressure Normal: 0.3 MPa (43.5 psi) / Peak: 1.0 MPa (145.0 psi)
Oil temperature Normal: -20–80 °C (-68 ℉) / Peak: 100 °C (212 ℉)
Solenoids
Proportional controlled
Items Unloading solenoid (C)
solenoid (A&B)
Rated voltage DC 24 V
Allowable voltage DC 16–32 V DC 20–32 V
Pulse width modulation control
Current Rating 0.71 A
0.6 A max.
Resistance 30 Ω at 20 °C (-68 ℉) 28.5 Ω at 20 °C (-68 ℉)
Watt consumption 7.5 W at 0.5 A, 20 °C (-68 ℉) 20.2 W at 24V, 20 °C (-68 ℉)
Coil insulation class JIS C 4008 class “H”
Water-proof class JIS D 0203 S2 JIS C 0920
Vibration-proof class JIS D 1601 class “3B”
Continual voltage 28V is allowed. 60%
Current rate Then coil surface temperature is ON: 3 min
under 90 °C OFF: 2 min
The control valve for fingertip option has the same

procedure for removal/installation as the basic control
valve. See Section 5-2-7 to install the control valve and
see the next section to take care of cabling.
8
Fingertip option
B15/18/20T, B18/20TL, B16/18/20X-7 8-19 Fingertip control valve

8-4-2 Wiring
The fingertip control valve is equipped with three sets of
solenoids A, B, and C, two of which use 8 pin connectors
and the rest one of which uses a 2 pin connector.
8 5
4 1
Fig. 8-32
Solenoid A connector pins
no. color no. color
1 YL/GN F_CONN B (2) 5 RD/BU F_CONN B (1)
2 RD F_CONN A (6) 6 WH 1352 J1 (J1-10)
3 RD F_CONN A (6) 7 BR 1352 J1 (J1-11)
4 RD F_CONN A (6) 8 VO 1352 J1 (J1-12)
Solenoid B connector pins

no. color no. color
1 BU/BK F_CONN B (4) 5 GN/BK F_CONN B (3)
2 RD F_CONN A (6) 6 WH/BK 1352 J1 (J1-14)
3 RD F_CONN A (6) 7 BR/YL 1352 J1 (J1-9)
4 RD F_CONN A (6) 8 OR 1352 J1 (J1-13)
Solenoid C connector pins

no. color no. color
4 BU/BK F_CONN B (4) 8 GN/RD F_CONN B (5)

8
Fingertip option

8-4-3 How it works
A. INLET section
(15) Spring (i) Passage

(h) Chamber (18) Pilot relief valve
(14) Valve (19) Spring
(20) Adjuster
(33) Plate
(d) Chamber (b) passage

(a) Chamber (3) Spring
(e) Chamber (j) Passage (f) Chamber
SEC.E-E (h) Chamber (5) Spring
(4) Spool
(2) Priority spool B
B
(23) Housing
(24) Poppet (c) Outlet
(25) Spring (29) Set screw
Tank (b) Passage D

Steering Relief
(d) Chamber Tank (g) Chamber

D
(44) Shuttle
(45) Spring
Main Relief Tank
(44) Shuttle
(43) Solenoid
(g) Chamber
(41) Check valve (42) Spring
SEC.D-D
Fig. 8-33

Flow priority
Oil from pump enters the valve through a passage in the

INLET section. From there it goes to chamber (a) of flow
priority spool (2). At steering, the spool slides to the right
side dependant on demanded steer flow.
The excessive flow goes to chamber (d). Steer flow

would go out through passage (b) to outlet (c). When
steering wheel is neutral, flow priority spool (2) keeps the
neutral position and only standby flow goes to steer
circuit. In this condition also, the excessive flow goes to
chamber (d).
Compensator
Compensator spool (4) keeps the constant difference

pressure between the chamber (e) pump pressure, and
the chamber (f), whichever higher pressure of the LIFT or
the TILT section is selected by plate (33). And then, from
chamber (d), the compensator spool (4) divides the
chamber (e) connecting with the LIFT or the TILT section
as priority flow, and the chamber (f) connecting with the
AUX section as excessive flow.
Unloading valve
When solenoid valve (43) is de-energized, shuttle (44)

keeps the neutral position. Chamber (g) of check valve
(41) is connecting with tank. Check valve (41) opens
connecting chamber (d) with tank to unload the pump
pressure.
Once solenoid valve (43) is energized, shuttle (44) is

shifted, and the pressure of chamber (g) becomes the
pressure of chamber (d). Check valve (41) closes to
maintain the minimum pressure for solenoid source
8
pressure.
Solenoid source pressure

Fingertip option
Flow regulator (14) provides small flow to solenoid source

passage (i) from chamber (h). The pressure of passage (i)
is determined by pilot relief valve (18). This pressure is
set by the adjuster (20).

B. LIFT section
(22) Spring
(15) Check valve (i) Chamber
(h) Outlet (16) Spring (2) Spool (21) Valve
(l) Passage (m) Passage
(g) Chamber (27) Screw
k
(3a) Spring
(3b) Spring 5
(b) Chamber
(a1) Solenoid valve (b1) Solenoid valve
(fa) Chamber (a) Chamber (j) Oil (fb) Chamber
(c) Chamber
(d) Solenoid source pressure
(e) Drain passage
SEC.D-D
(8) Shuttle (7) Sleeve

(17) Spring
(30) Plate
B B
SEC. B-B
Detail “d”
Fig. 8-34
Neutral position
When the LIFT knobs is not moved any way, both a1 and
b1 solenoids are de-energized to place spool (2) into the
neutral position by left and right springs (3a, 3b). The
spool (2) in the neutral position allows neither the flow to
nor from the lift cylinders, resulting in the mast stopped
and held in any position.
When spool (2) is in this position, the load-sensing

pressure keeps tank pressure connecting chamber (a)
with chamber (b).

