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Manual de Servicvio Unicarriers G1N1
Manual de Servicvio Unicarriers G1N1
This service manual has been prepared to provide necessary information concerning the maintenance and repair
procedures for the UniCarriers forklift (A)1N1 series.
Any changes effected in the series after publication of this service manual will be announced in a technical bulletin. It is,
therefore, recommended that each relevant technical bulletin be inserted in front of each section and be used together with
the service manual as a reference.
If a new model requires different service method or has undergone a major change, revised sections will be issued to replace
the applicable sections. Each revised section will include the description of how to service the parts for the former
specifications. The publication of a revised section will be announced in the technical bulletin.
This service manual consists of Sixteen sections as shown in the following table, which gives the updated symbols. When a
revised service manual is issued, this ‘‘INTRODUCTION” sheet should be replaced with a revised one.
Section Symbol
GENERAL INFORMATION (GI)
MAINTENANCE (MA)
CONTROL SYSTEM (CS)
OPTION (OP)
September 2013
0-0
FOREWORD
This manual contains maintenance and repair procedures.
In order to assure your safety and the efficient functioning of the lift truck, this manual should be
read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely
understood before starting any repair task.
All information in this manual is based on the latest product information at the time of publication.
The right is reserved to make changes in specifications and methods at any time without notice.
No modifications or alterations to a powered industrial truck, which may affect, for example,
capacity, stability or safety requirements of the truck shall be made without the prior written
approval of UniCarriers, its authorized representative, or a successor thereof. Contact an authorized
UniCarriers forklift dealer before making any modification or alteration to your industrial truck that
may affect, for example braking, steering, visibility and the addition of removable attachments. After
getting approval of UniCarriers, its authorized representative, or a successor thereof, capacity plate,
decals tags and operation and maintenance handbooks shall also be changed to the appropriate one.
Only in the event that UniCarriers is no longer in business and there is no successor in the interest
to the business, the user may arrange for a modification or alteration to a powered industrial truck,
provided, however, that the user shall:
SECTION GI
CONTENTS
HOW TO USE THIS MANUAL ............................ GI-2 GENERAL PRECAUTIONS ................................ GI-7
Outline of This Manual ................................... GI-2 JACKING, TOWING AND LIFTING .................. GI-11
Technical Term Definitions ............................. GI-3 Jacking ......................................................... GI-11
Manual Illustrations ........................................ GI-5 Towing (Freeing a stuck forklift) ................... GI-14
IDENTIFICATION INFORMATION ..................... GI-6 Lifting ............................................................ GI-14
Vehicle Model Classification Number ............. GI-6 TIGHTENING TORQUE OF STANDARD
Model Variation .............................................. GI-6 BOLTS .............................................................. GI-15
Vehicle Identification Number ......................... GI-7
Identification Plate .......................................... GI-7
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
How to use this manual, identification information, general precautions, jacking, lifting, towing
GI General information
and tightening torque of standard bolts.
MA Maintenance Inspection, adjustment, part replacement and lubricant replenishment
Precautions, controller unit inspection and adjustment, meter panel, LCD mode description,
CS Control system switches and sensors inspection, trouble diagnostic procedures, trouble diagnoses for
controller.
Battery and battery
BC Precautions, battery and battery charger.
charger
Precautions, electrical component parts, location of electrical units, harness layout, fuses,
EL Electrical system
lighting system, switches, miscellaneous electrical parts and location of optional parts.
Service data and specifications, trouble diagnoses and corrections, precautions and
MM Motor mechanism
preparation, traction motor, hydraulic pump motor and motor inspection.
Service data and specifications, trouble diagnoses and corrections, precautions and
DU Drive unit
preparation, construction, removal, disassembly, inspection, assembly and installation.
Service data and specifications, trouble diagnoses and corrections, precautions and
TR Front tire and rear tire
preparation, tire and road wheel.
Service data and specifications, trouble diagnoses and corrections, precautions and
BR Brake system preparation, construction, service brake (wet type), brake pedal, master cylinder, brake piping
and parking brake.
Service data and specifications, trouble diagnoses and corrections, precautions and
RA Rear axle
preparation, construction, component parts, removal, inspection, installation and adjustment.
Service data and specifications, trouble diagnoses and corrections, precautions and
ST Steering system preparation, steering wheel, steering column assembly, power steering valve, power cylinder,
rear axle and steering piping.
Service data and specifications, trouble diagnoses and corrections, precautions and
HD Hydraulic system preparation, hydraulic piping system, hydraulic pump (gear pump), control valve, control lever,
tilt cylinder, lift (mast) cylinder and oil tank.
Service data, trouble diagnoses and corrections, precautions and preparation, construction,
LM Loading mechanism
fork, lift chain, carriage assembly and mast assembly.
BF Forklift body and frame Service data, precautions, construction, removal, installation, body parts and accessories.
GI-2
HOW TO USE THIS MANUAL
OTHER ENTRIES
The following information is included at the beginning of all sections
as a supplement to the main text.
GI-3
HOW TO USE THIS MANUAL
Conversion
Foot/pound
SI unit Metric system factor to SI
system
unit
NOTE:
Converting the unit in metric system or foot/pound system to SI unit
is shown below.
Unit in metric system or foot/pound system x conversion factor = SI
unit
GI-4
HOW TO USE THIS MANUAL
Manual Illustrations
EXPLODED VIEWS
These contain part names, tightening torques, lubrication points and other information necessary to perform
removal, disassembly, repair, reassembly and installation procedures. (See example below.)
BRT0005
GI-5
IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION
Destination
Q: Europe & General areas
V: North America (UL-E)
Application
No code: Standard
Loading capacity
13: 1.25 ton (2,756 lb)
15: 1.5 ton (3,308 lb)
16: 1.6 ton (3,528 lb)
18: 1.8 ton (3,969 lb) or 1.75 ton (3,860 lb)
20: 2.0 ton (4,410 lb)
Frame size
L: Standard
Basic model
designation
1N1
Wheelbase
S: Short wheelbase
No code: Standard
wheelbase
G: Long wheelbase
Frame type
No code: 3-wheel
J: 4-wheel BSM0696
Model Variation
ATLET TCM
GI-6
GENERAL PRECAUTIONS
GIM0094
Identification Plate
The identification plate shows the vehicle type, vehicle model
classification number, vehicle identification number (chassis
number), permissible load at load center, mast type, maximum mast
elevation, battery voltage, available vehicle attachments and vehicle
weight.
GENERAL PRECAUTIONS
GI-7
GENERAL PRECAUTIONS
GI-8
GENERAL PRECAUTIONS
GI-9
GENERAL PRECAUTIONS
WARNING:
• When working with any battery always wear personal
protective equipment (PPE), as in rubber gloves, rubber
apron and protective face shield.
GI-10
JACKING, TOWING AND LIFTING
JACKING, TOWING AND LIFTING
CAUTION:
• Never get under the forklift or the fork while jacking or lifting
the forklift.
• Always perform jacking or lifting operation on a flat and solid
surface.
• Operate the key switch and individual operational levers only
when sitting in the operator's seat. Never touch these
controls when you are standing near the forklift.
• Be sure to apply the parking brake whenever jacking or
lifting the forklift.
• Do not chock the forklift with multiple wooden blocks
stacked one on top of the other. Only use one wooden block
in place.
• Be sure to use wooden blocks of sufficient strength to
support the weight of forklift.
• Never use cracked or broken wooden blocks. These may
cause unstable support, putting you in danger.
• Never place wooden blocks of different heights side by side
under the vehicle or the mast.
Jacking
CAUTION:
• Using the mast to raise the front wheels for an extended time
period will eventually bend the mast. Place wooden blocks
tightly under the front of the frame on both sides of the
forklift to take the stress off the mast.
• Wooden block area and height should be such that the
wooden blocks can just be inserted between the mast and
the ground surface when the mast is tilted back. Front-to-
back wooden block length should be 50 - 100 mm (1.97 - 3.94
in) larger than the mast rail front-to-back length. Side-to-side
wooden block width should be 20 - 40 mm (0.79 - 1.57 in)
greater than the outer mast outside width.
• When jacking up the forklift, raise it until the wheels are
slightly clear of the ground. Stop jacking. Do not attempt to
raise the forklift above this level.
GI-11
JACKING, TOWING AND LIFTING
Jacking (Cont’d)
3. Place a wedge block behind the rear wheel to avoid slipping.
GIM0095
4. Place the jack under the one side of the frame, as shown in the
illustration.
5. Slowly raise the front of the forklift until the front wheel is slightly
clear of the floor or ground. Do not go higher.
CAUTION:
Do not allow the jack to slip when jacking up the forklift.
GIM0106
GIM0107
GIM0100
GI-12
JACKING, TOWING AND LIFTING
GIM0101
MOM8503
REAR
1. Raise the forks about 100 mm (3.94 in) from the ground, and tilt
them slightly back.
2. Block the front wheels.
3. Place a garage jack under the counterweight center, and then
jack it up.
4. Jack up until the tires are slightly raised from the ground, place
a square timber under the left and right frame, and then slowly
MOM2106 lower the jack.
GI-13
JACKING, TOWING AND LIFTING
MOM8505
Lifting
CAUTION:
• Do not use wooden blocks whose height exceeds 300 mm
(11.81 in).
• Never hoist the vehicle unless it is absolutely necessary.
• Be sure that the hoist, nylon sling and lifting wire are in
perfect condition. The hoist and wire must have sufficient
strength to lift and support the forklift.
• Attach the lifting wire only to the specified points. Never
attach the wire to any other part of the forklift.
GIM0103
GI-14
JACKING, TOWING AND LIFTING
Lifting (Cont’d)
LIFTING REAR OF VEHICLE
1. Secure lifting wire to the hole of the battery plate. Slowly raise
forklift using hoist.
2. Place wooden block under counterweight.
3. Slowly lower forklift onto wooden block. Double-check to make
sure that wooden block is positioned correctly.
4. Make sure that forklift is settled firmly on wooden block by trying
to shake the forklift. It should be perfectly steady.
5. Chock front wheels to hold vehicle stationary.
GIM0104
GIM0105
GI-15
TIGHTENING TORQUE OF STANDARD BOLTS
TIGHTENING TORQUE OF STANDARD BOLTS
CAUTION:
• Special parts are excluded.
• This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade........... Mark
4T ................ 4 or no mark
7T ................ 7
9T ................ 9
GI-16
MAINTENANCE
SECTION MA
CONTENTS
LUBRICATION CHART .................................... MA-2 Drive Unit (Reduction Gear) ........................ MA-13
Lubrication Chart ........................................... MA-2 TIRES AND ROAD WHEELS .......................... MA-14
MAINTENANCE SCHEDULE ........................... MA-4 Tires and Road Wheels ............................... MA-14
Maintenance Schedule .................................. MA-4 BRAKE SYSTEM ............................................. MA-16
BATTERY .......................................................... MA-6 Brake System .............................................. MA-16
Battery ........................................................... MA-6 STEERING SYSTEM ....................................... MA-21
CONTROL SYSTEM ....................................... MA-10 Steering System .......................................... MA-21
Control System ............................................ MA-10 HYDRAULIC SYSTEM .................................... MA-22
MOTORS ......................................................... MA-11 Hydraulic System ........................................ MA-22
Motors ......................................................... MA-11 LOADING MECHANISM .................................. MA-27
ELECTRICAL COMPONENTS ....................... MA-12 Loading Mechanism .................................... MA-27
Electrical Components ................................ MA-12
DRIVE UNIT (REDUCTION GEAR) ................ MA-13
LUBRICATION CHART
LUBRICATION CHART
Lubrication Chart
(1) LUBRICATION SCHEDULE CHART
BSM0688EU
SUITABLE OIL
ITEM BELOW ABOVE
15°C (60°F) 15°C (60°F)
GASOLINE ENGINE OIL SAE NO. 20 SAE NO. 30
GEAR OIL SAE NO. 80 SAE NO. 140
W.B. GREASE N.L.G.I. NO. 2
CHASSIS GREASE N.L.G.I. NO. 1
1N1: DOT4
BRAKE FLUID A1N1: PSF (Power Steering
Fluid)
BRAKE DISK FLUID SAE 80W/API GL-4
Standard
ISO VG32 or equivalent
forklift
HYD. OIL
Cold storage SAE NO. 10W
forklift (ISO VG15)
REPLACE ELEMENT
MAM8510E
MA-2
LUBRICATION CHART
(2) GREASE/OIL AND CAPACITY 1N1
Capacity
System/component Oil and grease
1N1 JG1N1
Reduction gear SAE 80W/API GL4 0.4 (7/8 US pt, 3/4 Imp pt)/one side
(Drive unit)
Brake disk SAE 80W/API GL4 0.16 (3/8 US pt, 3/8 Imp pt)/one side
Brake DOT 4 -
Hydraulic oil tank Hydraulic oil I.S.O. VG32 17.9 (4-3/4 US gal, 4 Imp gal) 20.9
Greasing point The greasing points and grease type in use are listed in the above lubrication schedule chart.
Reduction gear SAE 80W/API GL4 0.35 (0.74 US pt, 0.62 Imp pt)/one side
(Drive unit)
Brake disk SAE 80W/API GL4 0.16 (0.34 US pt, 0.28 Imp pt)/one side
Brake fluid type PSF (Power Steering Fluid) or DEXRON
0.15 (0.32 US pt, 0.26 Imp pt)
equivalent
Hydraulic oil tank Hydraulic oil I.S.O. VG32 A1N1 17.9 (4.73 US gal, 3.94 Imp gal)
JAG1N1 20.9 (5.52 US gal, 4.60 Imp gal)
Greasing point The greasing points and grease type in use are listed in the above lubrication schedule chart.
MA-3
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE
Maintenance Schedule
The first maintenance should be at 1 month or 200 hours (which
ever comes first) after the truck is first put into use. See the (1)
marked interval. Periodic maintenance should be performed at least
every 6 months following the interval schedule:
Schedule A (Months):For trucks operating less then 600 hours
(effective), maintenance should be
performed according the maintenance
intervals in Months (A).
Schedule B (Hours): For trucks operating more then 600 hours
(effective), maintenance should be
performed according the maintenance
intervals in hours (B).
NOTE:
Under dusty, dirty or heavy operations, more frequent maintenance
is necessary. All items listed above must be maintained in order to
meet and keep control systems operating at design level. Failure to
maintain the systems could compromise the warranty.
Interval
Inspection items A (months) 1 (1) 6 12 18 24 … How to
check
B (hours) (1) 600 1200 1800 2400 3000 3600 4200 4800 …
200
Motor (Dust) C C C C C … Clean
Motor
Fuses I I I I I I I I I … Visual
Relays I I I I I I I I I … Visual
Switches I I I I I I I I I … Test
Lights (all) I I I I I I I I I … Test
Horn / buzzer I I I I I I I I I … Test
Gauge and Indicators I I I I I I I I I … Test
Wipers I I I I I I I I I … Visual / Test
Oil level I I I I I I I I I … Visual
Differential /
drive unit
MA-4
MAINTENANCE SCHEDULE
Interval
How to
Inspection items A (months) 1(1) 6 12 18 24 …
check
B (hours) 200(1) 600 1200 1800 2400 3000 3600 4200 4800 …
Visual /
Wheel nuts T T T T T T T T T …
Torque
Wheels
I I I I I I I I I … Visual
(readable / correct)
Warning labels (readable) I I I I I I I I I … Visual
Overhead guard (damage / cracks) I I I I I I I I I … Visual
General All bolt and nuts I I I I I I I I I … Visual
MA-5
BATTERY
BATTERY
Battery
(1) INSPECTION OF ELECTROLYTE LEVEL
CAUTION:
Fill distilled water when battery electrolyte level drops.
1. Open the cap and check the electrolyte level. If electrolyte level
is in between - in left figure, it is OK.
CAUTION:
Be careful because battery specifications may vary with each
maker.
BCM0014
2. If inspection finds a cell in which electrolyte level is too low,
check if there is any leakage and fill with distilled water. Continue
filling up with cap opened until electrolyte level rises to
position. However, be careful, for it may vary with each maker.
NOTE:
• Probable causes of leakage are as follows:
• Damage to cap
• Excessive filling with distilled water
• High electrolyte temperature during charging, leading to
electrolyte overflow
CAUTION:
• Use care not to fill distilled water excessively. It may cause
short or leakage.
• Electrolyte lid is pushed into battery cell and needs to be
secured to prevent leakage.
• If there are any cracks in electrolyte lid, replace with new one.
• Be careful because battery specifications may vary with each
maker.
• Before changing any components (i.e. lamps, fuses, meter
panels) or disconnecting any wiring. Always turn OFF key
switch and disconnect battery. This will reduce the
possibility of damage to the controller system.
MA-6
BATTERY
Battery (Cont’d)
(3) INSPECTION OF SPECIFIC GRAVITY
NOTE:
Specific gravity is very useful for determining battery life and
condition.
1. To measure specific gravity of each battery cell by gravimeter.
CAUTION:
Measure with gravimeter placed in battery cell. Use extra care
to prevent scattering of battery electrolyte outside when pulling
it out of the cell.
BCT0018
MA-7
BATTERY
Battery (Cont’d)
(6) INSPECTION OF EXTERNAL LEAKAGE ( LEAK)
Locate leaking cell following the flow chart below.
NOTE:
• Put tester to paint erased portion (paint is erased by file) when
putting the tester to iron box.
• White zinc sulphate crystals are most often stuck to terminal of
electrolyte leaking cell.
No
Remove battery Voltage is OK (no leak)
from vehicle body generated.
and wash it with
water. Yes
First time
BCT0006
Second time
Yes
NOTE:
For inspection of leak, measure in reverse polarity of all and
for leak inspection.
MA-8
BATTERY
Battery (Cont’d)
(7) INSPECTION OF BODY RESISTANCE
Check resistance between truck body and negative/positive
terminals of battery connector track side.
Normal:
If resistance value is “no infinity”, check lead wires, controller and
motor windings for grounding. Correct or replace faulty parts as
necessary.
MOM1994a
MA-9
CONTROL SYSTEM
CONTROL SYSTEM
Control System
(1) INSPECTION OF MAIN CONTACTOR
Contactor points
Make sure each contactor arm moves smoothly when pushed, and
that it quickly returns to its original position when released. If it is
questionable, disassemble and check the condition of the contactor.
If the contactor point is damaged or worn, beyond wear limit (1N1),
replace the contactor base and contactor frame as a unit.
Continuity
NOTE:
The circuit tester range selector must be set to “x1 ”.
MA-10
MOTORS
MOTORS
Motors
(1) CLEANING OF MOTOR
When motor is operated under severe dust conditions, occasionally
clean motor interior using dry compressed air in order to maintain
original insulation resistance.
MA-11
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
Electrical Components
(1) INSPECTION/REPLACEMENT OF FUSE
Check for blown fuse by referring to the right side of the figure.
Replace blown fuse with a new one.
CAUTION:
• When replacing fuse, always use one of specified capacity,
indicated on the fuse capacity label.
• If fuse blows again after replacing, electrical trouble is
considered. Immediately inspect and eliminate cause of the
trouble.
• Before changing any components (i.e. lamps, fuses, meter
panels) or disconnecting any wiring. Always turn OFF key
MAM0157
switch and disconnect battery. This will reduce the
possibility of damage to the controller system.
Battery 1 5 Meter
2 10 Option (Battery power supply)
Headlamp, tail lamp, stop lamp,
3 10
horn, back operation lamp (option)
4 10 (1N1) 20 Power supply for key switch
(A1N1)
Key switch 5 10 Controller
ELM0262
6 5 Option
7 5 Meter
8 10 Reverse lamp, back buzzer
Wattage (W)
Number of
Lamps
48V 36V parts
Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1
MA-12
DRIVE UNIT (REDUCTION GEAR)
DRIVE UNIT (REDUCTION GEAR)
1. Remove the oil level plug and check the gear oil level. Add if
necessary using the filler plug.
2. Apply liquid packing to the threads of the oil level plug. Then
install and tighten the plug to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]:
20 - 29 (2.1 - 2.9, 15 - 21)
MAM0158
MAM0159
3. Add new gear oil from the filler port after removing the filler plug.
CAUTION:
Only use the authorized genuine gear oil.
4. Apply liquid packing to the threads of the filler plug. Then install
and tighten the plug to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]:
20 - 29 (2.1 - 2.9, 15 - 21)
CAUTION:
MAM0160 After refilling, always check the oil level.
MA-13
TIRES AND ROAD WHEELS
TIRES AND ROAD WHEELS
Tire size
18x7-8 18x7-8 18x7-8 200/50-10 18x7-8 200/50-10 200/50-10
(Pneumatic solid)
Pneumatic
solid
Type
Clean (White)
Cushion — — —
Tire size
15x4.5-8 15x4.5-8 140/55-9 140/55-9 16x6-8 16x6-8 16x6-8
(Pneumatic solid)
Rim size
3.00D-8 3.00D-8 4.00E-9 4.00E-9 4.33R-8 4.33R-8 4.33R-8
(Pneumatic solid)
Rear
Pneumatic
solid
Type
Clean (White)
Cushion — — — — — —
Cushion
Tire size (Pneumatic solid) 154.5-8 140/55-9 140/55-9
Rim size (Pneumatic solid) 3.00D-8 4.00E-9 4.00E-9
Tire size (Cushion) 15511-1/4 15511-1/4
Rear
Cushion
MA-14
TIRES AND ROAD WHEELS
MAT0006
MAT0007
MAT0008
MA-15
BRAKE SYSTEM
BRAKE SYSTEM
Brake System
(1) INSPECTION OF BRAKE FLUID LEVEL
Check brake fluid level in brake reservoir tank. If it is between MAX
(upper limit) and MIN (lower limit) marks on the reservoir tank, fluid
level is correct. If it is lower than MIN (lower limit) mark, refill
specified brake fluid up to MAX (upper limit) mark.
CAUTION:
• Type of brake fluid: DOT4 (1N1), Power Steering Fluid, PSF
(A1N1).
• Do not overfill brake fluid.
BRM0087
• Be careful not to allow foreign matter to enter reservoir tank.
• Be careful not to splash brake fluid on painted areas; it may
cause paint damage.
• If brake fluid decreases abnormally, check for leaks in brake
line. Eliminate the cause of problem.
• Only use the authorized genuine brake fluid. Do not mix
different types of brake fluids.
BRM0098
MA-16
BRAKE SYSTEM
MAT0223L
5. Depress the brake pedal several times to verify the pedal feel is
getting heavy.
6. Repeat the operations from step 3 until the brake fluid stream in
the vinyl tube contains no air bubbles.
7. Tighten the bleeder valve securely. Perform the same
operations for the other side.
8. After bleeding the air, check the reservoir tank fluid level and
add an appropriate amount of brake fluid if necessary.
MA-17
BRAKE SYSTEM
CAUTION:
• Type of brake oil: SAE 80W/API GL4
• Place the vehicle on level ground. Ensure that the unit is
cooled down.
• Only use the authorized genuine brake oil.
1. Remove the oil level plug and check the brake oil level. Add new
brake oil from the filler port after removing the filler plug if
necessary.
BRM0071bEU
2. Apply liquid packing to the threads of the plugs. Then install and
tighten the plugs to the specified torque.
Tightening torque [N•m (kg-m, ft-lb)]: 15 (1.5, 11)
BRM0069EU
MA-18
BRAKE SYSTEM
BRM0079
2. Check brake pedal free play at push rod. If brake pedal free play
is outside specifications, adjust using push rod adjusting nut.
Then tighten adjusting nut and check pedal play at pedal pad.
Free play:
At push rod
0 - 0.5 mm (0 - 0.020 in)
At pedal pad
0 - 2.3 mm (0 - 0.091 in)
: 16 - 22 N•m (1.7 - 2.2 kg-m, 12 - 16 ft-lb)
BRM0080
CAUTION:
Always properly adjust play. If play is much less than standard,
push rod is continuously applied with load. This results in
blocking master cylinder return port, causing brake dragging.
Also, excessive play may cause push rod to come out of place.
MA-19
BRAKE SYSTEM
MAM0162
BRM0099
MA-20
STEERING SYSTEM
STEERING SYSTEM
Steering System
(1) INSPECTION OF STEERING WHEEL FOR PLAY
Check that the steering wheel play is within the standard on the
circumference with key switch turned off.
Play: 20 - 30 mm (0.79 - 1.18 in )
MAM0164
MA-21
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Hydraulic System
(1) INSPECTION OF HYDRAULIC FLUID LEVEL
CAUTION:
• To ensure precise measurement, place the vehicle on level
ground, set the mast upright and lower the carriage to the
lowest limit.
• Only use the authorized genuine hydraulic fluid. Do not mix
different types of fluids.
1. Remove the level gauge for hydraulic fluid and clean the level
gauge with a shop cloth.
BSM617EU
2. Insert the level gauge into the port and pull out the gauge.
3. On the level gauge, check that the fluid level is within the
optimum range shown in the figure. Add the specified fluid if
necessary.
CAUTION:
• Do not overfill the tank.
• Do not allow any foreign materials to get into the tank.
• If the fluid consumption is too large, there is a possibility of
fluid leakage. Inspect the system piping to identify the causal
points.
MAM0163EU
1. Turn key switch to ON and raise the fork slightly by operating the
MOM8507
lift (mast) cylinder. (The fork should not touch the ground when
the tilt cylinder is fully tilted forward.)
2. Operate the tilt cylinder forward to the full stroke.
3. Return the control lever to the neutral position and turn key
switch to OFF. Loosen the connectors in front of the left and
right tilt cylinders and disconnect the hoses.
4. With key switch ON, set the control lever in the backward
position and tilt the mast fully backward using a crane, in order
to return the oil from the tilt cylinder to the oil tank.
5. Return the control lever to the neutral position.
6. Turn key switch to ON and raise the lift (mast) cylinder to the full
stroke.
7. Return the control lever to the neutral position and turn key
switch to OFF.
8. Move the control lever to the lift (mast) cylinder lowering position
to lower the lift (mast) cylinder gradually. By doing so, return the
fluid from the lift (mast) cylinder to the oil tank.
9. Drain the oil from the oil tank and extract the fluid.
10. Remove dust collected in the oil tank and clean inside the oil
tank.
MA-22
HYDRAULIC SYSTEM
11. Attach the hoses and fill the oil tank with new hydraulic fluid
referring to the table below.
Model (A)1N1 J(A)G1N1
CAUTION:
The oil level should be between the upper limit and the lower
limit on the level gauge when the hydraulic fluid has permeated
through the hydraulic system and piping.
1 = Oiltank
2 = Micron filter assy
MAM0165 MAM0165
MA-23
HYDRAULIC SYSTEM
MAM0166
MA-24
HYDRAULIC SYSTEM
Standard pressure
MPa (bar, kg/cm2, psi)
MA-25
HYDRAULIC SYSTEM
MA-26
LOADING MECHANISM
LOADING MECHANISM
Loading Mechanism
(1) INSPECTION OF FORK
• Visually inspect the fork and replace it if cracked or damaged. (To
identify minute cracks, use the dye penetrant method.)
• If the fork is worn by 3 mm or more compared to a new one,
replace it. (The grounding face at the fork base is prone to wear.)
LMM0227
MAT0159J
MA-27
LOADING MECHANISM
1. Set the mast upright and raise the fork by 20 to 30 mm from the
ground level.
2. For the 2W mast, pull the lift chain at the middle point and check
the deflection. For the 2F, 3F and 3V masts, press the lift chain
at the middle point and check the deflection.
Standard: 25 - 30 mm (0.98 - 1.18 in)
3. If the deflection is outside the specified range, loosen the lock
nut and adjust the chain tension with the lift chain adjusting nut.
CAUTION:
• Ensure that equivalent tension is applied to the left side and
right side of the lift chain.
• After adjustment, always check the carriage operation for
smoothness.
LMT0152L
MA-28
LOADING MECHANISM
2W mast
Unit: mm (in)
2F mast
Unit: mm (in)
LMT0029
Lifting height Dimension “L”
MA-29
LOADING MECHANISM
LMT0035
3F mast
Unit: mm (in)
3V mast
Unit: mm (in)
LMT0030
MA-30
LOADING MECHANISM
LMT0031
LMT0161L
LMT0124J
MA-31
LOADING MECHANISM
BET0236L
Lift chain
• Apply gasoline engine oil to the entire surface of the chain.
MAT0163J
Mast support
• Supply grease from the grease nipple.
LMM0223
MAT0164J
MA-32
LOADING MECHANISM
LMM0231
LMM0212
MA-33
LOADING MECHANISM
MA-34
CONTROL SYSTEM
1N1 SECTION CS
CONTENTS
TECHNICAL DESCRIPTION ............................. CS-2 How To Follow Flow Chart .......................... CS-79
System .......................................................... CS-2 Symbol Identification ................................... CS-80
PRECAUTIONS ............................................... CS-10 Voltage and Resistance Measurement
LOCATION OF UNITS (LAYOUT) ................... CS-11 Procedures .................................................. CS-81
Standard Equipment (3 - wheel) .................. CS-11 TROUBLE DIAGNOSIS FOR CONTROLLER
Standard Equipment (4 - wheel) .................. CS-12 SYSTEM ........................................................... CS-82
Optional Equipment ..................................... CS-13 TROUBLE DIAGNOSIS FOR DRIVING
METER PANEL ................................................ CS-14 SYSTEM ........................................................... CS-90
Meters, Indicators and Lamps ..................... CS-14 TROUBLE DIAGNOSIS FOR LOADING
Setting Adjustment Items (Normal Mode) ... CS-14 SYSTEM OF MECHANICAL TYPE ................. CS-97
Meter Panel Explanation ............................. CS-15 TROUBLE DIAGNOSIS FOR LOADING
LCD MONITOR ................................................ CS-23 SYSTEM OF JOYSTICK TYPE ..................... CS-102
Adjustment Mode ........................................ CS-23 TROUBLE DAIGNOSIS FOR POWER
Diagnostic Mode .......................................... CS-31 STEERING SYSTEM ..................................... CS-108
Table of Error Code ..................................... CS-42 TROUBLE DIAGNOSIS FOR TURN SIGNAL
CONTROLLER ................................................. CS-43 LAMP SYSTEM ............................................. CS-109
Construction ................................................ CS-43 REFERENCE DATA OF CONTROL
Connector (Terminal layout) ........................ CS-45 SYSTEM ......................................................... CS-110
Controller Element Inspection ..................... CS-49 Main Print Board ........................................ CS-110
Removal and Installation (3 - wheel) ........... CS-56 Drive FET Board (for RH traction motor
Removal and Installation (4 - wheel) ........... CS-57 control) ...................................................... CS-114
UNIT INSPECTION AND ADJUSTMENT ........ CS-58 Drive FET Board (for LH traction motor
Control System ............................................ CS-58 control) ...................................................... CS-114
Joystick Control System (Option) ................ CS-70 Pump FET Board ....................................... CS-114
Knob Position Control System Traction Condenser Board ........................ CS-115
(Option 3 - wheel only) ................................ CS-77 Loading Condenser Board ........................ CS-115
TROUBLE DIAGNOSTIC PROCEDURES ...... CS-78 Joystick Controller ..................................... CS-116
Precautions ................................................. CS-78
CAUTION:
Where towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to
reduce possible damage to electrical system.
Bulletin issued:
Service Bulletins Issue date
SB-TX-CS0501-2 Prevention to damage controller 05-01-2006
SB-TX-CS0502 Changing ground circuit MP 29-11-2005
SB-TX-CS0601 Power mode indication scrolling on meter panel 05-05-2006
SB-TX-CS0602 Error code 558 occur with FN1+FN3 05-05-2006
SB-TX-CS0702 Incorrect measurement with damaged controller insulation 01-10-2007
CS-1
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
System
COMPARISON OF PREVIOUS TYPE AND NEW TYPE
CSM0086
CSM0087
CS-2
TECHNICAL DESCRIPTION
System (Cont’d)
AC motor control
CSM0088
Drive control Drive control type Induction motor AC inverter vector control
Drive control 2 motor turning control
Regeneration control Switchback, brake, accelerator off regeneration
Performance adjustment Power level (3 steps+ accurate adjustment 5 steps)/Acceleration Level (8 steps),
Regeneration level (8 steps each)
Anti-roll (8 steps)
Anti-roll control Anti-roll braking force control on slope
Various limitation Speed, high lift height, power cut (brake, parking brake)
Pump control Drive control Induction motor AC inverter vector control
Drive control Speed control by loading operation
Regeneration control Loading regeneration when loading operation stopped
Performance adjust. Power level (3 steps + accurate adjust 5 steps) Acceleration Level (8 steps)
Various limitation High lift height, high driving speed, cutout when reverse drive, pump cut
Mast lowering control Mast lowering lock when key switch is off
Magnetic proportional control Magnetic proportional loading control for optional unit (Joystick control system)
PS control Drive control type Electronic controlled hydraulic power steering
Drive control method Common pump motor control for loading
Control function Starting with steering operation detected/steering speed sensing control
Knob position control Compensate steering angle and tire angle offset by magnetic valve control
CS-3
TECHNICAL DESCRIPTION
System (Cont’d)
Item Function Outline
CS-4
TECHNICAL DESCRIPTION
System (Cont’d)
FEATURE OF DRIVE SYSTEM
Maintenance free AC Traction/Pump Motors
Pump motor is used for PS
High technology for superior function and high reliability by adoption of sensors with high performance
AC motor digital control adopting 32bit RISC CPU
Adoption of HEV (Hybrid Electric Vehicle) high responsible items such as resolver
CAN (Controller Area Network) communication between units
CSM0089
CS-5
TECHNICAL DESCRIPTION
System (Cont’d)
CSM0090
CSM0091
CS-6
TECHNICAL DESCRIPTION
System (Cont’d)
PRINCIPLE OF AC MOTOR
CSM0092
CS-7
TECHNICAL DESCRIPTION
System (Cont’d)
KNOB POSITION CONTROL SYSTEM
(OPTION 3 - WHEEL ONLY)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)
Input Output
CS-8
TECHNICAL DESCRIPTION
System (Cont’d)
Knob position control system (option 3 - wheel only)
CSM0093
CS-9
PRECAUTIONS
PRECAUTIONS
CAUTION:
• Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
• Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body and
do not pull on the cord.
• When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
• When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
• Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.
Inadvertent current flow may damage the element or other
parts being checked.
• Before using flow charts as a guide to troubleshoot units and
parts, become familiar with the instructions outlined under
“TROUBLE DIAGNOSTIC PROCEDURES”.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
CS-10
LOCATION OF UNITS (LAYOUT)
LOCATION OF UNITS (LAYOUT)
CSM0094
CS-11
LOCATION OF UNITS (LAYOUT)
CSM0094EU
CS-12
LOCATION OF UNITS (LAYOUT)
Optional Equipment
CSM0095EU
CS-13
METER PANEL
METER PANEL
CSM0096EU
CS-14
METER PANEL
LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
To darken the contrast, push function switch FN2. To lighten the
contrast, press function switch FN1.
NOTE:
Only for 3 - wheel trucks
CSM0098
CS-15
METER PANEL
NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)
CSM0099
POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function switch FN3 is pressed, the power
mode is switched.
CS-16
METER PANEL
Push function switches FN1 and FN2 simultaneously. The time set
mode will appear.
After setting the clock to the correct time, push function switch FN5.
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
• Push FN1 to increase the numerical value or advance one day of
the week.
• Push FN2 to decrease the numerical value or reverse one day of
the week.
• If an alarm is set, “ ” appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press FN5 to stop the buzzer. The day of the week can
be set to every day (ALL: every day).
Simultaneously press function switches FN1 and FN4. The clock will
move to the traction acceleration control mode.
Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.
Each time the key is pushed, the acceleration level (speed) will
decrease by 1 step.