Lift position
When a1 solenoid is energized, the force of solenoid is in

proportion with the input current.
The push rod of a1 solenoid pushes shuttle (8), then the

pressure of chamber (f) balances with the force of solenoid.
Spool (2) slides in the opposition to a1 solenoid until the
pressure of chamber (fa) equals the force of spring (3a).
Spool (2) is moved until a path is opened between

chamber (a) and chamber (g), chamber (c) and chamber
(a). Then, pressure oil opens lift lock check valve (15)
and flows from passage (g) to outlet (h).
The load-sensing signal would be the working pressure

through chamber (a). Pressure oil to head end of the lift
cylinders moves the rod up and the mast will rise.
Lowering position
When b1 solenoid is energized, the force of solenoid is in

The push rod of b1 solenoid pushes shuttle (8), then the

pressure of chamber (fb) balances with the force of solenoid.
Spool (2) slides to left side until the pressure of chamber (f)
equals the force of spring (3b). Pilot pressure of chamber (fb)
goes into head chamber of valve (21) through passage (k).
Valve (21) moves to the left side against the force of spring
(22) and opens a path between passage (m) and (l).
The pressure of chamber (i) is opened to tank through

valve (21), and then check valve (15) is lifted up.
Spool (2) opens a path between outlet (h) and passage

for return oil (j). The load-sensing pressure keeps tank
pressure connecting chamber (a) with chamber (b).
8
If the pilot pressure is lost, for any reason, valve (21) will return
to the neutral position and the path for return oil is closed. Then,
check valve (15) closes the path for return oil to stop lowering.
Fingertip option
Back-up lowering screw
If the control valve is out of control, lowering is available

by loosening the screw (27) as emergency.
NOTICE: Lowering speed is not controllable. Screw

needs to be opened carefully as slow as possible, and
make sure the safety in advance.

C. TILT section
(21) Valve (15) Valve (16) Spring (8) Shuttle

(h) Outlet (g) Passage (7) Sleeve
(m) Passage (2) Spool (17) Spring
(k) Orifice (i) Outlet
(l) Orifice
(n) Orifice
(22) Spring Relief valve cavity
(3a) Spring
(3b) Spring
(5) Cap
Detail “d”
(a) Chamber
(a1) Solenoid (b1) Solenoid
(fa) Chamber (e) Drain passage (b) Chamber (fb) Chamber
(c) Chamber
(d) Solenoid source pressure (j) Passage
(d) Solenoid source pressure
Fig. 8-35
Oil from LIFT section goes through chamber (c).
Neutral position
Spool (2) is in the neutral position, the load-sensing

pressure keeps tank pressure connecting chamber (a)
with chamber (b). The flow to and from the tilt cylinder is
stopped by spool (2).
Once de-energizing both a1 and b1 solenoids, spool

returns into neutral position by spring (3).
The mast can be stopped and held in any position. In the

neutral position, oil can not flow from passage (g) to
outlet (h) or (i).

Forward position
When b1 solenoid is energized, the force of solenoid is in

The push rod of b1 solenoid pushes shuttle (8), then the

pressure of chamber (fb) balances with the force of
solenoid. Spool (2) slides to left side until the pressure of
chamber (fb) equals the force of spring (3b).

passage (g) and outlet (i), chamber (c) and chamber (a).
Then, pressure oil opens load check valve (15) and flows
from passage (g) to outlet (i).
It then flows to head end of the tilt cylinders through outlet and
the mast tilts forward. Return oil from the rod end of the tilt
cylinders flows through outlet (h) into passage (j) and then to
tank. The load-sensing signal would be the working pressure
through chamber (a). Pump pressure goes into chamber of
valve (21) through orifice (k), and the spring chamber of valve
(21) is opened to tank through orifice (l). Valve (21) moves to
the left side against the force of spring (22) and opens a path
for return oil between passage (m) and orifice (n).
This has the effect of slowing down the flow of oil from the rod
end of the tilt cylinders and preventing cavitation in the head
end. If the pump pressure is lost, for any reason, valve (21) will
return to the neutral position and the path for return oil is closed.
Back position


pressure of chamber (fa) balances with the force of
solenoid. Spool (2) slides to right side until the pressure
of chamber (fa) equals the force of spring (3a).
Spool (2) is moved until a path is opened between 8

passage (g) and outlet (h), chamber (c) and chamber (a).
Fingertip option
Then pressure oil opens load check valve (15) and flows
from passage (g) to outlet (h).
It then flows to rod end of the tilt cylinders through outlet

and the mast tilts back. Return oil from the head end of
the tilt cylinders flows through outlet (i) into passage (j)
and then to tank. The load-sensing signal would be the
working pressure through chamber (a).

D. AUX section
(15) Check valve (16) Spring

(c) Chamber
(g) Passage (8) Shuttle (7) Sleeve
(2) Spool (h) Outlet (i) Outlet (17) Spring
(m) Passage
(3a) Spring
(3b) Spring
(5) Cap
Detail “d”
(a1) Solenoid (b) Chamber (a) Chamber (b1) Solenoid

(fa) Chamber (d) Solenoid source pressure (fb) Chamber
(e) Drain passage (j) Passage
Fig. 8-36
Oil from pump enters the AUX sections through the
passage in the INLET section as excess flow. From there,
it goes to both chamber (b) and chamber (c).
Neutral position
Since spool (2) is in the neutral position, the only path the
oil can take is from chamber (a) into downstream section
or tank.
Once de-energizing both a1 and b1 solenoids, spool

returns into neutral position by spring (3), and oil cannot
flow from passage (g) to outlet (h) or (i).