After setting the acceleration level, push function switch FN5. The
acceleration level will appear, and clock will return to its original letter
mode.
CS-17
METER PANEL
For faster acceleration (Quick): Push function switch FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
CSM0103
For slower acceleration (Slow): Push function switch FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.
After setting the acceleration level, push function switch FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.
CS-18
METER PANEL
CSM0104
Wrench mark
The controller and the sensors act together to regulate the forklift’s
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.
CS-19
METER PANEL
CSM0105
CSM0106
After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle may be operated during the pump cut warning.
However, move the vehicle to a safe location, and promptly charge
the battery.
CSM0106
CS-20
METER PANEL
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
CSM0106
CS-21
METER PANEL
D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor is WARNING
overheating. Immediately stop
Ignoring the warning indication and
forklift operation. Park the forklift in
continuing to operate the forklift
a safe area where there is no
can result in serious motor and
pedestrian or vehicular traffic.
controller damage.
Allow the controller and/or the
motor to cool.
Essential fluid BRAKE FLUID LEVEL DOWN The brake fluid level has fallen
below the specified level.
Battery Battery over voltage The controller has detected a high Turn the key switch OFF and ON
battery voltage again. If no error displayed, you can
operate the forklift without a
problem. If problem reoccur, contact
your dealer.
CS-22
LCD MONITOR
LCD MONITOR
Adjustment Mode
CSM0107
CS-23
LCD MONITOR
CS-24
LCD MONITOR
CSM0109
CS-25
LCD MONITOR
CSM0110EU
CS-26
LCD MONITOR
CSM0190
CS-27
LCD MONITOR
CSM0191EU
CS-28
LCD MONITOR
CSM0192
CS-29
LCD MONITOR
CSM0193
CS-30
LCD MONITOR
Diagnostic Mode
CSM0108
CS-31
LCD MONITOR
CS-32
LCD MONITOR
CSM0111
CS-33
LCD MONITOR
CSM0112
CS-34
LCD MONITOR
CSM0194
CS-35
LCD MONITOR
CSM0195
CS-36
LCD MONITOR
CSM0196
CS-37
LCD MONITOR
CSM0197
CS-38
LCD MONITOR
CSM0198
CS-39
LCD MONITOR
CSM0199
CS-40
LCD MONITOR
RESULT OF SELF-CHECK
If the error is not detected:
CSM0113
CS-41
LCD MONITOR
CONTROLLER ACTUATOR
Main contactor Short 400 - Lift down valve Short 500
CS-52 - CS-69 -
Open 401 - Open 501
Main fuse Open 403 CS-53 - PS correction valve Short 502 Knob
Battery voltage Low voltage 404 - Open 503 position
CS-77
control
Over 405 - - -
(Option)
voltage
Tilt Horizontal valve Short 504
CONT capacitor Abnormal 406 - - - Not equipped
Open 505
Drive FET Short 408
Lift valve Pull Short 506
Open 409 Joystick
CS-49 - Open 507
Drive FET left Short 410 control
Push Short 508 (Option)
Open 411
Open 509
Pump FET Short 412
CS-50 - Tilt valve Pull Short 510
Open 413 Joystick
Open 511
Drive current U Low output 414 control
sensor Push Short 512 (Option)
High output 415
Open 513
V Low output 416
3rd valve Pull Short 514
High output 417 Joystick
CS-51 - Open 515
Drive current U Low output 418 control
sensor left Push Short 516 (Option)
High output 419 CS-72-73
Open 517
V Low output 420
4th valve Pull Short 518
High output 421 Joystick
Open 519
D/Mo TEMP Abnormal 422 control
sensor Push Short 520 (Option)
Overheat 423 -
CS-54 - Open 521
D/Mo TEMP Abnormal 424
sensor left 5th valve Pull Short 522
Overheat 425 - Joystick
Open 523
D/CONT TEMP Abnormal 426 control
sensor - - Push Short 524 (Option)
Overheat 427 -
Open 525
D/CONT TEMP Abnormal 428
sensor left - - C1 solenoid valve Short 526 Joystick
Overheat 429 - control
Open 527
Pump current U Low output 430 (Option)
sensor High output 431 SENSOR
CS-51 -
V Low output 432 F/R Switch Same ON 450 - CS-58, -
72
High output 433
Accel sensor Low output 452
P/Mo TEMP Abnormal 434 CS-64 -
sensor CS-54 - High output 453
Overheat 435 -
Tire angle sensor Low output 454 CS-61
P/CONT TEMP Abnormal 436 (3 WH)
-
sensor - - High output 455 CS-62
Overheat 437 - (4 WH)
D/Mo REV Abnormal 438 - Tilt angle sensor Low output 456
sensor Not equipped
High output 457
D/Mo REV Abnormal 440 - Lift sensor Low output 458
CS-54 -
sensor left
High output 459
P/Mo REV Abnormal 442 -
sensor Tilt sensor Low output 460
CONT Abnormal 444 - - - High output 461 Joystick
CS-72,
communication control
3rd sensor Low output 462 73
(Option)
CONT type Abnormal 446 - - High output 463
select
4th sensor Low output 464
Meter
High output 465
Meter Abnormal 558 - - -
communication LIFT ACCEL Low output 466 Not equipped
Tilt H switch Short 468
Not equipped
Open 469
Steer Angle sensor Abnormal 470 - CS-60 -
Weight sensor Low output 472
Not equipped
High output 473
CS-42
CONTROLLER
CONTROLLER
Construction
CSM0117
CS-43
CONTROLLER
Construction (Cont’d)
CSM0118
CS-44
CONTROLLER
CSM0119
Controller assy
Input/
PIN NO. Contents Notes
Output
Input D20 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
D5 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
D6 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
Output D1 A.P.O. RELAY DRIVE A.P.O. Relay ON/OFF drive, Coile load; 0.1A
Input D19 FORWARD SWITCH F Switch ON then forward
D25 REVERSE SWITCH R Switch ON then backward
D10 ACCEL SENSOR POWER Sensor power (+5.0V)
D12 ACCEL SENSOR SIGNAL A Steps in the pedal then output voltage increase
D14 ACCEL SENSOR SIGNAL B Steps in the pedal then output voltage increase B = A/2
D8 ACCEL SENSOR GND Sensor GND
P7 TIRE ANGLE SEN. POWER Sensor power +5.0V ±0.2V
P14 TIRE ANGLE SEN. SIGNAL Steering right turn then output voltage increase
P11 TIRE ANGLE SEN. GND Sensor GND
P12 STEER ANGLE SEN. POWER Sensor power +12.8V ±0.2V 0.2A
P19 STEER ANGLE SEN. SIGNAL A 45 Pulse per revolution
P21 STEER ANGLE SEN. SIGNAL B 45 Pulse per revolution, Phase late from SIG.A (90 deg)
P22 STEER ANGLE SEN. SIGNAL N For neutral detects, 1 Pulse per revolution
P8 STEER ANGLE SEN. GND Sensor GND
D31 RIGHT TURN SWITCH R SW ON (Low level) then flasher ON/OFF
D35 LEFT TURN SWITCH L SW ON (Low level) then flasher ON/OFF
Output D7 FLASHER POWER Power for flasher Lamp
D2 R FLASHER OUT Flasher drive output Right
Input D22 PARKING BRAKE SWITCH Operates a parking brake then SW ON
D23 BRAKE SWITCH Steps in the brake pedal then SW ON
P28 LIFT UP SWITCH Operates a lift up then SW ON
P29 TILT SWITCH Operates a tilt lever then SW ON
P24 3RD SWITCH Operates a 3rd lever then SW ON
P25 4TH SWITCH Operates a 4th up lever then SW ON
P26 5TH SWITCH Operates a 5th up lever then SW ON
D24 HIGH MAST SWITCH Detects SW ON (1 Shot) then Hi-Mast mode
D26 SEAT SWITCH Site on the seat then SW ON
D15 MODE SELECT 1 For 36V only
D16 MODE SELECT 2 For G1N1 48V only
D18 MODE SELECT 3 For JG1N1 only
D28 SWITCH GND Switch GND
D29 SWITCH GND Switch GND
Input/ D33 M TO C COMMUNICATION DATA Meter to Controller communication data
Output D34 C TO M COMMUNICATION DATA Controller to Meter communication data
CS-45
CONTROLLER
CS-46
CONTROLLER
CSM0120
External of meter
Input 1 Battery voltage Meter Wake up, Battery voltage and capacity detect
2 Battery power + Meter power to battery +
3 Blank terminal -
4 Brake fluid level SW Low fluid level then SW: ON
5 Seat belt SW Belt set then SW: ON
6 Parking BK Key Input Key Input for Parking BK Warning Buzzer
7 Blank terminal -
8 Blank terminal -
9 Parking brake SW Brake OFF then SW: ON
10 Blank terminal -
11 Power GND Meter GND
12 Blank terminal -
CS-47
CONTROLLER
CS-48
CONTROLLER
Item Specification
Service data
CS-49
CONTROLLER
Item Specification
Type PDM5001
Durable voltage 100V
Service data
CSM0122
S1D2 G2 3M
G2 S1D2
G2 S2 3M
S2 G2 3M
CS-50
CONTROLLER
Item Specification
Type HC-TSA800V2YP12AR
Actual current ±800A
Output voltage +0.56 ~ +2.56V ~ +4.56V
Service data
Item Normal NG
CSM0123
FAN ASSEMBLY
Specifications
Item Specification
Type 2410ML-05W-B40-BQ1
6 pieces/controller
Numbers of fan
One piece/external fan
Rated voltage 24V
Item Normal NG
CS-51
CONTROLLER
Item Specification
Service data
CSM0126
CS-52
CONTROLLER
Capacity
500A
CSM0127
Inspection
Using a circuit tester, check continuity of each fuse.
Continuity
NOTE:
The circuit tester range selector must be set to “x1 ”.
CST0019
CS-53
CONTROLLER
CSM0128
Temperature sensor
Specifications
Item Specification
Service data
Item Normal NG
CSM0129 Sensor resistance
Resistance Failed temp. Sensor
25°C (77°F) = Approx. 50 k
Revolution sensor
Specifications
Item Specification
Service data
CSM0130
Item Normal NG
CS-54
CONTROLLER
MMM0020
CS-55
CONTROLLER
CSM0131EU
CS-56
CONTROLLER
CSM0132EUb
CS-57
UNIT INSPECTION AND ADJUSTMENT
UNIT INSPECTION AND ADJUSTMENT
Control System
CAUTION:
• Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
• When checking a unit, also check the condition of the
associated harness and connector.
• All units can be checked using interactive diagnostic
procedures. (Refer to “LCD MONITOR” on page 30.)
NOTE:
• The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
• This section deals with only resistance measurement procedures
for unit inspection.
ELM0272
CS-58
UNIT INSPECTION AND ADJUSTMENT
Forward -
Neutral -
Reverse -
CSM0133
CS-59
UNIT INSPECTION AND ADJUSTMENT
Service data
CSM0134
CSM0135
CS-60
UNIT INSPECTION AND ADJUSTMENT
Service data
Measuring
points Standard value Remarks
(terminals)
CSM0136
Adjustment
1. Call up tire angle sensor diagnostic screen from interactive
diagnostic display.
2. Loosen tire angle sensor securing screws.
3. While observing the tire angle sensor output on the display to
check if it is within the specified range, rotate the tire angle
sensor.
4. Tighten tire angle sensor securing screws.
: 1.2 - 1.8 N•m (0.13 - 0.18 kgf-m, 11 - 15 in-lb)
CSM0137
CS-61
UNIT INSPECTION AND ADJUSTMENT
Service data
Measuring
points Standard value Remarks
(terminals)
CSM0207
CS-62
UNIT INSPECTION AND ADJUSTMENT
CSM0239
Tire angle sensor fixes the kingpin plate to the kingpin as shown in
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the steering
control system function correctly. Notes concerning assembly are as
follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.
CSM0240
CS-63
UNIT INSPECTION AND ADJUSTMENT
CSM0138
Specification
Total resistance (k) 2.5 - 5.0 (Reference value)
Service data
Measuring
Standard value
points Remarks
(V)
(terminals)
Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0140 : 1.5 - 1.8 N•m (0.16 - 0.18 kgf-m, 14 - 15 in-lb)
CS-64
UNIT INSPECTION AND ADJUSTMENT
CSM0141
CS-65
UNIT INSPECTION AND ADJUSTMENT
Brake switch ON/OFF switching point Pedal height: 115.5 mm (4.547 in)
(from floor upper surface)
CSM0142
Adjustment
CSM0202
CS-66
UNIT INSPECTION AND ADJUSTMENT
CSM0143
CS-67
UNIT INSPECTION AND ADJUSTMENT
CST0038
Centering adjustment
Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.
CST0039
CS-68
UNIT INSPECTION AND ADJUSTMENT
Inspection
Measure resistance between lift solenoid terminals.
<Reference value>
CSM0144
CS-69
UNIT INSPECTION AND ADJUSTMENT
CSM0145
JOYSTICK CONTROLLER
CSM0146
CS-70
UNIT INSPECTION AND ADJUSTMENT
CSM0200
Specifications
Inspection
Check resistance between terminals using circuit tester ( range).
Resistance ()
Terminals Remarks
(Reference value)
A (+)-A (-)
30 20°C (68°F)
B (+)-B (-)
36 20°C (68°F)
C1 (+)-C1 (-)
44 90°C (194°F)
CS-71
UNIT INSPECTION AND ADJUSTMENT
No continuity No continuity
- Continuity
( ) ( )
No continuity No continuity
- Continuity
( ) ( )
CSM0147
CSM0148
CS-72
UNIT INSPECTION AND ADJUSTMENT
CSM0149
Specification
Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).
CS-73
UNIT INSPECTION AND ADJUSTMENT
CSM0150
Inspection
Check continuity between terminals using circuit tester ( range).
- Continuity No continuity
CS-74
UNIT INSPECTION AND ADJUSTMENT
CSM0151
CS-75
UNIT INSPECTION AND ADJUSTMENT
CSM0152
CS-76
UNIT INSPECTION AND ADJUSTMENT
Inspection
Check resistance between terminals using circuit tester.
For steering wheel angle sensor and tire angle sensor inspections,
refer to “UNIT INSPECTION AND ADJUSTMENT” on page 58 and
59.
CS-77
TROUBLE DIAGNOSTIC PROCEDURES
TROUBLE DIAGNOSTIC PROCEDURES
Precautions
CAUTION:
• Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
• After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
• When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
• When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
• Basic trouble diagnostic procedures must be performed as
follows:
Malfunction occurrence
Perform self-diagnosis.
NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)
CST0062
CS-78
TROUBLE DIAGNOSTIC PROCEDURES
MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.
WORK FLOW
Confirmation of malfunction
Remedial procedures
CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.
A
: Current measurement in 50-ampere range (AC)
50
CS-79
TROUBLE DIAGNOSTIC PROCEDURES
Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
• Connector guides for male terminals are shown in black.
• Connector guides for female terminals are shown in white.
CST0063
Connector direction
• Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
• Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.
CST0064
CST0065
KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.
CS-80
TROUBLE DIAGNOSTIC PROCEDURES
Voltage and Resistance Measurement
Procedures
VOLTAGE MEASUREMENT
• Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
• To facilitate voltage measurements for parts or terminals
(adjacent to controllers), it is best to use an alligator clip with the
black (ground) test probe of a circuit tester and fasten it to the
battery ground terminal during measurements.
CST0066
RESISTANCE MEASUREMENT
• Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
• A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
CST0067
CS-81
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CAUTION:
• To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully
understand under what conditions the symptoms occur.
• For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( ).
For checking the current sensor, only measure voltage.
• When checking controller elements, also check the
associated harnesses and bus bars.
• If the cause of the malfunction may be in the mechanical
systems, always check the mechanical systems that are not
included in the flowchart.
CS-82
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
SYMPTOM:
The meter does not display. The forklift also does not operate
(in any operation of traction/loading/power steering).
CSM0153
CSM0154
CSM0155
CS-83
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0156
CSM0157
CSM0158
CS-84
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0159
CSM0160
CSM0161
CS-85
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
SYMPTOM:
The meter does not display. The forklift operates (in any
operation of traction/loading/power steering).
CSM0162
CSM0163
CSM0164
CS-86
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
SYMPTOM:
The meter displays. The forklift does not operate (in any
operation of traction/loading/power steering).
CSM0153
CSM0155
CSM0156
CS-87
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0157
CSM0158
CSM0159
CS-88
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
CSM0160
CSM0165
CS-89
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Cannot move forward and backward.
CSM0166
CSM0167
CS-90
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
CSM0168
SYMPTOM:
Cannot drive forward or backward.
CSM0169
CSM0167
CS-91
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
The traction speed is slow. The acceleration is slow. Or, there
is no power.
CSM0170
CSM0171
CS-92
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
CSM0172
CSM0173
CSM0174
CS-93
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
CSM0167
CSM0175
CS-94
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Straight-line instability
CSM0176
CSM0167
CS-95
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Regenerative braking malfunction
CSM0177
CSM0167
CS-96
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)
CSM0178
CSM0167
CS-97
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
CSM0179
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.
CSM0167
CS-98
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
The mast does not lower (but can be raised).
CSM0180
CSM0181
CSM0167
CS-99
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.
CSM0170
CSM0171
CSM0182
CS-100
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPE
CSM0183
CSM0167
CSM0175
CS-101
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)
CSM0184
CSM0185
CS-102
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
CSM0186
CSM0201
CSM0180
CS-103
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
CSM0187
CSM0167
CSM0179
CS-104
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.
CSM0188
CSM0167
CS-105
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.
CSM0170
CSM0171
CSM0182
CS-106
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPE
CSM0183
CSM0167
CSM0175
CS-107
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
SYMPTOM:
Power steering malfunction (include the knob position
malfunction of OPT mechanism)
CSM0189
CSM0167
CS-108
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
SYMPTOM:
Turn signal lamp malfunction
CS-109
REFERENCE DATA OF CONTROL SYSTEM
REFERENCE DATA OF CONTROL SYSTEM
D20 KEY SW2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
D5 KEY SW1 (IGN) VB level (key switch 1 ON) • The controller does not –
operate
D21 BATT OFF DETECT VB level (battery switch ON) • The controller does not –
operate
D81 Capacitor voltage VB level (main relay ON) • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
• Low voltage protection • Battery low voltage: 404
D1 A.P.O. RELAY DRIVE Operation (key ON) • The meter does not operate • Controller communication
malfunction: 444
D19 FORWARD SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved forward
D25 REVERSE SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved backward
D10 ACCEL SENSOR POWER 5.0±0.2V • The traction is not possible • Accelerator pedal position
• Poor acceleration/maximum sensor output large: 453
D12 ACCEL SENSOR SIGNAL A 0.2 - 4.7V (normal)
speed • Accelerator pedal position
D14 ACCEL SENSOR SIGNAL B 0.2 - 4.7V (normal) sensor output small: 452
D8 ACCEL SENSOR GND GND connection
P7 TIRE ANGLE SEN. POWER 5.0±0.2V • Straight-line instability • Tire angle sensor output
• Poor turning ability large: 455
P14 TIRE ANGLE SEN. SIGNAL 0.3 - 4.8V (normal)
• Knob position malfunction • Tire angle sensor output
P11 TIRE ANGLE SEN. GND GND connection small: 454
P12 STEER ANGLE SEN. POWER 12.8±1V • Knob position malfunction • Steering angle sensor
• The steering is not possible malfunction: 470
P19 STEER ANGLE SEN. SIGNAL A 0 - 3.5V rectangular pulse
• Steering force malfunction
P21 STEER ANGLE SEN. SIGNAL B 0 - 3.5V rectangular pulse
P22 STEER ANGLE SEN. SIGNAL N 0 - 3.5V rectangular pulse
P8 STEER ANGLE SEN. GND GND connection
D31 RIGHT TURN SWITCH GND level (switch ON) • Turn signal does not blink –
• Turn signal continues
D35 LEFT TURN SWITCH GND level (switch ON)
blinking
D7 FLASHER POWER VB input • Turn signal does not turn on –
D2 RIGHT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D17 LEFT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D22 PARKING BRAKE SWITCH GND level (switch ON) • The traction is not possible –
D23 BRAKE SWITCH GND level (switch ON) • The traction is not possible –
• Brake regenerative
malfunction
P28 LIFT UP SWITCH GND level (switch ON) • The lift does not rise –
• The loading motor does not
rotate
P29 TILT SWITCH GND level (switch ON) • No tilt operation –
• The loading motor does not
rotate
P24 3RD SWITCH GND level (switch ON) • No 3rd operation –
• The loading motor does not
rotate
P25 4TH SWITCH GND level (switch ON) • No 4th operation –
• The loading motor does not
rotate
CS-110
REFERENCE DATA OF CONTROL SYSTEM
CS-111
REFERENCE DATA OF CONTROL SYSTEM
P3 SOL. POWER RETURN (Solenoid chopper return line) • Unstable valve control at –
open
P54 PM TEMP SENSOR - Voltage between P52 and P54: • Loading speed decrease • PM temperature rise: 435
Approx. 3.8V (25°C) • PM temperature sensor
P52 PM TEMP SENSOR +
malfunction: 434
D60 LH TM TEMP SENSOR - Voltage between D58 and • Left traction speed decrease • Left TM temperature sensor
D60: Approx. 3.8V (25°C) rise: 425
D58 LH TM TEMP SENSOR +
• Left TM temperature sensor
malfunction: 424
D54 RH TM TEMP SENSOR - Voltage between D52 and • Right traction speed • Right TM temperature
D54: Approx. 3.8V (25°C) decrease sensor rise: 423
D52 RH TM TEMP SENSOR +
• Right TM temperature
sensor malfunction: 422
P51 PM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • PM motor revolution sensor
operate malfunction: 442
P47 PM REV. SEN. SIGNAL B GND GND
P45 PM REV. SEN. SIGNAL B (The measurement is not
possible)
P46 PM REV. SEN. SIGNAL A GND GND
P44 PM REV. SEN. SIGNAL A (The measurement is not
possible)
P49 PM REV. SENSOR GND (The measurement is not
possible)
P48 PM REV. SENSOR POWER + (The measurement is not
possible)
P50 PM REV. SEN. POWER SHIELD GND connection
D61 LH TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • LH TM motor revolution
operate sensor malfunction: 440
D57 LH TM REV. SEN. SIGNAL B GND GND
D55 LH TM REV. SEN. SIGNAL B (The measurement is not
possible)
D56 LH TM REV. SEN. SIGNAL A GND GND
D53 LH TM REV. SEN. SIGNAL A (The measurement is not
possible)
D49 LH TM REV. SENSOR GND (The measurement is not
possible)
D48 LH TM REV. SENSOR POWER + (The measurement is not
possible)
D59 LH TM REV. SEN. POWER SHIELD GND connection
D51 RH TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • RH TM motor revolution
operate sensor malfunction: 438
D47 RH TM REV. SEN. SIGNAL B GND GND
D45 RH TM REV. SEN. SIGNAL B (The measurement is not
possible)
D46 RH TM REV. SEN. SIGNAL A GND GND
D44 RH TM REV. SEN. SIGNAL A (The measurement is not
possible)
D43 RH TM REV. SENSOR GND (The measurement is not
possible)
D42 RH TM REV. SENSOR POWER + (The measurement is not
possible)
D50 RH TM REV. SEN. POWER GND connection
SHIELD
CS-112
REFERENCE DATA OF CONTROL SYSTEM
D3 MAIN CONTACTOR DRIVE + VB level • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
D4 MAIN CONTACTOR DRIVE - PWM drive (VB-GND)
• The main contactor is not
input
D68 Traction current sensor power 12.5±1V • The controller does not • Traction right U-phase
supply operate current sensor output large:
D70
415
D71 • Traction right U-phase
D72 current sensor output small:
414
D73 Right U-phase traction current At no motor driving: 2.5±0.1V • Traction right V-phase
sensor signal current sensor output large:
D75 Right W-phase traction current 417
sensor signal • Traction right V-phase
current sensor output small:
D78 Left U-phase traction current
416
sensor signal
• Traction left U-phase current
D79 Left W-phase traction current sensor output large: 419
sensor signal • Traction left U-phase current
D62 Traction current sensor power GND sensor output small: 418
supply GND • Traction left V-phase current
D69 sensor output large: 421
D74 • Traction left V-phase current
sensor output small: 420
D80
P70 Loading current sensor power 12.5±0.1V • The controller does not • Loading U-phase current
supply operate sensor output large: 431
P71
• Loading U-phase current
P72 sensor output small: 430
P73 Loading U-phase traction cur- At no motor driving: 2.5±0.1V • Loading V-phase current
rent sensor signal sensor output large: 433
• Loading V-phase current
P75 Loading V-phase traction current sensor output small: 432
sensor signal
P74 Loading current sensor power GND
supply GND
P78
D64 Cooling fan power supply At fan driving: 24.0±3V • Internal cooling fan • Right Drive Cont.
malfunction temperature sensor
D65
malfunction: 426
• Loading Pump Cont.
temperature sensor
malfunction: 436
D102 Traction right controller tempera- Voltage between D102 and • The controller does not • Right Drive Cont.
ture + D103: Approx. 3.8V (25°C) operate temperature sensor rise:
• Left traction speed decrease 427
D103 Traction right controller tempera-
• Right Drive Cont.
ture -
temperature sensor
malfunction: 426
D85 Traction left controller tempera- Voltage between D85 and • The controller does not • Left Drive Cont. temperature
ture + D86: Approx. 3.8V (25°C) operate sensor rise: 429
• Right traction speed • Left Drive Cont. temperature
D86 Traction left controller tempera-
decrease sensor malfunction: 428
ture -
P102 Loading controller temperature + Voltage between P85 and P86: • The controller does not • Pump Cont. temperature
Loading controller temperature - Approx. 3.8V (25°C) operate rise: 437
P103
• Loading speed decrease • Pump Cont. temperature
sensor malfunction: 436
CS-113
REFERENCE DATA OF CONTROL SYSTEM
D99 INV-RESET Inverter block signal: Inverter • Right traction malfunction • Traction right FET short:
stops at 5V or more 408
• Traction right FET open:
D100 FAIL Inverter malfunction diagnosis
409
at GND level
D101 GND-C GND
D104 KEY1 VB level
D105 12V 12.5±1V
D106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
D82 INV-RESET Inverter block signal: Inverter • Left traction malfunction • Traction left FET short: 412
stops at 5V or more • Traction left FET open: 411
D83 FAIL Inverter malfunction diagnosis
at GND level
D84 GND-C GND
D107 KEY1 VB level
D108 12V 12.5±1V
D109 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
CS-114
REFERENCE DATA OF CONTROL SYSTEM
E1 Batt+ • VB level (E1-E2) (contactor • The controller does not • CONT condenser
input) operate malfunction: 406
E2 Batt-
• Main contactor short: 400
E13 Batt+ • VB level (E13-E14) • Main contactor open: 401
(contactor input) • Main fuse open: 403
E14 Batt-
E16 Batt+ • VB level (E16-E15) • The controller does not • CONT condenser
(contactor input) operate malfunction: 406
E15 Batt-
• Main contactor short: 400
• Main contactor open: 401
• Main fuse open: 403
F1A Controller cooling fan 1 power Voltage between F1* and F2* • Controller internal cooling • Right Drive Cont.
supply At fan driving: 24.0±3V fan malfunction temperature sensor
malfunction: 426
F1B Controller cooling fan 2 power
• Loading Pump Cont.
supply
temperature sensor
F1C Controller cooling fan 3 power malfunction: 436
supply
F1D Controller cooling fan 4 power
supply
F1E Controller cooling fan 5 power
supply
F1F Controller cooling fan 6 power
supply
F2A Controller cooling fan 1 GND
F2B Controller cooling fan 2 GND
F2C Controller cooling fan 3 GND
F2D Controller cooling fan 4 GND
F2E Controller cooling fan 5 GND
F2F Controller cooling fan 6 GND
CS-115
MEMO
Joystick Controller
Terminal
No. Possible error mode/Related
Items Characteristic/Specification Related trouble diagnosis
(Controller symptom
side)
O25 POWER Joystick controller input power • Joystick controller –
supply: 8.5±1V malfunction
O26 POWER Joystick controller input power
supply: 8.5±1V
O27 GND Joystick controller power • Joystick controller –
supply GND malfunction
O30 GND Joystick controller power
supply GND
O32 KEY SW 2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
O31 KEY SW 1 (IGN) VB level (key switch 1 ON) • Joystick controller –
malfunction
O34 JS SENEOR POWER Proportional solenoid control • Proportional solenoid –
lever power supply: 5.0±0.2V control malfunction
• Proportional solenoid valve
malfunction
• The loading motor does not
rotate
• The loading motor speed is
slow
O36 LIFT SIGNAL 1 At lever operation • No lift operation • Lift sensor output large: 459
Between D34 voltage x 90% • The loading motor does not • Lift sensor output small:
and D34 voltage x 10% rotate 458
O37 LIFT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O35 JS SENSOR GND Proportional solenoid control • Proportional solenoid –
lever power supply GND control malfunction
• Proportional solenoid valve
malfunction
• The loading motor does not
rotate
O38 TILT SIGNAL 1 At lever operation • No tilt operation • Tilt sensor output large: 461
Between D34 voltage x 90% • The loading motor does not • Tilt sensor output small:
and D34 voltage x 10% rotate 460
O39 TILT SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O40 3RD SIGNAL 1 At lever operation • No 3rd operation • 3rd sensor output large:
Between D34 voltage x 90% • The loading motor does not 461
and D34 voltage x 10% rotate • 3rd sensor output small:
O41 3RD SIGNAL 2 At lever operation • The loading motor speed is 462
Between D34 voltage x 90% slow
and D34 voltage x 10%
O42 4TH SIGNAL 1 At lever operation • No 4th operation • 4th sensor output large: 465
Between D34 voltage x 90% • The loading motor does not • 4th sensor output small:
and D34 voltage x 10% rotate 464
O43 4TH SIGNAL 2 At lever operation • The loading motor speed is
Between D34 voltage x 90% slow
and D34 voltage x 10%
O44 1 STICK DETECT SW GND level (switch ON) • Unstable joystick control –
(FC-B)
O45 MULTI FUNCTION DETECT GND level (switch ON) • Unstable joystick control –
SW (JS-A)
O46 MULTI FUNCTION 1 TO 4 SW GND level (switch ON) • Multifunction lever –
4th/5th malfunction
CS-116
REFERENCE DATA OF CONTROL SYSTEM
CS-117
CONTROL SYSTEM
A1N1 SECTION CS
CONTENTS
TECHNICAL DESCRIPTION ............................. CS-1 Connector (Terminal layout) ........................ CS-51
System .......................................................... CS-1 Controller Element Inspection ..................... CS-55
PRECAUTIONS ............................................... CS-10 Removal and Installation ............................. CS-58
LOCATION OF UNITS (LAYOUT) ................... CS-11 UNIT INSPECTION AND ADJUSTMENT ........ CS-59
Standard Equipment (3 - wheel) .................. CS-11 Control System ............................................ CS-59
Standard Equipment (4 - wheel) .................. CS-12 Joystick Control System (Option) ................ CS-71
Optional Equipment ..................................... CS-13 Knob Position Control System
METER PANEL ................................................ CS-14 (Option) ....................................................... CS-78
Meters, Indicators and Lamps ..................... CS-14 Tilt Leveling Device (Option) ....................... CS-79
Setting Adjustment Items (Normal Mode) ... CS-14 TROUBLE DIAGNOSTIC PROCEDURES ...... CS-83
Meter Panel Explanation ............................. CS-16 Precautions ................................................. CS-83
LCD MONITOR ................................................ CS-26 How To Follow Flow Chart .......................... CS-84
Adjustment Mode ........................................ CS-26 Symbol Identification ................................... CS-85
Manager Mode ............................................ CS-34 Voltage and Resistance Measurement
Diagnostic Mode .......................................... CS-38 Procedures .................................................. CS-86
Table of Error Code (1) ............................... CS-49 Table of Error Code (2) ............................... CS-87
CONTROLLER ................................................. CS-50
Construction ................................................ CS-50
CAUTION:
Where towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to
reduce possible damage to electrical system.
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
System
VEHICLE CONTROL SYSTEM COMPONENTS
CS-1
TECHNICAL DESCRIPTION
System (Cont’d)
AC motor control
CS-2
TECHNICAL DESCRIPTION
System (Cont’d)
Item Function Outline Input Output
• The controller must prevent rapid torque change in case of • Accelerator sensor
follows; • Brake SW
• Changing accelerator pedal from ON to OFF or F/R SW • Revolution sensor
Cushion from F (or R) to neutral. • F/R SW
(Ramp) control • Starting each regenerative control, the controller must
prevent rapid torque change.
• Finishing accelerator off/brake regenerative control
because of going down the vehicle's speed.
• The controller must limit max motor output in case of • Brake SW
follows; • PKB SW
• According to the quantity of open percent of accelerator
pedal.
Power down
• During brake SW ON.
control
• During PKB SW ON.
Driving
• If max motor output limitation by brake or PKB SW is
control • Traction motors
keeping for a setting time, the controller must stop motor
(Cont’d)
output.
• Max acceleration is changed by power mode and drive • Meter panel
accelerator level.
• NT characteristic for running is changed by power mode.
• The acceleration after switch back regenerative is changed
by SB regenerative level.
Driving • The switch back regenerative torque is changed by power
performance mode and SB regenerative level.
change control • The brake regenerative torque is changed by BK
regenerative level.
• The accelerator off regenerative torque is changed by AOL
regenerative level.
• The anti-roll off speed is changed by ARL regenerative
level.
• The pump motor revolution speed is controlled by load SW. • Load SW
• The revolution speed is depended on each load SW. • Traction revolution
Speed and
• In case of multi load SW input, the rotation speed is sensor
acceleration
controlled by decided priority.
control
• Max revolution speed is limited by the vehicle speed.
• The pump motor revolution speed is controlled by load SW.
Loading • In case of stopping load operation, revolution of motor is • Load SW
regenerative decreased by regenerative. • Pump motor
control
• In case of receiving pump cut signal from meter, the • Meter panel
Power down
controller stop Loading control.
control
• This case is caused by near empty of battery.
Loading Loading • Max acceleration is changed by load accelerator level. • Meter panel
control performance • NT characteristic for running is changed by power mode.
change control
• The motor revolution is controlled by open percent of each • Finger tip sensor
joystick. • Oil pressure sensor
• Servo solenoid is controlled with by open percent of each
joystick and load weight.
Servo solenoid
• C1 solenoid is controlled in case of loading operation.
valve control • Pump motor
• In case of one stick, the controller limits one operation that
(Joystick • C1 servo solenoid
is tilt forward and lift down simultaneously.
control)
• Due to prevent the lift hunting, shock at start/stop and lift
down rapidly and some other feeling problem. The
controller takes in ramp and delay control about servo
solenoid.
CS-3
TECHNICAL DESCRIPTION
System (Cont’d)
Item Function Outline Input Output
• During operating the steer with no load operation, the • Steer sensor
Speed control controller controls the motor revolution by steer speed and • Thermo sensor
ambient temperature of the vehicle. (meter)
• Due to prevent the kick back and scratch of steer, the • Traction revolution
Power controller takes in ramp and delay control. sensor
Ramp and
steering • PKB SW • Pump motor
delay control
control • Load SW
• F/R SW
Starting • Starting motor control is 4 modes. That is “Steering”, “F/R • Steer sensor
control of SW”, “Accelerator pedal”, “Steering and Accelerator pedal” • F/R SW
motor and “Steering continue”. • Accelerator sensor
• The controller controls PS C solenoid to agree with steering • Steering sensor
Steering knob
and tire angle. • Tire angle sensor • PS C correct
position
• The relationship between steering and tire angle are solenoid
correct control
calculated by formula.