Activate


pressure of chamber (fa) balances with the force of
solenoid. Spool (2) slides to right side until the pressure
of chamber (fa) equals the force of spring (3a).

passage (g) and outlet (i), and oil flow from chamber (b)
to chamber (a) is stopped. This causes the oil pressure
increased and open load check valve (16). The pressure
oil from the pump can now flow from passage (g) to outlet
(h). The path for return opens from outlet (i) to chamber
(j).
8
Fingertip option

E. Relief valves
If the control valve is held in lift or tilt position, after the

cylinder rod is fully extended or retracted, the oil flow
from outlet port to cylinders is stopped. The oil under
pressure must be released.
(a) Chamber (b) Passage (c) Chamber
(8) Pilot Spring (6) Pilot Popet (9) Spring (4) Main Popet
(7) Adjuster Kit (2) Plug (1) Cap (5) Pilot Seat (3) Sleeve
(15) O-ring (12) O-ring (14) (13) O-ring

(11) Back-up Ring
(10) O-ring
Fig. 8-37
Main relief valves in INLET and OUTLET

sections
The pressure oil flows through the orifice of piston (4).

The pressure oil opens pilot poppet (6) against the force
of spring (8). This lets the oil flow go through spring
chamber (a) to passage (b). The oil then returns to tank.
When the pilot poppet is opened, it causes a decrease of
the pressure in spring chamber (c) that lets main piston
(4) move up until the oil pressure is released.
Adjustable pressure: Range 3.9–24.5 MPa (565.6–

3,553.4 psi), Adjuster screw 17.7 MPa (2,567.2 psi) per
rotation.

(a) Chamber (b) Passage (c) Chamber
(2) Plug (6) Pilot Popet (4) Main Popet
(9) Adjuster Kit (8) Spring (14) O-ring (1) Cap (15) O-ring
(18) O-ring (16) Wave Washer (7) Spring (5) Piston
(10) O-ring (3) Popet
(13) Back-up Ring (11) Back-up Ring
(12) O-ring
Fig. 8-38
Port relief valve in TILT section
The pressure oil flows through the orifice of piston (5).

The pressure oil opens pilot piston (6) against the force of
spring (8) in spring chamber (a). This lets the oil flow go
through spring chamber (a) to passage (b). The oil then
returns to tank. When the pilot poppet (6) is opened, it
causes a decrease in the pressure in spring chamber (c)
that lets main poppet (4) move up until the oil pressure is
released.
Adjustable pressure: Range 4.9–27.9 MPa (710.7–

4,046.6 psi), Adjuster screw 15.7 MPa (2,277.1 psi) per
8
rotation.
Fingertip option

8-5 Fault diagnosis
8-5-1 Fault display

You can view the fault code and the fault text displayed in
the red area in Fig. 8-39:
Fig. 8-39
Fault
Description (Fingertip Controller PIN No.) Display Text
Code
L1 Lift sol (J1-12) open/short LIFT SOL FAULT
L2 Lowering sol (J1-13) open/short LOW SOL FAULT
L3 Tilt Forward sol (J1-11) open/short TILT FWD SOLFAU
L4 Tilt Backward sol (J1-9) open/short TILT BACK SOLFAU
L5 AUX1 Left sol (J1-10) open/short AUX1 L-SOLFAU
L6 AUX1 Right sol (J1-14) open/short AUX1 R-SOLFAU
L7 AUX2 Left sol (P1-2) open/short AUX2 L-SOLFAU
L8 AUX2 Right sol (D2-2) open/short AUX2 R-SOLFAU
L9 ISO (STD), Unloading SOL (Fingertip OPT) (P1-5) open/short ISO/UNLOAD SOL
21 OverVoltager/UnderVoltage (Curtis code 21, 22) EXT VOLT FAULT
PDO Timeout/SDO Fault (Curtis code 51, 52)
51 EXT TIME FAULT
CAN BUS Fault (Curtis code 53)
C1 Total Current Exceeded 18A (Curtis code 25) EXT CUR FAULT
C2 12V/5V Power supply fault (Curtis code 13, 14, 15) EXT POWER FAULT
FF FINGERTIP KNOBS OUT OF RANGE FINGERTIP FAULT
Fault diagnosis 8-32 B15/18/20T, B18/20TL, B16/18/20X-7

8-5-2 Troubleshooting
Knobs does not move
1. From EasyView, check if the parameter Fingertip

Enable is enabled (1).
Fig. 8-40
2. Check if any errors have occurred.
3. If there is no error, check the output of <Fingertip

and Valve> from Test Menu and then replace the
knobs if there is no knobs signal.
8
Fingertip option
Fig. 8-41
B15/18/20T, B18/20TL, B16/18/20X-7 8-33 Fault diagnosis

Power supply fails
1. Check the PIN J1-3 of the fingertip extension

module.
 Measurements of J1-3 (Battery+) and J1-1
(GND) should equal the same voltage as the
battery.
2. If your measurement does not meet the specified

amount, check the fingertip harness for any
Fig. 8-42
faulty connection between 1352 J1 #3 and
F_CONN A #6; J1-1 and F_CONN A #1 or #5;
and J1-2 and F_CONN A #1 or #5.

Mast lifting is abnormal
If the error code L1 is displayed on the dashboard:
1. Check if the connector is connected to the lifting

solenoid valve coil.
2. If the connection is fine, check the readings of the

KNOB Lift Command and the Lifting Sol current
when the lift knob is completely held back.
 The maximum readings for the KNOB Lift
Command are 1000 and 490–520mA for the
Lifting Sol current.
Fig. 8-43
8
Fingertip option
Fig. 8-44
3. If the Knob Command reads “0,” change the lift
knobs.
4. Change the CAN module if the problem

continues even after you have replaced the lift
knob.