Lift down • In case of sitting of operator, lift down solenoid is driven • Seat SW
solenoid with PWM. • Tilt down solenoid
control (MC) • This function is only MC.
• In case of pushing the tilt horizontal SW with no load, if the • Tilt angle sensor
tilt angle is horizontal, the controller drives tilt horizontal • Oil pressure sensor
Tilt auto solenoid. • Tilt horizontal SW
• Tilt horizontal
horizontal • In case of pushing the tilt horizontal SW with load, the
solenoid
control controller drives tilt horizontal solenoid without tilt angle.
• Aux output
(Optional) • The controller judged by oil pressure whether load or no
load.
• During tilt angle is horizontal, AUX OUTPUT is driven.
• In case of operating turn SW, the controller switches each • Turn SW
Flasher control • Flasher out
flasher out ON and OFF by the direction of turn SW.
• In case of password entry, the meter informs power mode • Meter panel
and level to the controller. So, the controller controls with
Password
informed power mode and level.
entry (Log in)
• This function is related to “Driving performance change
control” and “Loading performance change control”.
• The controller checks the vehicle spec. by MODE SELECT • Mode select SW -
Vehicle SW at every key ON. And if the vehicle spec. is changed • Meter panel
control before, NT characteristic is changed and all settings that
Vehicle status
are record to EEPROM are reset.
change
• If the battery voltage setting is changed at Adjustment
mode, NT characteristic is also changed and the control
function that is related to voltage is also changed.
Real time • The controller calculates consumption energy by • Battery current
energy multiplying battery voltage and current and inform it to sensor
consumption meter panel. • Battery voltage
meter
• The controller calculates load by oil pressure sensor and • Oil pressure sensor • Meter panel
Load meter inform it to meter panel. And it calculates three load that is,
• current load • load for indicator • load for warning
• In case of PKB OFF during not sitting, the controller informs • PKB SW
PKB alarm
this to meter panel.
• The controller judges the sitting or not sitting by seat SW. • Key SW
• At the time of key OFF to ON, • Accelerator sensor
if the operator doesn’t sit the seat, then traction and load • F/R SW
operation is stopped. • Load SW
Inhibiter if the operator operates shift lever or accelerator pedal, then • Steer sensor
• All output
control traction operation is stopped. • Brake SW
if the operator operates load lever, then load operation
(except steering) is stopped.
• At the time of key ON to START during auto power mode,
inhibiter control is same as key OFF to ON.
CS-4
TECHNICAL DESCRIPTION
System (Cont’d)
Item Function Outline Input Output
• If the setting time passes with no operation, the vehicle is • Accelerator sensor
controlled with minimum current consumption mode. At • F/R SW
that case, the controller controls APO relay to OFF. Other • Load SW
Auto power case, APO relay is controlled with ON. • Steer sensor
OFF • Traction revolution
sensor
• Load revolution
sensor
• In case of low battery voltage that is setting, the controller • Battery voltage
controls the vehicle to be stopped except power steering
Vehicle and lift down.
control • In regenerative mode, if the battery cut off, should not be • All output
(Cont’d) damaged by overvoltage.
• If the power circuit is open at very short time by vibration,
the power switching devices must be controlled not to
Voltage
detect any error after closing the power circuit.
protection
• To prevent over discharge of battery, the motor output is
control
limited by battery voltage level. If this function does not
work, the vehicle detects low battery voltage and stopped
before power down control by pump cut signal. We have to
obey the sequence that the vehicle detects pump cut signal
and limits the loading control first, then if the operator still
use the vehicle, the vehicle detects low battery voltage and
stops the vehicle almost.
• If the controller detects the main circuit failure, the controller
Main circuit
controls specified fail safe control. The main circuit
protection
includes FET, condenser and contactor.
Input (Sensor, • If controller detects the input failure, the controller controls
digital input) specified fail safe control.
Output (Relay, • If the controller detects the output failure, the controller
solenoid) controls specified fail safe control.
Fail safe
Overheat • If the controller detects overheat, the controller limits the - -
control
protection output of motor. The controller must not stop the control.
Current fail • If the current is out of specified range, the controller
safe controls specified fail safe control.
Voltage fail • If the voltage is out of specified range, the controller
safe controls specified fail safe control.
• Others fail safe includes such as “sum check error”, “vehicle
Others
status error” and “communication error”.
• Transmission method: RS-232C start-stop synchronous
communication
• Rate: 2400bps±2% (2403.85)
• Data length: 8bit
• Parity check: odd number
• Stop bit: 1bit
• Data structure: “start bit” + “data 8bit” + “odd number parity
bit” + 1 stop bit” (11 bit)
Communi-
• Signal voltage level: logic level 1 input = -3 to -25V
cation with Protocol - -
output = -5 to -15V
meter
0 input = +3 to +25V
output = +5 to +15V
• Data format (packet format): “LF” + “address” + “data n” +
“data n+1” + ….. + “SUM”
• Detection of communication error: if the period of packet is
longer than 1 sec, the controller detects communication
error. The controller controls with previous data that is not
detected error.
CS-5
TECHNICAL DESCRIPTION
System (Cont’d)
Item Function Outline Input Output
• First of all, the controller and meter communicate of initial
communication for realizing the vehicle spec. and control
mode.
Initial • Data meter controller: “vehicle spec” such as vehicle
type, area, battery voltage and weight
• Data controller meter: “control mode
• Transmission period: 40ms
• This is communicated during normal mode.
• The controller and meter communicate the present vehicle
status and error.
• Data controller meter: “vehicle stop sig”, “pump cut sig”,
Normal
“log in sig”, “ambient temperature”, “power mode”, “accel
level (traction and pump)” and “setting for password entry”
• Data meter controller: “vehicle status” and “error sig”
Communi- • Transmission period: 200ms
cation with
• This is communicated during adjustment mode. - -
meter
• The controller and meter communicate the present vehicle
(Cont’d)
settings.
Adjustment
• Data meter controller: “function ON/OFF”, “sensor
setting” and “vehicle performance setting”
• Transmission period: 200ms
• This is communicated during factory mode.
• The controller and meter communicate the present vehicle
settings.
Factory
• Data meter controller: “function ON/OFF”, “sensor
setting” and “vehicle performance setting”
• • Transmission period: 200ms
• This is communicated during diagnosis mode.
• The controller and meter communicate the present vehicle
Diagnosis
settings and status.
• Transmission period: 200ms
CS-6
TECHNICAL DESCRIPTION
System (Cont’d)
PRINCIPLE OF AC MOTOR
CSM001
CS-7
TECHNICAL DESCRIPTION
System (Cont’d)
KNOB POSITION CONTROL SYSTEM
(OPTION)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)
Input Output
CS-8
TECHNICAL DESCRIPTION
System (Cont’d)
Knob position control system (option)
CSM002
CS-9
PRECAUTIONS
PRECAUTIONS
CAUTION:
• Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
• Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body and
do not pull on the cord.
• When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
• When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
• Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.
Inadvertent current flow may damage the element or other
parts being checked.
• Before using flow charts as a guide to troubleshoot units and
parts, become familiar with the instructions outlined under
“TROUBLE DIAGNOSTIC PROCEDURES”.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
CS-10
LOCATION OF UNITS (LAYOUT)
LOCATION OF UNITS (LAYOUT)
212014EU
CS-11
LOCATION OF UNITS (LAYOUT)
2012013EU
CS-12
LOCATION OF UNITS (LAYOUT)
Optional Equipment
BSM0663EU
CS-13
METER PANEL
METER PANEL
CS-14
METER PANEL
CS-15
METER PANEL
LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
To darken the contrast, push function switch FN2. To lighten the
contrast, press function switch FN1.
CSM0098
CS-16
METER PANEL
DEFAULT SETTING
Perform the initial value setting after operating the vehicle into the
following position.
Mast: vertical
Lift: 30 cm (11.8 in) up (no load or tare weight (palette, etc)
condition)
NOTE:
If the vehicle is equipped with the tilt horizontal function (option),
simple load indicator (option), the mast angle and the load indicator
are set to the zero position after performing the initial value setting.
1. When FN1 and FN5 are pressed at the same time, the clock
display switches to the initial value setting screen.
2. When FN5 is pressed, the initial values are set and the screen
returns to the clock display.
CS-17
METER PANEL
REGENERATION MARK
When the real time energy consumption indicator is displayed and
then when - (minus) kW is displayed, the regeneration mark is
displayed, too.
CS-18
METER PANEL
NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)
CSM0099
POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function switch FN3 is pressed, the power
mode is switched.
CS-19
METER PANEL
Push function switches FN1 and FN2 simultaneously. The time set
mode will appear.
After setting the clock to the correct time, push function switch FN5.
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
• Push FN1 to increase the numerical value or advance one day of
the week.
• Push FN2 to decrease the numerical value or reverse one day of
the week.
• If an alarm is set, “ ” appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press FN5 to stop the buzzer. The day of the week can
be set to every day (ALL: every day).
Simultaneously press function switches FN1 and FN4. The clock will
move to the traction acceleration control mode.
Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.
Each time the key is pushed, the acceleration level (speed) will
decrease by 1 step.
After setting the acceleration level, push function switch FN5. The
acceleration level will appear, and clock will return to its original letter
mode.
CS-20
METER PANEL
For faster acceleration (Quick): Push function switch FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
For slower acceleration (Slow): Push function switch FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.
After setting the acceleration level, push function switch FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 4
P-LEVEL SET: Level 6 (36V battery model for North America)
(Permissible setting range: Level 1 - 8)
WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.
CS-21
METER PANEL
CSM0102
Wrench mark
The controller and the sensors act together to regulate the forklift’s
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.
CS-22
METER PANEL
CSM0103
CSM0104
After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle may be operated during the pump cut warning.
However, move the vehicle to a safe location, and promptly charge
the battery.
CSM0106
CS-23
METER PANEL
CSM0105
When function switch FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
CSM0106
CS-24
METER PANEL
D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor is WARNING
overheating. Immediately stop
Ignoring the warning indication and
forklift operation. Park the forklift in
continuing to operate the forklift
a safe area where there is no
can result in serious motor and
pedestrian or vehicular traffic.
controller damage.
Allow the controller and/or the
motor to cool.
Essential fluid BRAKE FLUID LEVEL DOWN The brake fluid level has fallen
below the specified level.
Battery Battery over voltage The controller has detected a high Turn the key switch OFF and ON
battery voltage again. If no error displayed, you can
operate the forklift without a
problem. If problem reoccur, contact
your NISSAN FORKLIFT dealer.
CS-25
LCD MONITOR
LCD MONITOR
Adjustment Mode
CS-26
LCD MONITOR
CS-27
LCD MONITOR
CS-28
LCD MONITOR
CS-29
LCD MONITOR
CS-30
LCD MONITOR
CS-31
LCD MONITOR
CS-32
LCD MONITOR
CS-33
LCD MONITOR
Manager Mode
CS-34
LCD MONITOR
CS-35
LCD MONITOR
CS-36
LCD MONITOR
CS-37
LCD MONITOR
Diagnostic Mode
CS-38
LCD MONITOR
CS-39
LCD MONITOR
CS-40
LCD MONITOR
CS-41
LCD MONITOR
CS-42
LCD MONITOR
CS-43
LCD MONITOR
CS-44
LCD MONITOR
CS-45
LCD MONITOR
CSM0198
CS-46
LCD MONITOR
CSM0199
CS-47
LCD MONITOR
RESULT OF SELF-CHECK
If the error is not detected:
CSM0113
CS-48
LCD MONITOR
CS-49
CONTROLLER
CONTROLLER
Construction
CS-50
CONTROLLER
35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
23 22 21 20 19 18 17 16 15 14 13 15 14 13 12 11 10 9 UNIT SIDE
12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
UPSIDE
L/W R Y/BR B G/R Y L P W Y OR B B L P GY L/W W/R L W
718 717 716 978 715 801 802 803 804 127 129 992 993 315 669 762 761 906 680 681
L P W W Y/L B/W PU G Y P B/Y
781 771 704 743 670 665 664 705 742 671 660
G BR/Y R BR/W Y/L G G/B
691 690 688 687 685 684 682
HARNESS SIDE
L L/B BR G R W L G B B GY B/R OR L BR/W GY B/Y L R
786 711 710 126 253 254 410 450 960 940 979 934 124 733 723 724 722 811 810 : MC only
: Joystick Contorl only
BSM0665
CS-51
CONTROLLER
Pump Controller
CS-52
CONTROLLER
CS-53
CONTROLLER
CS-54
CONTROLLER
Service data
Measurement
terminals Normal value ()
Controller Judge of abnormal
Tester Tester (Reference value)
(+) (-)
Pump VB U 26k
U VB 26k
VB V 25k
V VB 25k
VB W 26k
W VB 26k
(-) U 26k
U (-) 26k
(-) V 25k
V (-) 25k
(-) W 26k
W (-) 26k
±10%
Traction +B U 19k
(RH and LH) U +B 19k
+B V 21.5k
V +B 21.5k
+B W 21.5k
W +B 21.5k
-B U 19k
U -B 19k
-B V 21.5k
V -B 21.5k
-B W 21.5k
W -B 21.5k
NOTE:
• Measurement with digital tester and circuit tester range selector
must be set to "Auto range".
• Measured values may differ depending on the model of the digital
testers, the above values are for reference.
CS-55
CONTROLLER
Service Data
Item Normal NG
Operation Operation check with constant voltage Failed cooling fan
CONTACTOR ASSEMBLY
Specifications
Item Specification
Type SU280
Rated voltage 36/48 V
Contacting voltage (1 h after conducting coil) Less than 22 V
Open voltage Less than 9 V
Rated time 1 hour (48 V chopper)
Cut off capacity 1500A
Mechanical life Over 3 million cycle
(1) Contactor coil
(2) Battery current sensor
(3) FS1 fuse
Service Data
Item Normal NG
Coil resistance 44 / at 20°C (68°F) Abnormal contact
Service Data
Item Normal NG
Output V Approx. 2.5 V between 3-4 Failed sensor
Source V Approx. 5.0 V between 1-2 Failed VCM
NOTE:
The circuit tester range selector must be set to "X1DCV".
CS-56
CONTROLLER
Controller Element Inspection (Cont’d)
FS1 FUSE (ON CONTACTOR ASSEMBLY)
Specifications
Item Specification
Type CNL500
Capacity 500 A
Inspection
• Visually check the fuse is not broken. If necessary replace it with
a new one.
• Using a circuit tester, check continuity of the fuse.
Continuity
NOTE:
The circuit tester range selector must be set to “x1 ”.
Temperature sensor
Specifications
Item Specification
Resistance R 100°C (212°F) 1000
R 25°C (77°F) 603
Service Data
Item Normal NG
Sensor
603 [at 25°C (77°F)] Failed temp. sensor
resistance
Revolution sensor
Specifications
Item Specification
Input voltage 5 - 24 DCV
Temperature range -40 ~ 140°C (-40 ~ 284°F)
Anti vibration 4G
Type Magnetic pickup
Service Data
Item Normal NG
Revolution
Self check by revolution sensor IC
sensor Failed revolution sensor
detection
checking
CS-57
CONTROLLER
(1) Controller assembly (2) Air guide plate (3) Contactor assembly (4) Controller cable (VB)
(5) Battery plug cable (+) (6) Body harness (+) (7) Contactor bracket (8) Clip
(9) Joystick controller assembly
CS-58
UNIT INSPECTION AND ADJUSTMENT
UNIT INSPECTION AND ADJUSTMENT
Control System
CAUTION:
• Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
• When checking a unit, also check the condition of the
associated harness and connector.
• All units can be checked using interactive diagnostic
procedures. (Refer to “LCD MONITOR” on page 30.)
NOTE:
• The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
• This section deals with only resistance measurement procedures
for unit inspection.
ELM0272
CS-59
UNIT INSPECTION AND ADJUSTMENT
Forward -
Neutral -
Reverse -
CSM0116
CS-60
UNIT INSPECTION AND ADJUSTMENT
Service data
CSM0117
CSM0118
CS-61
UNIT INSPECTION AND ADJUSTMENT
Service data
Measuring
points Standard value Remarks
(terminals)
CSM0119
Adjustment
1. Call up tire angle sensor diagnostic screen from interactive
diagnostic display.
2. Loosen tire angle sensor securing screws.
3. While observing the tire angle sensor output on the display to
check if it is within the specified range, rotate the tire angle
sensor.
4. Tighten tire angle sensor securing screws.
: 1.2 - 1.8 N•m (0.13 - 0.18 kgf-m, 11 - 15 in-lb)
CSM0120
CS-62
UNIT INSPECTION AND ADJUSTMENT
Service data
Measuring
points Standard value Remarks
(terminals)
CSM0207
CS-63
UNIT INSPECTION AND ADJUSTMENT
CSM0239
Tire angle sensor fixes the kingpin plate to the kingpin as shown in
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the steering
control system function correctly. Notes concerning assembly are as
follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.
CSM0240
CS-64
UNIT INSPECTION AND ADJUSTMENT
CSM0121
Specification
Total resistance (k) 2.5 - 5.0 (Reference value)
Service data
Measuring
Standard value
points Remarks
(V)
(terminals)
Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0123 : 1.5 - 1.8 N•m (0.16 - 0.18 kgf-m, 14 - 15 in-lb)
CS-65
UNIT INSPECTION AND ADJUSTMENT
CSM0124
CS-66
UNIT INSPECTION AND ADJUSTMENT
Brake switch ON/OFF switching point Pedal height: 115.5 mm (4.547 in)
(from floor upper surface)
CSM0125
Adjustment
CSM0202
CS-67
UNIT INSPECTION AND ADJUSTMENT
CSM0126
CS-68
UNIT INSPECTION AND ADJUSTMENT
Centering adjustment
Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.
CST0039
CS-69
UNIT INSPECTION AND ADJUSTMENT
Inspection
Measure resistance between lift solenoid terminals.