If no error is displayed on the dashboard:
1. If the pump motor operation fails, check if the

parameter Fingertip Enable is ON from <Truck
Setup>, Calibration, EasyView.
Fig. 8-45

Mast lowering is abnormal.
If the error code L2 is displayed on the dashboard:
1. Check if the connector is normally connected to

the lowering solenoid valve coil.
2. If the connection is fine, check the readings of the

KNOB Pot Lower and the Lowering Sol Current
when the lift knob is completely held back.
 The specified readings are: 490mA for the
current, ON for the KNOB Pot Lower.
Fig. 8-46
8
Fingertip option
Fig. 8-47
3. If the Knob Command reads “0,” change the lift
knob.
4. Change the CAN module if the problem persists

even after you have replaced the lift knob.


parameter Fingertip Enable is set to ON from
<Truck Setup>, Calibration, EasyView.
Fig. 8-48
2. If the problem persists, check from EasyView if
the unloading valve is in normal operation and if
the PWM reading is normal. 50% is the normal
reading of PWM.
Fig. 8-49
3. If normal operation fails, check if the connector is
correctly connected.
4. If normal operation continues to fail even after

you have connected the connector, replace the
unloading valve.

Mast tilting is abnormal.
If an error code L3 (Tilt Forward) or L4 (Tilt Backward) is

displayed on the dashboard:
1. Check if the connector is normally connected to

the tilt forward/backward solenoid valve coil.
2. If the connection is fine, check the readings of

the KNOB Pot Tilt Up/Down and the Tilt
FWD/Back Sol Current when the tilt knobs is
pushed or pulled to the full.
current, and ON for the KNOB Pot Tilt
Up/Down.
Fig. 8-50
3. If normal operation fails, replace the tilt knobs.

even after you have replaced the tilt knobs.
8
Fingertip option


Fig. 8-51

AUX1 (Sideshift) operation is abnormal.
If an error code L5 (Shift to Left) or L6 (Shift to Right) is

1. Check if the connector is normally connected to the

AUX1 Left/Right shideshifting solenoid valve coil.

the KNOB Pot AUX1 Left/Right and the AUX1
Left/Right Sol Current when the AUX1 knobs is
pushed or pulled to the full.
current, and ON for the KNOB Pot AUX1
Left/Right.
Fig. 8-52
8
Fingertip option
Fig. 8-53
3. If normal operation fails, replace the AUX1 knobs.

even after you have replaced the AUX1 knobs.


Fig. 8-54

AUX2 operation is abnormal.
If the error code L7 (Shift to Left) or L8 (Shift to Right) is

1. Check if the connector is connected to the AUX2

Left/Right shideshifting solenoid valve coil.

the KNOB Pot AUX1 Left/Right and the AUX1
Left/Right Sol current when the AUX2 knobs held
completely forward or backward.
current, and ON for the KNOB Pot AUX1
Left/Right.
Fig. 8-55
8
Fingertip option
Fig. 8-56
3. If normal operation fails, replace the AUX2 knob.

even after you have replaced the AUX2 knob.


Fig. 8-57

Auto tilt leveling is abnormal.
1. Check if the auto tilt leveling switch is operated

as shown in Fig 8-58.
 LED turns on during switch operation.
2. From the menu <Truck Setup>, EasyView, check

if Auto Tilt Enable is set to 1. Fig. 8-58
 0: OFF, 1: ON
Fig. 8-59
3. Check if the auto tilt leveling switch operates
normally.
8
Fingertip option

Auto clamping is abnormal.
1. Press once the auto tilt leveling switch as shown

in Fig.8-60 and check if it operates normally.
 The auto clamp switch is automatically
deactivated 3 seconds after Key ON and 10
seconds after the last operation.
Fig. 8-60
2. From the menu <Truck Setup>, EasyView, check

if Auto Tilt Enable is set to 1.
 0: OFF, 1: ON
Fig. 8-61
3. Check if the auto clamp switch operates normally.

9 Schematics
9-1 Hydraulic schematic ....................................1
9-2 Hydraulic schematic

(with fingertip)...............................................2
9-3 Electrical schematic .....................................3
9
Schematics
● Vehicle Hydraulic Schematic MODEL: B15/18/20T-7, B18/20TL-7, B16/18/20X-7
CONTROL VALVE
2 SECTION A158140
3 SECTION A158141
4 SECTION A158142
B15/18/20T, B18/20TL
S/A CYLINDER
SOLID SOFT 190104-00126 B16/18/20X TILT CYLINDER

CUSHION 190104-00128 P/S CYLINDER (A155010)
(190104-00093)
WIDE 190104-00130
LIFT CYLINDER
STANDARD D512374
PRIMARY D512413
FFT
SECONDARY D512394
PRIMARY D501865
FF
SECONDARY D512388
STEERING UNIT
(D512926)
PRIMARY
SECONDARY
or STANDARD
PROTECTOR
(D502539)
MAIN RELIEF V/V
PROTECTOR
(D501495)
FLOW REGULATOR
(D501493)
PRIORITY VALVE
RETURN FILTER (D518223)
(D516976) HYDRAULIC PUMP
(400910-00078)
SUCTION FILTER
(A155222)
D502604
● Vehicle Hydraulic Schematic - Fingertip Option MODEL: B15/18/20T-7, B18/20TL-7, B16/18/20X-7
CONTROL VALVE
3 SECTION 410105-00973
4 SECTION 410105-00974
B15/18/20T, B18/20TL
TILT CYLINDER S/A CYLINDER
(A252110)
SOLID SOFT 190104-00126 B16/18/20X
CUSHION 190104-00128 P/S CYLINDER
(190104-00093)
LIFT CYLINDER WIDE 190104-00130
STANDARD D512374
PRIMARY D512413
FFT
SECONDARY D512394
PRIMARY D501865
FF
SECONDARY D512388
PRIMARY
SECONDARY
or STANDARD
STEERING UNIT
(D512926)
MAIN RELIEF V/V

PROTECTOR
(D502539)
PROTECTOR SWITCH AS-PRESSURE

(D501495) : “FINGERTIP” ONLY
FLOW REGULATOR (A154432)
(D501493)
FINGERTIP EXTENSION PUMP MOTOR

MODULE (300611-01010) CONTROLLER (300611-00991) HYDRAULIC PUMP
(400910-00078)
RETURN FILTER
(D516976)
D500067
●Electric Schematic MODEL: B15/18/20T-7, B18/20TL-7, B16/18/20X-7
12 FUSE BOX(A)
11
2/RD 10
D/D CONVERTER
98/RD/BU 9 20A HORN
2/RD 4 3 4/YL/RD 4/YL/RD 8

KEY SWITCH
59/RD/WH 7 10A
LEFT 43/OR/RD 6
EMERGENCY SW (OPT) TRACTION D1-3 86/YL 56/OR/BK FAN/FINGERTIP(OPT)
5
KEY SWITCH 5A
89/RD/GN 4 SOL VALVE/POWER
D1-1 3/OR 5A
43/OR/RD 3
1
2/RD FUSE 84/RD/YL 2 BACK-UP
5A
500A 9/BU/YL 1
+12V F/R UNIT F/R SWITCH 5A
8 ENABLE 3 3/OR
-12V
+ BATTERY
1/BK 6
+5V BATT + 2 98/RD/BU
12
FUSE BOX(B)
12V OUT (BACK-UP) 1
85/RD/GN 5 12V + 5 43/OR/RD
9/BU/YL 6/BR D1-6 +12V 2 GND 11
LINE 84/RD/YL 4 3 BATT - 1 1/BK 131/BU/YL
vcc
Forward 10
BATT +
CTR D1-12 3/OR 3/OR 2 4 Revers
12V - 6 1/BK 129/BU/GN L LAMP
13/OR/RD D1-13 9 5A
FWD
FWD D1-22 20/YL/GN 20/YL/GN 3 8
REV DC/DC CONVERTER
REV D1-33 21/BR 21/BR 1 7 10A
GND BATT -
1/BK 7 131/BU/YL 6
7/WH D1-7 7/WH 1 GND
D1-26 26/RD/BK 26/RD/BK 3 +5V 82/BU/RD 5 OPT LAMP
D1-16 16/OR/BK 16/VO/BK 2 OUT A 5A
THM1 130/YL/GN 4 R LAMP/LICENCE
8/VO D1-8 60/WH/BU 4 GND
FLASHER UNIT (OPT) 5A
B1 64/RD 6 +5V
43/OR/RD
32/GY D1-32 3
58/BK 5 OUT B
A1 85 112/YL/WH 112/YL/WH 2 STROBE/FLASHER
31/GN D1-31 5A
ACCELERATOR 86 1/BK 113/GN/YL 1 REAR LAMP
+5V 5A
2
1
26/RD/BK 26/RD/BK 87 87/BK/RD
D1-26 D1-17 18/BU/RD 17/GN/YL 17/GN/YL 1 30
D1-7 7/WH 7/WH 2
86/YL 85
2 7/WH 89/RD/GN 86
SEAT SWITCH 96/GN/RD 87
1 30/RD D1-30 2 87/BK/RD RELAY-LIFT SOL VALVE
LEFT D1-24 101/GN 89/RD/GN 30
31/GN 87a
8/VO TRACTION MOTOR PILOT BUZZER D1-25 25/RD/WH 1 92/WH/GN
7/WH (WARNING) D1-28 28/BU/BK 3 94/YL/BU
+
89/RD/GN 1
ENCODER
32/GY D1-29 29/BU/GN POWER (OPT)

GND A
T/S SW (OPT) 1/BK 2

MR D1-2 71/RD/BK
D1-13 13/OR/RD 96/GN/RD 1 DIODE-COMP.
3or4 wheel
B
1
3/OR 1/BK 2
D1-10 3/OR 3/OR 2 open:4-Wheel,closed:3-wheel
98/RD/BU 4 1/BK B
LIFT SOL VALVE
THERMAL THERMAL D1-14 77/GN/WH 1/BK 3 96/GN/RD A
77/GN/WH 2
3/OR 1 98/RD/BU 2
7/WH SENSOR SENDER 1/BK 1 80/BK 87
PEDAL BRAKE SWITCH EMERGENCY C 71/RD/BK 85
FAN RELAY (OPT)
13/OR/RD 4 126/BU/WH 126/BU/WH 2
EM BRAKE-LEFT 13/OR/RD 86
D1-5 12/WH/RD 12/WH/RD 3 125/BU/RD 125/BU/RD 1
1/BK 30
75/YL/GN 2 128/BR/YL 128/BR/YL 2 EM BRAKE-RIGHT
76/BK 1 127/BU/YL 127/BU/YL 1
D1-23(CAN H) 23/YL/BK 89/RD/GN 1 HEAD LAMP (OPT)
EM CONN A EM CONN B 1/BK 2 CONTROLLER FAN
D1-35(CAN L) 35/YL 33/BK/WH 2
1
BRAKE OIL SW
34/BK/YL
56/OR/BK 1 FRONT COMB-R(OPT)
80/BK 2 DOOR FAN
RIGHT 7/WH 2
GND
TRACTION 38/BU/GN 1 SEAT BELT SW
56/OR/BK 1
51/WH D2-7 7/WH 3 80/BK 2 D/M FAN-R
101/GN 2
25/RD/WH 1 103/BR/YL 2 S/B LAMP 56/OR/BK 1
THM1 D2-1 3/OR 4 80/BK 2 D/M FAN-L
2 84/RD/YL
52/BU/BK D2-8 ANGLE SENSOR 34/BK/YL
B1 3 BRAKE OIL J2 1 93/GY
53/BU/GN D2-32 35/YL 6 CAN L 56/OR/BK 1
A1 23/YL/BK 5 CAN H 80/BK 2 P/M FAN
54/OR/RD D2-31 23/YL/BK
STOP LAMP SW (OPT)
D2-23(CAN H) 25/RD/WH 1 +12V
R-LAMP CONN
51/WH +5V D2-35(CAN L) 35/YL
33/BK/WH BRAKE OIL 1/BK
53/BU/GN 55/RD D2-26 D2-11 3/OR 1
1/BK 6 -12V 130/YL/GN
52/BU/BK 55/RD RIGHT 4 94/YL/BU
TRACTION MOTOR D2-28 73/BU/RD 104/GN/WH 2 T/S LAMP
54/OR/RD 82/BU/RD J1 HEAD LAMP-R
74/BU/WH 3 HEAD LAMP T/S LAMP-R
+
D2-29
25/RD/WH
ENCODER
8 +12V
GND A
7/WH 7 GND
MR 5 1/BK 2
INSTRUMENT MONITOR 85/RD/GN 1 BACK-UP BUZZER (OPT)