<Reference value>
CSM0127
CS-70
UNIT INSPECTION AND ADJUSTMENT
CSM0144
JOYSTICK CONTROLLER
CS-71
UNIT INSPECTION AND ADJUSTMENT
CSM0200
Specifications
Inspection
Check resistance between terminals using circuit tester ( range).
Resistance ()
Terminals Remarks
(Reference value)
A (+)-A (-)
30 20°C (68°F)
B (+)-B (-)
36 20°C (68°F)
C1 (+)-C1 (-)
44 90°C (194°F)
CS-72
UNIT INSPECTION AND ADJUSTMENT
No continuity No continuity
- Continuity
( ) ( )
No continuity No continuity
- Continuity
( ) ( )
CSM0145
CSM0146
CS-73
UNIT INSPECTION AND ADJUSTMENT
CSM0147
Specification
Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).
CS-74
UNIT INSPECTION AND ADJUSTMENT
CSM0148
Inspection
Check continuity between terminals using circuit tester ( range).
- Continuity No continuity
CS-75
UNIT INSPECTION AND ADJUSTMENT
CSM0149
CS-76
UNIT INSPECTION AND ADJUSTMENT
CSM0150
CS-77
UNIT INSPECTION AND ADJUSTMENT
Inspection
Check resistance between terminals using circuit tester.
For steering wheel angle sensor and tire angle sensor inspections,
refer to “UNIT INSPECTION AND ADJUSTMENT” on page CS-59
and further.
CS-78
UNIT INSPECTION AND ADJUSTMENT
Tilt Leveling Device (Option)
INSPECTION
Tilt horizontal switch
Check continuity.
When press button: Continuity should not exist.
When do not press button: Continuity should exist.
CSM0245
CSM0299
CSM0242
CS-79
UNIT INSPECTION AND ADJUSTMENT
Item Resistance
Normal () 30 - 77
Malfunction () 0 or
CSM0243
CS-80
UNIT INSPECTION AND ADJUSTMENT
2012012
SETTING
1. Park the vehicle on a flat, level road.
2. Set rear tire to the straight-ahead position. (Knob can take any
position.)
3. Set the mast to vertical.
4. Raise the fork approximately 300 mm (11.8 in) from the ground.
5. After calling up “ADJUSTMENT MENU” “1-2. SENSOR”
“16 SENSOR INITIAL SET”, push function key FN3 and turn
“OFF” to “ON”.
NOTE:
Procedure is same as “Knob Position Control and Neutral Setting”
as above.
CS-81
UNIT INSPECTION AND ADJUSTMENT
CSM0244
CS-82
TROUBLE DIAGNOSTIC PROCEDURES
TROUBLE DIAGNOSTIC PROCEDURES
Precautions
CAUTION:
• Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
• After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
• When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
• When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
• Basic trouble diagnostic procedures must be performed as
follows:
Malfunction occurrence
Perform self-diagnosis.
NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)
CST0062
CS-83
TROUBLE DIAGNOSTIC PROCEDURES
MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.
WORK FLOW
Confirmation of malfunction
Remedial procedures
CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.
A
: Current measurement in 50-ampere range (AC)
50
CS-84
TROUBLE DIAGNOSTIC PROCEDURES
Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
• Connector guides for male terminals are shown in black.
• Connector guides for female terminals are shown in white.
CST0063
Connector direction
• Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
• Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.
CST0064
CST0065
KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.
CS-85
TROUBLE DIAGNOSTIC PROCEDURES
Voltage and Resistance Measurement
Procedures
VOLTAGE MEASUREMENT
• Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
• To facilitate voltage measurements for parts or terminals
(adjacent to controllers), it is best to use an alligator clip with the
black (ground) test probe of a circuit tester and fasten it to the
battery ground terminal during measurements.
CST0066
RESISTANCE MEASUREMENT
• Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
• A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
CST0067
CS-86
TROUBLE DIAGNOSTIC PROCEDURES
CS-87
TROUBLE DIAGNOSTIC PROCEDURES
CS-88
TROUBLE DIAGNOSTIC PROCEDURES
CS-89
TROUBLE DIAGNOSTIC PROCEDURES
454
• Stop the steering knob position correct control
• Turn angle
• Max turn speed and max turn accel are limited.
Tire angle sensor
How to reset: Output is return to normal range.
Fail mode:
• 3 wheel signal 4.95 volt for 15 secs
• 4 wheel signal 4.8 volt for 15 secs.
455
Fail operation: Same as 454
How to reset: Output is return to normal range.
Fail mode: Low output (Sig. is less than 0,2 Volt over 100ms)
Fail operation:
456 • Tilt auto horizontal control
stops tilt operation in case of tilt horizontal SW is applicable.
Tilt angle sensor How to reset: Key OFF
Fail mode: High output (Sig. is over 4.8 Volt over 100ms)
457 Fail operation: Same as 456
How to reset: Key OFF
CS-90
TROUBLE DIAGNOSTIC PROCEDURES
CS-91
TROUBLE DIAGNOSTIC PROCEDURES
CS-92
TROUBLE DIAGNOSTIC PROCEDURES
CS-93
BATTERY AND CHARGER
SECTION BC
CONTENTS
PRECAUTIONS AND PREPARATION ............. BC-2 CHARGER ....................................................... BC-11
Precautions ................................................... BC-2 How to Charge the Battery
BATTERY ........................................................... BC-3 (Off-Forklift Type) ........................................ BC-11
Specifications ................................................ BC-3 BATTERY MOUNTING .................................... BC-12
Trouble Diagnoses and Corrections .............. BC-4
Removal ........................................................ BC-5
Installation ..................................................... BC-6
Inspection ...................................................... BC-6
NOTE:
This section describes the general precautions and maintenance information for the handling and charging of the
battery.
For the actual handling and charging of the battery, please confirm with the instruction manual of battery and charger
used.
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
WARNING:
• Do not smoke or place any fire near the battery being
serviced or handled.
• Be careful not to spill electrolyte on your body or clothes as
this may cause injury or chemical burns.
• If electrolyte flows out or leaks from the battery case,
immediately dilute with a neutralizing detergent (such as
sodium bicarbonate, calcium hydroxide, etc.) and then rinse
with a large amount of running water.
• Never place any metal objects (such as tools, etc.) on or
across battery terminals. This may ignite and explode
hydrogen gas emitted from the battery or cause damage to
the battery and personal injury.
• Static electricity may explode the battery. Do not attempt to
wipe or clean the upper surface or terminals of the battery
with a dry cloth or do not place a vinyl cover over the battery.
Always wipe clean the battery case with a wet cloth.
CAUTION:
• Electrolyte leakage may corrode the battery itself. Always
tighten battery vent caps firmly.
• Do not allow any one who is unfamiliar with battery handling
instructions to inspect the battery.
BC-2
BATTERY
BATTERY
Specifications
EXCEPT NORTH AMERICA
(A)G1N1 /
(A)1N1
J(A)G1N1
BC-3
BATTERY
Battery has reached its life if the following phenomena appear. (Also take into account the battery age and operating
conditions.):
• Electrolyte decreases fast and supplying frequency increases.
• Electrolyte temperature becomes 50°C (122°F) or more.
• Timer of charger cannot be turned OFF (or sometimes cannot be turned OFF).
• There is greater variance in voltage and specific gravity among cells.
• Electrolyte color changed to brown (emergence of PbO2 sediment in electrolyte).
• Electrolyte color changed to gray (high electrolyte temperature causes Pb sediment and dropping).
• Specific gravity does not reach 1.250 or more even after charging or equation charging is complete.
BC-4
BATTERY
Removal
CAUTION:
• Always use chain block and hoist which can stand battery
weight when mounting and removing battery.
• Stabilize vehicle body by pulling parking brake lever and
fixing stoppers to front and rear wheels before operation.
• Always employ a person who has completed a slinging or a
hoisting skill course to perform battery hoisting and lowering
work.
• Use care not to damage harness of battery cable, etc.,
battery support and overhead guard when mounting and
removing battery.
BCM0012
4. Align the battery raising tool with the hook and the notch in the
protection roof.
5. Lift the battery box vertically out of its lodging.
WARNING:
Use extra care with hanger. Never let it make contact with
terminal of battery when placing it. If contact is made, sparks,
leading to burns and explosions occur.
BCM0013
BC-5
BATTERY
Installation
Battery mounting follows procedure in reverse order of removal.
CAUTION:
• Confirm mounting direction of battery case.
• Mount battery by putting battery case to rear plate and
sliding it so as not to damage bracket of battery connector
and electrolyte level warning harness.
• Connect battery connector.
• Sandwiching of harness causes short and burns of harness,
leading to unexpected malfunctions.
Inspection
WARNING:
• Never use fire in a spot for inspecting battery.
• Never let battery electrolyte containing dilute sulfuric acid
stick to eyes, skins, clothes or the like. It may cause loss of
eye sight and burns and holes on clothes. If stuck, wash it
with a lot of water. If it enters eyes or you drink it by mistake,
wash or drink a lot of water and consult with a doctor as
soon as possible.
BC-6
BATTERY
Inspection (Cont’d)
ELECTROLYTE LEVEL
CAUTION:
Fill distilled water when battery electrolyte level drops.
1. Open the cap and check the electrolyte level. If electrolyte level
is in between - in left figure, it is OK.
CAUTION:
Be careful because battery specifications may vary with each
maker.
BCM0014
2. If inspection finds a cell in which electrolyte level is too low,
check if there is any leakage and fill with distilled water. Continue
filling up with cap opened until electrolyte level rises to
position. However, be careful, for it may vary with each maker.
NOTE:
• Probable causes of leakage are as follows:
• Damage to cap
• Excessive filling with distilled water
• High electrolyte temperature during charging, leading to
electrolyte overflow
CAUTION:
• Use care not to fill distilled water excessively. It may cause
short or leakage.
• Electrolyte lid is pushed into battery cell and needs to be
secured to prevent leakage.
• If there are any cracks in electrolyte lid, replace with new one.
• Be careful because battery specifications may vary with each
maker.
ELECTROLYTE TEMPERATURE
Measure electrolyte temperature of each battery cell with a
thermometer.
NOTE:
When battery electrolyte temperature rises, electrolyte and capacity
of the battery expand. However, specific gravity decreases because
there is no change in weight. Contrary when electrolyte temperature
drops, specific gravity increases. Thus, when measuring specific
gravity, evaluate result by converting electrolyte temperature at 20°C
BCT0017
(68°F). (Refer to “SPECIFIC GRAVITY” section.)
BC-7
BATTERY
Inspection (Cont’d)
SPECIFIC GRAVITY
NOTE:
Specific gravity is very useful for determining battery life and
condition.
1. To measure specific gravity of each battery cell by gravimeter.
CAUTION:
Measure with gravimeter placed in battery cell. Use extra care
to prevent scattering of battery electrolyte outside when pulling
it out of the cell.
BCT0018
BCT0020
BC-8
BATTERY
Inspection (Cont’d)
BATTERY MAINTENANCE
Cleaning
If dust is accumulated on upper surface of battery, the dust can
absorb water and cause leakage between terminals. Periodically
clean the upper surface of the battery with a wet cloth and dry it
when inspecting electrolyte level.
WARNING:
• Never clean the upper surface of the battery with a dry cloth,
dust it or put a vinyl cover on it. It may generate static
electricity and cause battery explosion.
• Never put fingers or driver into battery connection. Never
touch connection terminal of the battery. It may cause
electric shock and short.
CAUTION:
Always clean the battery before charging.
Transparent and
Appearance Fe (iron) below 0.0005%
colorless
NO2 (nitric acid) below 0.0005% Cu (copper) below 0.0005%
NH3 (ammonia) below 0.0005% Mn (manganese) below 0.0005%
KMnO4
Cl (chlorine) below 0.0005% (potassium below 0.0003%
permanganate)
STORING BATTERY
• Be sure battery is fully charged before placing it in storage.
CAUTION:
Before charging, add distilled water so that electrolyte is a little
higher than the prescribed level.
• When not in use, battery should be stored in cool and dark place
(well ventilated and temperature and humidity are low). Check
specific gravity from time to time and, when it is below 1.200,
charge the battery. Perform equation charging once every two
months. Battery determines a life of forklift, and thus be sure to
record every maintenance work.
BC-9
BATTERY
Inspection (Cont’d)
EXTERNAL LEAKAGE OF BATTERY ELECTROLYTE
(⊕ LEAK)
Locate leaking cell following the flow chart below.
NOTE:
• Put tester to paint erased portion (paint is erased by file) when
putting the tester to iron box.
• White zinc sulphate crystals are most often stuck to terminal of
electrolyte leaking cell.
No
Remove battery Voltage is OK (no leak)
from vehicle body generated.
and wash it with
water. Yes
First time
BCT0006
Second time
Yes
NOTE:
For inspection of leak, measure in reverse polarity of all and
for leak inspection.
BC-10
CHARGER
CHARGER
BCM0015
BC-11
BATTERY MOUNTING
BATTERY MOUNTING
BCM0016
BC-12
ELECTRICAL SYSTEM
1N1 SECTION EL
CONTENTS
PRECAUTIONS ................................................. EL-2 SWITCHES ....................................................... EL-19
Precautions .................................................... EL-2 Key Switch ................................................... EL-19
LOCATION OF ELECTRICAL UNITS ............... EL-3 Battery Switch .............................................. EL-19
Electrical Component Parts (3 - wheel) .......... EL-3 Combination Switch ..................................... EL-20
Electrical Component Parts (4 - wheel) .......... EL-3 Back Operation Lamp Switch (Option) ......... EL-21
HARNESS LAYOUT .......................................... EL-5 Seat Switch .................................................. EL-21
Outline ............................................................ EL-5 Seat Belt Switch ........................................... EL-22
Body Harness for Mechanical Control System . EL- Parking Brake Switch ................................... EL-22
6 MISCELLANEOUS ELECTRICAL PARTS ...... EL-23
Body Harness for Joystick Control System .... EL-9 Horn Switch .................................................. EL-23
Tail Harness ................................................. EL-12 Horn Relay ................................................... EL-23
Guard Harness ............................................. EL-12 Tail Lamp, Auto Power Off, Battery Switch,
Hydraulic Control Valve Switch Harness for Joystick Control System Relay ..................... EL-24
Mechanical Control System .......................... EL-13 Horn ............................................................. EL-24
Sub-harness for Joystick Control System Warning Buzzer ............................................ EL-25
(Option) ........................................................ EL-13 Back Buzzer ................................................. EL-25
FUSES ............................................................. EL-14 BATTERY CABLES AND MOTOR CABLES ... EL-26
Fuse and Fuse Box ...................................... EL-14 Battery Cables and Moter Cables ................ EL-26
Fusible Link .................................................. EL-15 LOCATION OF OPTIONAL PARTS ................. EL-28
LIGHTING SYSTEM ........................................ EL-16 Earth Band ................................................... EL-28
Lamps ........................................................... EL-16
Headlamp ..................................................... EL-17
Back operation lamp (Option) ....................... EL-17
Patrol lamp (Option) ..................................... EL-18
Bulletin issued:
Service Bulletins Issue date
SB-TX-EL-0701-02 RPM sensor error with new motor 12-112007
PRECAUTIONS
PRECAUTIONS
Precautions
CAUTION:
• When performing removal and installation procedures, be
sure to turn key switch to OFF and disconnect battery plug.
• When replacing a fuse or a bulb for accessories, alway use
one of specified capacity.
EL-2
LOCATION OF ELECTRICAL UNITS
ELM0251EU
EL-4
HARNESS LAYOUT
HARNESS LAYOUT
Outline
ELM0252EU
EL-5
HARNESS LAYOUT
ELM0253
*: For EUROPE only
**: Except for NORTH AMERICA
EL-6
HARNESS LAYOUT
ELM0254
***: For NORTH AMERICA only
EL-7
HARNESS LAYOUT
B10 : To brake fluid level switch B49 : To revolution sensor (Pump motor)
B11 : To brake fluid level switch B50 : To revolution sensor (Shield earth)
B12 : To lighting and turn signal lamp switch B51 : To revolution sensor (Shield earth)
B14 : To cabin harness (Option) B53 : To PS correction solenoid (Except for NORTH AMERICA)
B32 : To electrical horn (For NORTH AMERICA) B71 : To patrol lamp (Option)(Except for NORTH AMERICA)
B33 : To electrical horn (For NORTH AMERICA) B72 : To patrol lamp (Option)(Except for NORTH AMERICA)
EL-8
HARNESS LAYOUT
ELM0255
EL-9
HARNESS LAYOUT
ELM0256
***: For NORTH AMERICA only
EL-10
HARNESS LAYOUT
EL-11
HARNESS LAYOUT
Tail Harness
ELM0257
Guard Harness
ELM0258
EL-12
HARNESS LAYOUT
ELM0259
ELM0260
EL-13
FUSES
FUSES
ELM0261
INSTALLATION
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in
reverse order of removal.
NOTE:
• When removing fuse box, remove fuse box cover. Insert a small
screwdriver into hook to unlock, then remove fuse box from
bracket.
• When installing fuse box, insert part to be fitted into bracket and
securely lock with hook.
EL-14
FUSES
6 5 Option
7 5 Meter
Fusible Link
INSPECTION
Check for blown fusible link using circuit tester.
CAUTION:
If fusible link is blown, replace with a new one of specified
capacity. Also, check related electrical parts to determine the
cause of problem, and repair if necessary.
ELM0263
EL-15
LIGHTING SYSTEM
LIGHTING SYSTEM
Lamps
REMOVAL AND INSTALLATION.
ELM0265
EL-16
LIGHTING SYSTEM
Lamps (Cont’d)
SPECIFICATIONS
Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1
CAUTION:
In checking, make sure that resistance between connector
terminal and case/screw is 100 kor more using circuit tester.
Headlamp
CAUTION:
Install lens with water-drain hole facing down.
ADJUSTMENT
Adjust headlamp aim so that axis of light is 6 degrees below
horizontal line.
CAUTION:
• Place vehicle and tester on the same horizontal plane.
• Keep all tires inflated to correct pressure.
ELM0266
EL-17
LIGHTING SYSTEM
ELM0267
EL-18
SWITCHES
SWITCHES
Key Switch
REMOVAL
1. Disconnect harness connector.
2. Remove ring nut and remove key switch from rear cover.
INSTALLATION
Install key switch in reverse order of removal.
ELM0268
INSPECTION
Check continuity between terminals using circuit tester ( range).
Switch position
Terminal Remarks
OFF ON RE-START
1 To fuse
2 From fuse
3
4 Re-start
ELM0269
Battery Switch
CAUTION:
Remove battery switch after turning off key switch,
disconnecting battery plug and making battery switch off
(pushed state).
INSPECTION
Check continuity between terminals using circuit tester ( range).
Switch condition
Terminal
ELM0270 Pulled Pushed
For battery cables Continuity
ELM0271
EL-19
SWITCHES
Combination Switch
ELM0272
DESCRIPTION
• The turn signals and forward-reverse switches were integrated
into a single unit. Also, a lighting switch structure was adopted.
• An auto return function was adopted for the turn signal lever.
• Turn signal switch is installed left side for joystick control system
(option) vehicle.
NOTE:
Please refer to control system (CS) section for forward-reverse
switch (lever) and steering angle sensor.
ELM0273
Lighting switch
ELM0274
INSPECTION
Check continuity between terminals using circuit tester ( range).
T-1
T-2
T-3
ELM0275
EL-20
SWITCHES
L-1
L-2
L-3
Switch OFF
Switch ON
BET0141L
ELM0277
Seat Switch
INSPECTION
Check continuity.
When sitting on the seat: Continuity should exist.
When not sitting on the seat: Continuity should not exist.
VCT0023L
EL-21
SWITCHES
INSPECTION
Check continuity.
When insert buckle: Continuity should exist.
When disconnect buckle: Continuity should not exist.
VCT0031L
INSPECTION
Check continuity between terminals using circuit tester ( range).
1
VCT0037L
2
3
EL-22
MISCELLANEOUS ELECTRICAL PARTS
MISCELLANEOUS ELECTRICAL PARTS
Horn Switch
INSPECTION
• Check horn sound by pushing horn switch while turning steering
wheel from lock to lock.
• Remove steering wheel (Refer to ST section) and visually check
horn brush for wear or damage.
Horn Relay
SPECIFICATIONS
ELM0276
INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals and
using circuit tester ( range) while applying or releasing battery
voltage to/from coil side terminals and .
ELM0278
EL-23
MISCELLANEOUS ELECTRICAL PARTS
ELM0279
INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals using circuit
tester ( range) while applying or releasing battery voltage to/
from coil side terminals.
Terminal
Coil - Continuity
Contacting point - Continuity
ELM0280
Horn
SPECIFICATIONS
Horn
ELM0281
EL-24
MISCELLANEOUS ELECTRICAL PARTS
Warning Buzzer
SPECIFICATIONS
Warning buzzer
ELM0282
INSPECTION
A warning buzzer sounds when the driver stands up from the seat
without applying the parking brake.
– –
– –
ON
– –
– –
–
– –
OFF
– –
– –
• 3-second delay is implemented for detection of unseated status.
Back Buzzer
SPECIFICATIONS
Back buzzer
ELM0283
EL-25
BATTERY CABLES AND MOTOR CABLES
BATTERY CABLES AND MOTOR CABLES
ELM0287
EL-26
BATTERY CABLES AND MOTOR CABLES
ELM0289
EL-27
LOCATION OF OPTIONAL PARTS
LOCATION OF OPTIONAL PARTS
Earth Band
DESCRIPTION
For normal tires (black tires), the carbon is contained as a material.
Therefore, if the vehicle is charged with electricity, it will be
discharged from the tires.
For non-marking tires (colored tires), the carbon is not contained as
a material. Therefore, if the vehicle is charged with electricity, it
cannot be discharged.
The circuit board, element, or parts may be damaged by this
electrification.
To prevent this damage, install the earth band to the vehicle and
discharge the static electricity from the vehicle.
ELM0284
WIRING DIAGRAM
WIRING DIAGRAM
CIRCUIT DIAGRAM
EL-28
B
JOYSTICK CONTROLLER
1N1 -series CABIN ASSY
(OPTION FOR T'
RELAY (OPTION)
EUROPE ONLY)
Fingertip / mechanical controlled
JOYSTICK CONTROLLER (OPTION)
From serial number to serial
G1N1-721551 => G1N1-722977
1N1-721779 => 1N1-723538
S1N1-720481 => S1N1-721094
SEAT BELT SW SEAT BELT SW
688
L/GY
608 630 626 636 609 680 682 688 690 691
JOYSTICK CONTROL
SYSTEM (OPTION)
HARN-SUB HARN-SUB
PS CORRECTION
682
687
682
HARN-SUB HARN-SUB
W B 679
PUMP CONTROLLER
LIGHT SW
1 4 8 11 23 26 30 33 36 39 42 53 56 59 62 65 76 79 82 85 88 90 102 104 107
2 5 7 9 12 14 16 18 21 19
24 27 29 31 34 37 40 43 44 46 48 50 52 54 57 60 63 66 68 69 71 73 75 77 80 83 86 89 91 93 95 97 98 100 103 105 108
3 6 10 13 15 17 20 22 25 28 32 35 38 41 45 47 49 51 55 58 61 64 67 70 72 74 78 81 84 87 92 94 96 99 101 106 108
5
6 1
2
4
5
7
8
10 12 14 16 22 19 25 28 31 34 36 38 40 43 46
11 13 15 17 20 23 26 29 32 35 37 39 41 44 47
3 6 9 18 21 24 27 30 33 42 45 48
7 B
8 145 151 T' Vehicle side
B P
Combination meter
1 BATTERY VOLTAGE 11 POWER GND
151
2 BATTERY POWER + 12 NOT USED
145
PATROL LAMP 20 19 18 17 16 15 14 13 12 11
(OPTION) 10 9 8 7 6 5 4 3 2 1
Meter side
687
P S C OR R E C T ION
682
687
LIF T VALVE AS S Y
682
HAR N-S UB HAR N-S UB
680
P /M T E MP S E NS OR
P /M R E V S E NS OR
R H T /M T E MP S E NS OR
R H T /M R E V S E NS OR
R H T /M R E V S E NS OR
R H T /M T E MP S E NS OR
P /M R E V S E NS OR
671
P /M T E MP S E NS OR
670
P UMP C ONT R OLLE R
443
146
669 442 665 160
156
664
678
679
676
146 159
677
LIG HT S W
1 4 8 11 23 26 30 33 36 39 42 53 56 59 62 65 76 79 82 85 88 90 102 104 107
2 5 7 9 12 14 16 18 19 21 24 27 29 31 34 37 40 43 44 46 48 50 52 54 57 60 63 66 68 69 71 73 75 77 80 83 86 89 91 93 95 97 98 100 103 105 108
3 6 10 13 15 17 20 22 25 28 32 35 38 41 45 47 49 51 55 58 61 64 67 70 72 74 78 81 84 87 92 94 96 99 101 106 108
1 4 7 10 12 14 16 19 22 25 28 31 34 36 38 40 43 46
2 5 8 11 13 15 17 20 23 26 29 32 35 37 39 41 44 47
3 6 9 18 21 24 27 30 33 42 45 48
B
T' Vehicle s ide
C ombination meter
1 B AT T E R Y VOLTAG E 11 P OWE R G ND
2 B AT T E R Y P OWE R + 12 NOT US E D
LH T /M T E MP S E NS OR
3 NOT US E D 13 OP T R E LAY 2
LH T /M R E V S E NS OR
4 B R AK E F LUID LE V E L S W 14 OP T R E LAY 1
5 S E AT B E LT S W 15 WAR NING B UZZE R DR IV E R E LAY
6 PAR K ING B K K E Y INP UT 16 NOT US E D
7 NOT US E D 17 NOT US E D
8 NOT US E D 18 NOT US E D
9 PAR K ING B R AK E S W R E LE AS E 19 C ONT. TO ME T E R C OMMUNIC AT ION DATA
LH T /M R E V S E NS OR
LH T /M T E MP S E NS OR
PAT R OL LAMP 20 19 18 17 16 15 14 13 12 11
(OP T ION) 10 9 8 7 6 5 4 3 2 1
Meter s ide
E L M0285
540 541
000 101
542 543
000 102
900
910
129
128
280 281
101
280 281
127
126
671
670
761 661 661
670
763 663
762 662 662
979 979 671
660
664
740
SEAT
BELT
SW LIFT SOL. VALVE
380 480 311
722 722 732
380
381
746
GND
GND
POWER
POWER
746 733
EMG
RELAY
134 133 132 450 253 412 411 254 911 140 142 144 146 913 148 150 912 141 143 145 147 914 149 151 152 915 153 916 917 154 155 156 157 918 158 159 160 919 603 605 607 609 611 613 720 745 731
120 100
140 142 144 146 148 150 141 143 145 147 149 151 152 915 153 916 154 155 156 157 158 159 160 919
POWER
POWER
GND
GND
137 600
604 136 JOYSTICK CONT. 500 505 510 000 255
RELAY
601 135
608 631 520 505
680 680
501 506 511 000
681 681
608
682 682 954
410 221 442 405 465 409 220 441 404 464 212 213 969 241 361
686 624 624 625
PATROL BACK
431 LAMP OPERA- 687 687
(OPTION) TION
LAMP 688 688 634 634 635
125 727 (OPTION)
903
ELM0286
ELM0285 - WIRING DIAGRAM 2005-2006 MODELS
ELECTRICAL SYSTEM
A1N1 SECTION EL
CONTENTS
PRECAUTIONS ................................................. EL-2 MISCELLANEOUS ELECTRICAL PARTS ...... EL-15
Precautions .................................................... EL-2 Horn Switch .................................................. EL-15
LOCATION OF ELECTRICAL UNITS ............... EL-3 Horn Relay ................................................... EL-15
Electrical Component Parts (3 - wheel) .......... EL-3 Tail Lamp, Auto Power Off, Battery Switch,
Electrical Component Parts (4 - wheel) .......... EL-3 Joystick Control System Relay ..................... EL-16
HARNESS LAYOUT .......................................... EL-5 Horn ............................................................. EL-16
Outline ............................................................ EL-5 Warning Buzzer ............................................ EL-17
FUSES ............................................................... EL-6 Back Buzzer ................................................. EL-17
Fuse and Fuse Box ........................................ EL-6 BATTERY CABLES AND MOTOR CABLES ... EL-18
Fusible Link .................................................... EL-7 Battery Cables and Motor Cables ................ EL-18
LIGHTING SYSTEM .......................................... EL-8 LOCATION OF OPTIONAL PARTS ................. EL-21
Lamps ............................................................. EL-8 Earth Band ................................................... EL-21
Headlamp ....................................................... EL-9 DC/DC converter (Option) ............................ EL-22
Back operation lamp (Option) ......................... EL-9 WIRING DIAGRAM ........................................... EL-23
Patrol lamp (Option) ..................................... EL-10 Power Supply for Controller ......................... EL-23
SWITCHES ...................................................... EL-11
Key Switch .................................................... EL-11
Battery Switch .............................................. EL-11
Combination Switch ...................................... EL-12
Back Operation Lamp Switch (Option) ......... EL-13
Seat Switch .................................................. EL-13
Seat Belt Switch ........................................... EL-14
Parking Brake Switch ................................... EL-14
LOCATION OF ELECTRICAL UNITS
LOCATION OF ELECTRICAL UNITS
ELM0250EU
ELM0801EU
EL-3
PRECAUTIONS
PRECAUTIONS
Precautions
CAUTION:
• When performing removal and installation procedures, be
sure to turn key switch to OFF and disconnect battery plug.
• When replacing a fuse or a bulb for accessories, alway use
one of specified capacity.
EL-2
LOCATION OF ELECTRICAL UNITS
LOCATION OF ELECTRICAL UNITS
ELM0250EU
ELM0801EU
EL-3
LOCATION OF ELECTRICAL UNITS
ELM0251EU
EL-4
HARNESS LAYOUT
HARNESS LAYOUT
Outline
ELM0252EU
EL-5
FUSES
FUSES
ELM0261
INSTALLATION
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in
reverse order of removal.
NOTE:
• When removing fuse box, remove fuse box cover. Insert a small
screwdriver into hook to unlock, then remove fuse box from
bracket.
• When installing fuse box, insert part to be fitted into bracket and
securely lock with hook.
EL-6
FUSES
6 5 Option
7 5 Meter
Fusible Link
INSPECTION
Check for blown fusible link using circuit tester.
CAUTION:
If fusible link is blown, replace with a new one of specified
capacity. Also, check related electrical parts to determine the
cause of problem, and repair if necessary.
ELM0263
EL-7
LIGHTING SYSTEM
LIGHTING SYSTEM
Lamps
REMOVAL AND INSTALLATION.
BSM0619
EL-8
LIGHTING SYSTEM
Lamps (Cont’d)
SPECIFICATIONS
Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1
CAUTION:
In checking, make sure that resistance between connector
terminal and case/screw is 100 kΩ or more using circuit tester.
Headlamp
CAUTION:
Install lens with water-drain hole facing down.
ADJUSTMENT
Adjust headlamp aim so that axis of light is 6 degrees below
horizontal line.
CAUTION:
• Place vehicle and tester on the same horizontal plane.
• Keep all tires inflated to correct pressure.
ELM0266
EL-9
LIGHTING SYSTEM
ELM0267
EL-10
SWITCHES
SWITCHES
Key Switch
REMOVAL
1. Disconnect harness connector.
2. Remove ring nut and remove key switch from rear cover.
INSTALLATION
Install key switch in reverse order of removal.
ELM0268
INSPECTION
Check continuity between terminals using circuit tester (Ω range).
Switch position
Terminal Remarks
OFF ON RE-START
1 To fuse
2 From fuse
3
4 Re-start
ELM0269
Battery Switch
CAUTION:
Remove battery switch after turning off key switch,
disconnecting battery plug and making battery switch off
(pushed state).
INSPECTION
Check continuity between terminals using circuit tester (Ω range).
Switch condition
Terminal
ELM0270 Pulled Pushed
For battery cables Continuity
ELM0271
EL-11
SWITCHES
Combination Switch
ELM0272
DESCRIPTION
• The turn signals and forward-reverse switches were integrated
into a single unit. Also, a lighting switch structure was adopted.
• An auto return function was adopted for the turn signal lever.
• Turn signal switch is installed left side for joystick control system
(option) vehicle.
NOTE:
Please refer to control system (CS) section for forward-reverse
switch (lever) and steering angle sensor.
ELM0273
Lighting switch
ELM0274
INSPECTION
Check continuity between terminals using circuit tester (Ω range).
T-1
T-2
T-3
ELM0275
EL-12
SWITCHES
L-1
L-2
L-3
Switch OFF
Switch ON
BET0141L
ELM0277
Seat Switch
INSPECTION
Check continuity.
When sitting on the seat: Continuity should exist.
When not sitting on the seat: Continuity should not exist.
VCT0023L
EL-13
SWITCHES
INSPECTION
Check continuity.
When insert buckle: Continuity should exist.
When disconnect buckle: Continuity should not exist.
VCT0031L
INSPECTION
Check continuity between terminals using circuit tester (Ω range).
1
VCT0037L
2
3
EL-14
MISCELLANEOUS ELECTRICAL PARTS
MISCELLANEOUS ELECTRICAL PARTS
Horn Switch
INSPECTION
• Check horn sound by pushing horn switch while turning steering
wheel from lock to lock.
• Remove steering wheel (Refer to ST section) and visually check
horn brush for wear or damage.
Horn Relay
SPECIFICATIONS
ELM0276
INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals and
using circuit tester (Ω range) while applying or releasing battery
voltage to/from coil side terminals and .
ELM0278
EL-15
MISCELLANEOUS ELECTRICAL PARTS
ELM0279
INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals using circuit
tester (Ω range) while applying or releasing battery voltage to/
from coil side terminals.
Terminal
Coil - Continuity
Contacting point - Continuity
ELM0280
Horn
SPECIFICATIONS
Horn
ELM0281
EL-16
MISCELLANEOUS ELECTRICAL PARTS
Warning Buzzer
SPECIFICATIONS
Warning buzzer
ELM0282
INSPECTION
A warning buzzer sounds when the driver stands up from the seat
without applying the parking brake.
– – ×
– – ×
ON
– – ×
– –
– ×
– –
OFF
– – ×
– –
• 3-second delay is implemented for detection of unseated status.
Back Buzzer
SPECIFICATIONS
Back buzzer
ELM0283
EL-17
BATTERY CABLES AND MOTOR CABLES
BATTERY CABLES AND MOTOR CABLES
EL-18
BATTERY CABLES AND MOTOR CABLES
EL-19
BATTERY CABLES AND MOTOR CABLES
EL-20
LOCATION OF OPTIONAL PARTS
LOCATION OF OPTIONAL PARTS
Earth Band
DESCRIPTION
For normal tires (black tires), the carbon is contained as a material.
Therefore, if the vehicle is charged with electricity, it will be
discharged from the tires.
For non-marking tires (colored tires), the carbon is not contained as
a material. Therefore, if the vehicle is charged with electricity, it
cannot be discharged.
The circuit board, element, or parts may be damaged by this
electrification.
To prevent this damage, install the earth band to the vehicle and
discharge the static electricity from the vehicle.