D2-13 75/YL/GN
B
98/RD/BU 4
D2-5 76/BK
90/RD/BK 1
D2-2 114/YL/RD
THERMAL THERMAL 2
HORN SW
51/WH SENSOR SENDER 3
113/GN/YL 6 +12V
98/RD/BU 2
1/BK 1 GND
GRAB BAR SW (OPT)
28/BU/BK 7 L-S TX 90/RD/BK 1
29/BU/GN 2 L-S RX 94/YL/BU
73/BU/RD 8 R-S TX 104/GN/WH
74/BU/WH 3 R-S RX 92/WH/GN
48/BU 9 P-S TX
49/VO 4 P-S RX DIODE-DIR
10 90/RD/BK 1
5 2
1/BK
PUMP HORN
CAN PORT SERIAL PORT 87 110/WH/BU
1
85 1/BK
GND P1-26 64/RD VARISTOR
60/WH/BU P1-7 3 3 +12V 86 85/RD/GN
P1-16 58/BK 4 4 BUZZER 30 84/RD/YL
5 103/BR/YL 5 S/B LAMP
35/YL 35/YL 38/BU/GN 2 S/B SW

P1-35(CAN L) 2
17/GN/YL 7 SEAT SW
BACK UP LAMP (OPT)
THM1 6
61/GN/RD P1-8 59/RD/WH 1 B+
P1-23(CAN H) 23/YL/BK 23/YL/BK 7
B1 7/WH 6 B- 131/BU/YL 3
63/BR P1-32 11/BU/BK 8 PARKING 2 43/OR/RD
A1
62/GN/BK P1-31 3/OR 3/OR 1 KEY SW
OPT LAMP CONN. LIGHT SW(OPT)
P1-1 +5
7 113/GN/YL
2
60/WH/BU P1-9 65/BU 65/BU 2
63/BR +5V
64/RD P1-26 3/OR 1 SAFETY RELAY 1 81/RD 81/RD 8
MAST TILT SW2 (OPT) (OSS CONTROLLER) 3 93/GY
61/GN/RD 64/RD HEAD LAMP (OPT)
PUMP MOTOR 7 94/YL/BU
P1-4 68/WH/GN 68/WH/GN 2
62/GN/BK L-LAMP CONN
+
69/BU/WH 69/BU/WH 1 5 110/WH/BU

ENCODER
P1-13
GND A
4 82/BU/RD 129/BU/GN 1
MR TILT SOLENOID (OPT)
2 1/BK 2
1/BK
P1-19 78/YL/GN 78/YL/GN 2
3/OR 1 6 92/WH/GN 92/WH/GN
HEAD LAMP-L
B
Auto tilt SW3 (OPT) 8 112/YL/WH T/S LAMP-L

P1-20 79/YL/BU 79/YL/BU 2
3/OR 1
THERMAL THERMAL
60/WH/BU TILT LEVER (OPT)
SENSOR SENDER
3/OR 1 FRONT COMB-L(OPT)
1 47/RD/GN P1-25 P1-25 47/RD/GN 47/RD/GN 2 56/OR/BK
2 117/YL/WH P1-6 TILT
P1-10 44/VO 44/VO 4
AUX1
P1-22 45/YL 45/YL 6
PRESSURE SENSOR(OPT) P1-33 46/BK/WH 46/BK/WH 8
AUX2
35/YL
P1-7 60/WH/BU 60/WH/BU 5 GND +12V
23/YL/BK
- BATTERY P1-24 67/GN/YL 67/GN/YL 7 OUT 90/RD/BK 1/BK 2
130/YL/GN 1
LIFT SENSOR 3/OR 98/RD/BU
LICENCE LAMP(OPT)
1/BK 1/BK
P1-28 48/BU
P1-29 49/VO 2 3 6 5 4 1 7 8
F_CONN. A
(FOR FINGERTIP)
2
1
60/WH/BU 2 PARKING BRAKE SW

91/BR/YL 11/BU/BK 1 (OPT FOR FR/LEVER) 6
P1-17 75/YL/GN 2
114/YL/RD 1
F_BACK UP RELAY (OPT) 69/BU/WH 4
124/BU/GN 5
86 69/GN/WH P1-13 3/OR 1
85 115/GN P1-3 118/BU/BK 3
87a P1-14 24/WH/BK 24/WH/BK 2
30 84/RD/YL
87 85/RD/GN HEIGHT SW1 (OPT) F_CONN. B
70/OR/BK P1-21 (FOR FINGERTIP)
P1-5 124/BU/GN
P1-34
P1-2 118/BU/BK
600123-00222
A Drive motor controller, line contactor, and line fuse
Accelerator exterior and specifications ......................3-24 removal/installation .................................................... 2-26
Accelerator mechanism .............................................3-25 Drive motor controller panal removal/installation ....... 2-25
Accelerator removal/installation .................................3-26 Drive motor disassembly/assembly and test ............. 3-10
Air removal in brake oil ..............................................3-36 Drive motor exterior and specifications ....................... 3-4
Attachment hydraulic lines removal/installation .........5-42 Drive motor mechanism............................................... 3-6

Drive motor, axle, and EM brake removal/installation . 3-8
Drive wheel removal/installation ................................ 3-12
B
Drive/brake system components ................................. 3-2
Battery condition inspection .......................................2-10
Drive/brake system troubleshooting .......................... 3-46
Battery exterior and specifications .............................. 2-6
Battery functions ......................................................... 2-8
E
Battery maintenance..................................................2-12
Battery wiring .............................................................. 2-9 EasyView “Administration” menu description ............ 2-62
Brake pedal adjustment .............................................3-35 EasyView “Tools” menu description .......................... 2-54
EasyView installation and initial settings ................... 2-45
Electrical system components ..................................... 2-2
C
EM parking brake exterior and specifications ............ 3-42
Carriage and mast height adjustment ........................5-74
EM parking brake manual release of braking ............ 3-45
Carriage removal/installation .....................................5-74
EM parking brake mechanism ................................... 3-43
Carriage roller bearings adjustment...........................5-76
EM parking brake test ............................................... 3-44
Chain removal/installation .........................................5-50
Exterior and specifications......................................... 5-28
Chain tension check ..................................................5-48
Chain wear check ......................................................5-46
F
Communication protocol ............................................. 2-4
Construction of this manual ........................................ 1-2 F/R unit exterior and specifications ........................... 3-27
Control valve Disassembly/assembly ........................5-26 F/R unit mechanism .................................................. 3-28
Control valve exterior and specifications .................... 5-6 F/R unit removal/Installation ...................................... 3-29
Control valve mechanism ........................................... 5-7 Fingertip armrest unit circuit configuration and key
Control valve relief valve adjustment .........................5-19 functions ...................................................................... 8-9
Control valve removal/installation ..............................5-24 Fingertip armrest unit disassembly/assembly ............ 8-14
Controller firmware update ........................................2-51 Fingertip armrest unit exterior view ............................. 8-8
Controller panel exterior and specifications ...............2-17 Fingertip armrest unit forward/reverse switch ............ 8-12
Controllers circuit and functions.................................2-18 Fingertip armrest unit hydraulic control knobs ........... 8-11
Controllers test ..........................................................2-23 Fingertip armrest unit removal/installation ................. 8-13
Controllers wiring .......................................................2-20 Fingertip armrest unit Wiring ..................................... 8-10

Fingertip control valve exterior and specifications ..... 8-18
Fingertip control valve mechanism ............................ 8-22
D
Fingertip control valve wiring ..................................... 8-20
DC-DC converter circuit and functions ......................2-32
Fingertip extension module circuit configuration and key
DC-DC converter exterior and specifications .............2-31
functions ...................................................................... 8-5
DC-DC converter wiring .............................................2-33
Fingertip extension module exterior and specifications8-4
Diagnosis codes ........................................................2-82
Fingertip extension module Removal/installation ........ 8-7
Disassembly/assembly instructions ...........................1-35
Fingertip extension module wiring ............................... 8-6
Drive axle Adjustment ................................................3-17
Fingertip option components and circuit ...................... 8-2
Drive axle disassembly/assembly ..............................3-18
Fingertip option fault Diagnosis ................................. 8-32
Drive axle exterior and specifications ........................3-13
Floor plates removal/installation .................................. 7-5
Drive axle mechanism ...............................................3-14
Forks alignment ........................................................ 5-38 O
Forks removal/installation ......................................... 5-39 Overhead guard removal/installation .......................... 7-4
Fuse box function and composition .......................... 2-28
Fuse box removal/installation ................................... 2-30
P
Fuse box wiring ......................................................... 2-29
Parameter calibration codes ..................................... 2-84
Pressure removal in the hydraulic system ................ 5-18
G
Primary lift cylinder disassembly/assembly............... 5-62
Glossary...................................................................... 1-5 Primary lift cylinder removal/installation .................... 5-60
Priority valve disassembly/assembly ........................ 4-21
H Priority valve exterior and specifications ................... 4-18
Handling faults on instrument panel/EasyView ......... 2-87 Priority valve mechanism .......................................... 4-19
Hood removal/installation............................................ 7-2 Priority valve removal/installation ............................. 4-20
Horn .......................................................................... 2-35 Pump motor and main hydraulic pump
Hydraulic system components .................................... 4-2 removal/installation ................................................... 4-10
Hydraulic system oil flow............................................. 4-4 Pump motor controller removal/installation ............... 2-27
Hydraulic system troubleshooting ............................. 4-24 Pump motor disassembly/assembly and test ............ 4-12
Hydraulic tank and filter ............................................ 4-22 Pump motor exterior and specifications ...................... 4-6
Pump motor mechanism ............................................. 4-8
I
Instrument panel calibration ...................................... 2-43 R
Instrument panel diagnosis ....................................... 2-41 Removal/installation.................................................. 2-14
Instrument panel names and functions ..................... 2-36 Resistance to chassis inspection .............................. 2-11
L S
Lamp group............................................................... 2-34 Safety precautions .................................................... 1-19
Levers and switch group adjustment/removal/installation .....5-22 Service brake pedal ass’y exterior and specifications ... 3-30
Lift/tilt/auxiliary system components ........................... 5-2 Service brake pedal ass’y mechanism...................... 3-31
Lift/tilt/auxiliary system oil flow .................................... 5-4 Service brake pedal removal/installation .................. 3-38
Lift/tilt/auxiliary system troubleshooting .................... 5-84 Sideshift cylinder disassembly/assembly .................. 5-44
Line contactor and fuse test ...................................... 2-24 Sideshifter and cylinder removal/installation ............. 5-40
Lubricants ................................................................. 1-30 Standard torques ...................................................... 1-44
STD/SEC lift cylinder air removal.............................. 5-64
M STD/SEC lift cylinder disassembly/assembly ........... 5-70
Main hydraulic pump exterior and specifications ...... 4-14 STD/SEC lift cylinder drift test .................................. 5-66
Main hydraulic pump mechanism ............................. 4-15 STD/SEC lift cylinder kick adjustment....................... 5-65
Main hydraulic pump removal/installation ................. 4-16 STD/SEC lift cylinder removal/installation................. 5-68
Maintenance ............................................................. 1-26 Steer (rear) wheel and hub
Mast assembly mechanism....................................... 5-30 adjustment/removal/installation [B15/18/20T (TL)] ... 6-29
Mast disassembly/assembly and roller bearing Steer (rear) wheel and hub
adjustment ................................................................ 5-80 adjustment/removal/installation [B16/18/20X] ........... 6-41
Mast removal/installation .......................................... 5-78 Steer angle sensor [B16/18/20X] .............................. 6-40
Master cylinder disassembly/assembly ..................... 3-40 Steer angle sensor removal/installation
Needle valve for emergent lowering ......................... 5-21 [B15/18/20T (TL)]...................................................... 6-28
Steer axle housing ass’y disassembly/assembly
[B15/18/20T (TL)]...................................................... 6-34
Steer axle link ass’y removal/installation [B16/18/20X] ..6-46
Steer axle removal/installation [B16/18/20X] .............6-44
Steer axle spindle removal/installation/disassembly/assembly
[B15/18/20T (TL)] ......................................................6-32
Steering control group exterior and specifications ...... 6-6
Steering control group mechanism ............................. 6-8
Steering cylinder removal/installation/disassembly/assembly
[B16/18/20X] ..............................................................6-48
Steering knuckle, king pin, and bearing
removal/installation [B16/18/20X] ..............................6-47
Steering operation group [B16/18/20X] .....................6-36
Steering operation group exterior and specifications
[B15/18/20T (TL)] ......................................................6-24
Steering operation group exterior and specifications
[B16/18/20X] ..............................................................6-36
Steering operation group mechanism [B15/18/20T (TL)] .....6-26
Steering operation group mechanism [B16/18/20X] ..6-38
Steering system air removal ......................................6-15
Steering system components ..................................... 6-2
Steering system oil flow .............................................. 6-4
Steering system pressure check................................6-16
Steering system troubleshooting ...............................6-50
Steering unit disassembly/assembly..........................6-22
Steering wheel column removal/installation ...............6-20
Steering wheel cover removal/installation .................6-18
Steering wheel removal/installation ...........................6-19
T
Tilt cylinder alignment ................................................5-52
Tilt cylinder disassembly/assembly............................5-58
Tilt cylinder drift test...................................................5-54
Tilt cylinder removal/installation .................................5-56
Top cover and counterweight removal/installation ...... 7-6
V
Vehicle exterior and specifications ............................. 1-9
W
Warning label definition .............................................. 1-4

Foreword

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Foreword

This manual includes explanations of the vehicle system, and

DOOSAN reserves the right to change the content of this manual

1-2 Glossary ........................................................5

1-3 Exterior and specifications .........................9

1-6 Lubricants ...................................................30

1-7 Disassembly/assembly instructions ........35

1-8 Standard torques ........................................44

1-1-1 Construction of this manual

The introductory section of this manual provides an

To help the reader find the information they need for

To help you identify what information each page contains,

How to use this manual 1-2 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

Section title Applicable models

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-3 How to use this manual

Each label is designed to indicate to the reader the

How to use this manual 1-4 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-5 Glossary

A control device for a drive motor, which is comprised of an inverter and

Glossary 1-6 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-7 Glossary

Glossary 1-8 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

1-3-1 B15/18/20T-7 and B18/20TL-7

Head lamp Overhead guard

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-9 Exterior and specifications

16 Overall Width in(mm) 42.9 (1090)

25 Lifting Loaded / Unloaded fpm(mm/s) 61/108 (310/550)

33 Loaded , Front / Rear lb(kg) 8858 / 1269 (4018 / 576)

Front in(mm) 35.5 (902)

Exterior and specifications 1-10 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-11 Exterior and specifications

16 Overall Width in(mm) 42.9 (1090)

25 Lifting Loaded / Unloaded fpm(mm/s) 79 / 118 (400 / 600)

39 Tread Width Front in(mm) 35.5 (902)

Normal in(mm) 20.8x39.1x27.5 (528x992x698)

Exterior and specifications 1-12 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-13 Exterior and specifications

Exterior and specifications 1-14 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-15 Exterior and specifications

16 Overall Width in(mm) 42.9 (1090)

25 Speed Lifting Loaded / Unloaded fpm(mm/s) 79 / 118 (400 / 600)

33 Loaded , Front / Rear lb(kg) 9337 / 1219 (4235 / 553)

Front in(mm) 35.5 (902)

Normal in(mm) 25.1x39.1x27.5 (638x992x698)

Exterior and specifications 1-16 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-17 Exterior and specifications

Exterior and specifications 1-18 B15/18/20T-7, B18/20TL-7, B16/18/20X-7

The reader is responsible for thoroughly reading,

Also note that the safety instructions outlined below are

• Familiarize yourself with the safety instructions

• Ensure you follow all the safety rules,

• Do not assume that you can perform the

B15/18/20T-7, B18/20TL-7, B16/18/20X-7 1-19 Safety precautions

Fit for the job

• Do not operate the vehicle or perform License

• Do not operate the vehicle or perform

• Do not operate the vehicle or perform

• Do not operate the vehicle or perform

• Wear the appropriate protective gear for the

• Wear a mask when sanding the body of the

• Wear welder’s gloves, welding mask/goggles,

• Ensure the vehicle is in a clear, open