BSM0623
EL-21
LOCATION OF OPTIONAL PARTS
LOCATION
DC/DC converter
Connector
3 wheel 20121008EU
Connector
DC/DC converter
4 wheel
20121009EU
Connection type
20121010EU
12V CONNECTION
CIRCUIT DIAGRAM
Connector
20121011EU
EL-22
WIRING DIAGRAM
WIRING DIAGRAM
FUSE BOX
BAT
METER
W 100 5A 740 Y
OPT
10A 520 SB
LIGHT
10A 401 R
To Rear Comb Lamp LH
KEY SW
20A 110 P
To Cabin Harness
IGN
CONT
GY 120 10A 125 GY
OPT
5A 516 W
METER
5A 727 L
LIGHT
10A 451 G
1
2
3
IGN SW
110 120 120 110
127 127
OFF ON RE START 4
127 127 Y 5
120 120 GY 6
110 110 P
727 727 8
728 728
20 711
19 710
6 905
9
2 740
1 11 990 728
COMB. METER
IGN 728 L
PKB INPUT 905 L
BAT 740 Y
RS232C(C_to_M) 710 BR 10
RS232C(M_to_C) 711 L/B 11
GND 990 B 12
13
Power Supply
Signal
CAN
Earth
BSM0624
EL-23
WIRING DIAGRAM
CONTACTOR UNIT
BATTERY SW
CURRENT VB To Rear Comb
FS1 SEN
Lamp LH CONTROLLER
To Rear Comb
W 100 802 804 803 801 280 281 Lamp RH CN A CN A
801 802 803 804 280 281 W 254 786 35
100 R 253 781 23
G/B
711 34
GY
802 804 803 801 280 281 To Turn
W
P
Y
L
L 410 771 22
Lamp LH 710 33
W 804 126 32
P 803 253 31
BATTERY L 802 254 801 7 30
Y 801 410 802 6 29
G 450
VCM CONTROLLER
450 803 5 28
Y 127
804 4
G 126
127 3
BR 710
129 2
L/B 711 992 1
B 992
OR 129 CN B CN B
L 781
124 993 8 23
1
L
P
786
771
* 315 7
669 6
2
3
*MC Model Only OR 124 662 5
To Brake SW P 669
To PKB SW L 315
To F/R SW GY 662 811 17
4 B 993 810 16
5 R 810
6 811 811 L 811
810 810
TRACTION CONTROLLER
FAN
411 20
L 783 412 19
P 773
G/B 281 851 17
8 GY 122 783 28
G/Y 411 773 27
(RIGHT )
L/R 412
B 106
OR 851 106 1
Y 853
+B
To Light & Turn SW
-B
To Seat SW
121 10
TRACTION CONTROLLER
L 782
P 772
9 GY 121
782 28
772 27
(LEFT)
+B
10 -B
11
12
FUSIBLE LINK VB
900 900
W/R 900 -B
0.5A
13 GY 123
PUMP CONTROLLER
P 771
L 787
L 781 781 21
R 105 771 20
787 12
CONTROLLER GND
B 990
105 2
123 1
BSM0625
EL-24
WIRING DIAGRAM
Lighting System
IGN SW
HEADLAMP TURN LAMP
CABIN HARN RH RH
110 120 120 110 FUSE BOX
127 127
OFF ON RE START BAT
METER
127 127 Y W 100 5A 740 Y
120 120 GY OPT
GND
BAT
10A 520 SB
IGN
110 110 P
LIGHT
10A 401 R 516 520 981
225 223 KEY SW 520 516
DIODE 20A 110 P
981
SB
W
B
IGN 200 213 409 251
225 R CONT
GY 120 10A 125 GY
223 W
OPT
G
R
R
Y
222 224 224 222 5A 516 W
METER
5A 727 L
901 901 LIGHT 409 213
10A 451 G 251 200
200 213 409 251
TAIL LAMP RELAY 221 221 GUARD
251 200 HARNESS RH
222 409 213
G
R
R
W
Y
224 R
901 B 1
221 OR 2
3
4
5
431 431
430 430 6
HORN RELAY 432 432
7
430 R 8
432 Y/L 9
431 W
HORN 10
431 W
947 B
727 727
728 728 11
12
AUTO POWER 125 126 126 125
OFF RELAY
728 L
727 L
125 GY
126 G
COMB. SW 13
14
HORN SW 970 432 432 970
15
432 Y/L 16
970 B
662 662
F/R SW
661 910 910 661 17
FWD
661 L/Y 18
REV
662 GY 19
910 B 20
21
22
411 413 413 411
23
900 412 412 900
24
213 222 222 213
25
LIGHT&TURN SW
OFF TAIL HEAD R L
900 900 W/R
222 222 W 212 410
W
R
Y
L
BACK OPERATION
LAMP SW
OR
B/R
L/B
OR
BR
381
W
B
G
G
R
Y
P
Y
B
Y
L
L
IGN
PKB SW
RS232C(C_to_M)
RS232C(M_to_C)
GND
BAT
BRAKE FLUID SW
PKB INPUT
BUZZER DRIVE
EL-25
WIRING DIAGRAM
B 106
11 G/Y 411 To Traction Controller (RIGHT )
12 L/R 412
R 505 R 505
B 950 B 950
13
14
15 505 950
16
982 521
DC/DC CONVERTER
B 950 OUTPUT (-)
R 505 OUTPUT (+12V)
B 982 INPUT (-)
17 L 521 INPUT (+IGN48V)
18 361 361
19 BACK BUZZER
360 250
20
21 GY 361
22 G 360
23
24 PATO LAMP
25
G 250
B 989
R 240
G 241
GY
PU
BR
442 465
P
B
R
B
P
B
W 254
986 936 669 443 454 TURN
L 405
311 911 986 480 936 669 105 106 443 442 454 465
986 936 669 451 451
401 401
465 465
480
G 451
REVERSE
GY 465
R 401
BRAKE SW DIODE DIODE 442 442
221 221
STOP/TAIL
P 442
BRAKE FLUID SEAT BELT OR 221
SW SW SEAT SW
BSM0627
EL-26
WIRING DIAGRAM
Traction System
CONTACTOR UNIT
BATTERY SW
CURRENT VB
FS1 SEN
1
W 100 802 804 803 801 801 802 803 804 280 281 280 281 2
3
G/B
GY
100 802 804 803 801 280 281 4
W
P
Y
L
5
BATTERY 6
7
8
9
10
11
12
13
14
15
FUSE BOX 16
BAT 17
METER 18
W 100 5A 740 Y
19
OPT
10A 520 SB 20
To Cabin Harness
IGN SW LIGHT
10A 401 R
110 120 120 110 KEY SW
127 127 20A 110 P
OFF ON RE START
127 127 Y IGN
CONT
120 120 GY GY 120 10A 125 GY 21
110 110 P OPT
5A 516 W
METER 22
5A 727 L 23
LIGHT To Rear Comb Lamp LH
10A 451 G
727 727
728 728
AUTO POWER 125 126 126 125
OFF RELAY
728 L
727 L
125 GY
126 G
COMB. SW
662 662
To Rear Comb 26
Lamp LH
B/W
B/R
B/R
B/Y
B/Y
L/B
OR
OR
BR
PU
GY
382
PU
BR
B
L
L
P
B
L
GND
IGN
PKB INPUT
PKB SW
Power Supply
Signal DIODE DIODE
CAN BRAKE SW
Earth PKB SW ACCEL SEN
COMB. METER
BSM0628
EL-27
WIRING DIAGRAM
1
CONTROLLER
2 Y 127
3 G 126 CN A CN A
4 BR 710 786 35
5 L/B 711 781 23
711 34
6 W 804 771 22
710 33
7 P 803 126 32
8 L 802
9 Y 801
801 7
10 B/Y 660 665 18
802 6
11 PU 664 664 17
VCM CONTROLLER
803 5
12 B/R 934
804 4
13 B/W 665
127 3
14 OR 129
129 2
B 992 660 13
934 992 1 24
L 781
15
*MC Model Only L
P
786
771
* CN B CN B
124 993 8 23
16 OR 124 315 7
17 L/Y 661 669 6
18 L 315 662 5
19 P 669 661 4
20 GY 662
To Light & Turn SW B 993
900 900 FUSIBLE LINK
W/R 900
0.5A
982 982
21 B 982 281 12
To DC/DC Converter 0.3A
843 22
122 10
TRACTION CONTROLLER
22 G/B 281
23 GY 122
R 843
B 829
W 827
826 783 829 5 28
L
825 773 27
R
(RIGHT )
L 783 826 14
P 825 25
W
773
R
R
B
827 13
843 842 829 827 826 825 B 106 106 1
842 843 829 827 826 825
843 842 829 827 826 825 W
+B
V
-B
W U
V
TEMP SEN REVO SEN U
25 L 782 831 14
P 772 830 25
832 13
990 B R 650
CONTROLLER W +B
GND
V
-B
U
26
VB
W
W
R
R
B
P 771
L 787
W 106 105 781 21
L 781
771 20
R 105 787 12
V
TEMP SEN REVO SEN U ACCEL OFF REGEN SELECT
650 105 2
R
651 123 1
TRACTION MOTOR LH BR
EU&NORTH AMERICA:CONNECTED
JPN&GOM:UNCONNECTED
SEAT SW BSM0629
EL-28
WIRING DIAGRAM
G/B
BATTERY
GY
802 804 803 801 280 281
W
P
Y
L
100 9
10
11
12
13
14
15
16
17
18
19
FUSE BOX To Rear Comb 20
BAT Lamp LH 21
METER 22
W 100 5A 740 Y
OPT
10A 520 SB To Cabin
IGN SW LIGHT Harness
10A 401 R
110 120 120 110 KEY SW
127 127 20A 110 P
OFF ON RE START
127 127 Y IGN
CONT
120 120 GY GY 120 10A 125 GY
110 110 P OPT
5A 516 W
METER
718 718 5A 727 L 23
978 715 715 978 LIGHT 24
10A 451 G
STEERING 716 717 717 716 25
ANGLE SEN 26
12V 715 G/R 27
GND 978 B
SIG A 716 Y/BR
SIG B 717 R
SIG N 718 L/W
727 727
728 728
28
AUTO POWER 125 126 126 125 29
OFF RELAY
728 L
727 L
125 GY
126 G
COMB. METER
30
IGN 728 L 31
PKB INPUT 905 L 32
BAT 740 Y 33
RS232C(C_to_M) 710 BR
RS232C(M_to_C) 711 L/B
GND 990 B
20 711
19 710
34
6 905
35
705 704 724
GY
W
R
B
G
L
B
L
W
733 723
W
L
R
B
G
B
L
B
Power Supply
Signal
TILT ANGLE LIFT PRESSURE
CAN SEN SEN LIFT DOWN PS KNOB
SOL VALVE SOL VALVE
Earth TILT HORI S/V TILT HORI SW (PS.C)
BSM0630
EL-29
WIRING DIAGRAM
VCM CONTROLLER
13 Y 801 802 6
14 OR 129
450 803 5 28
15 B 960 705 16
960 804 4 27
16 W 704 742 15
940 127 3 26
17 G 705 671 14
979 129 2 25
18 Y 127
19 992 1
Y 742
20 W 743 CN B CN B
21 B 940
22 G 450 124 993 8 23
L 781 732 22
723 21
*MC Model Only L
P
786
771
*
671 P P 671 724 19
670 Y/L Y/L 670 722 18
979 GY GY 979
CONTROLLER
671 671 671 671 GND
TIRE ANGLE TIRE ANGLE
979 979 SEN (4W) 670 670 SEN (3W) 990 B
670 670 979 979
23 OR 124
24 GY 724
25 L 732
TRACTION CONTROLLER
26 B/Y 722
27 BR/W 723 853 281 12 35
B 993
900 900 FUSIBLE LINK 122 10
To Light & Turn SW W/R 900
0.5A
(RIGHT )
982 982
To DC/DC Converter B 982 851 17
0.3A
28 G/B 281
29 GY 122 +B
B 106 106 1
775 977
OR 851 -B
785
Y 853
MAINTE CONN
977 B
CAN H 785 L
TRACTION CONTROLLER
CAN L 775 P
30
31
32 121 10
33 676 20
SEAT SW
677 19
678 7
(LEFT)
106 B
105 R 679 16
GY 121
W 676 +B
BR 677
Y/R 678 746 1
-B
34 LG 679
35 B 746
PUMP MOTOR
VB
TEMP SEN 841 841 -B
Y/R
BR
LG
W
840 840
679 678
PUMP CONTROLLER
EL-30
WIRING DIAGRAM
280 281
W 100 802 804 803 801 801 802 803 804 280 281 1
To Pump Controller
(PUMP -B ) 280 281 2
G/B
GY
802 804 803 801 3
W
100
P
Y
L
4
5
6
FUSE BOX 7
BAT 8
METER 9
W 100 5A 740 Y
OPT
10A 520 SB To Cabin 10
IGN SW LIGHT Harness 11
10A 401 R To Rear Comb
110 120 120 110 KEY SW Lamp LH
20A 12
127 127 110 P
OFF ON RE START 13
127 127 Y IGN 14
CONT 15
120 120 GY GY 120 10A 125 GY
110 110 P 16
OPT
5A 516 W 17
727 727 METER 18
5A 727 L 19
728 728 LIGHT 20
10A 451 G
21
AUTO POWER 125 126 126 125 22
OFF RELAY 23
728 L 24
727 L
125 GY
126 G
COMB. METER
IGN 728 L
PKB INPUT 905 L
BAT 740 Y
RS232C(C_to_M) 710 BR
RS232C(M_to_C) 711 L/B
GND 990 B To Controller GND
To Fusible Link
20 711
19 710
25
26
6 905 27
28
29
30
2 740 To Horn Relay
1 11 990 728
680
749 971 763 906
691 688 685 682
W/R
BR/W
L/W
BR/Y
B/Y
Y/L
Y/L
OR
GY
GY
GY
G
R
R
Y
BR/W
L/W
G/B
BR/Y
B/Y
Y/L
Y/L
OR
GY
GY
GY
G
R
R
R
Y
Y/L
R
W/R
BR/W
L/W
G/R
G/B
Y/G
Y/R
B/Y
BR/Y
680 682
GY
G
R
R
Y
B
L
761 763 762 604 615 906 681 902 684 903 687 904 690
762 761 763 604 615 681 682 680 906 684 685 683 902 687 688 686 903 690 691 689 904
JOYSTICK
OPT 761 763 762 604 615 906 681 902 684 903 687 904 690
680 682 683 685 686 688 689 691
Power Supply 762 761 763
Signal R
N
CAN
F
Earth TILT HORIZONTAL HORN SW LIFT SEN TILT SEN 3RD SEN 4TH SEN
SW EMERGENCY SW
F/R SW JOYSTICK BSM0632
EL-31
WIRING DIAGRAM
CN A CN A
To Controller GND B 992
1 Y 127 781 23
711 34
2 OR 129 771 22
710 33
3 G 126 126 32
4 BR 710
5 L/B 711 801 7
6 W 804 802 6
7 P 803 803 5
8 L 802 804 4
VCM CONTROLLER
9 Y 801 3
127
L 781
129 2
10 P 771 1
992
11
CN B CN B
12 OR 124
13 W 681 124 23
691 15
14 G/B 682 690 14
15 L 680 688 13
16 W/R 906 762 5
687 12
17 G 684 761 4
685 11
18 Y/L 685 906 3
684 10
19 BR/W 687 680 2
682 9
20 R 688 681 1
21 BR/Y 690
22 G 691
23 GY 762
24 L/W 761
PUMP MOTOR
PUMP CONTROLLER
840 820 8 23
W 823 15
840 P 771 841 821 7 22
822 14
841 R L 787 781 21
L 781 771 20
823 823 GY 123 787 12
822 822 105
R
821 821 840
W 105 2
820 820 841
REVO SEN R 123 1
823 B B 823
822 W W 822 U V W
821 L L 821
25 820 R R 820
26
U
27
28 V
29
W
30
GY 749
SEAT SW To Traction Controller (LEFT )
OR 747
105 R
106 B G/B 281
To Traction Controller (RIGHT )
B 106
To Controller GND
EL-32
MOTOR MECHANISM
SECTION MM
CONTENTS
SERVICE DATA AND SPECIFICATIONS ........ MM-2 PUMP MOTOR ................................................ MM-11
General Specifications ................................. MM-2 Removal ..................................................... MM-11
Tightening Torque ........................................ MM-2 Installation 1N1 .......................................... MM-12
General Specifications ................................. MM-3 Installation A1N1 ........................................ MM-12
Tightening Torque ........................................ MM-3 MOTOR DISASSEMBLY AND ASSEMBLY .. MM-13
TROUBLE DIAGNOSES AND Disassembly 1N1 ....................................... MM-13
CORRECTIONS ................................................ MM-4 Assembly .................................................... MM-14
PRECAUTIONS AND PREPARATION ............ MM-6 Inspection ................................................... MM-15
Precautions .................................................. MM-6 Disassembly A1N1 ..................................... MM-16
Special Service Tool ..................................... MM-6 Assembly .................................................... MM-17
TRACTION MOTOR .......................................... MM-7 Inspection ................................................... MM-17
Removal ....................................................... MM-7
Removal ....................................................... MM-8
Installation 1N1 ............................................. MM-9
Installation A1N1 ........................................ MM-10
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
General Specifications
TRACTION MOTOR PUMP MOTOR
Applied model 1N1 series 1N1 series
Applied model
Type Open-self AC motor S1N1 & 1N1 G1N1 & JG1N1 36V model
Model MTA450-1 Type Open-self AC power
Rated voltage V 36 48
Model MPA480-01 MPA4110-01
Rated output kW/h 4.0 5.0
Rated voltage V 48 48 36
Weight kg (lb) 35 (77) Rated output kW/h 8.0 11.0 8.0
Maker HITACHI
Weight kg (lb) 39.5 (87.1) 47 (104)
Maker HITACHI
Tightening Torque
TRACTION MOTOR PUMP MOTOR
MTA450-1 MPA480-01/MPA4110-01
Unit Unit
N•m kg-m ft-lb N•m kg-m ft-lb
MM-2
SERVICE DATA AND SPECIFICATIONS
General Specifications
TRACTION MOTOR PUMP MOTOR
Applied model A1N1 series A1N1 series
Tightening Torque
TRACTION MOTOR PUMP MOTOR
TSA200-100-209 TSA200-140-207/
Unit TSA200-160-208
N•m kg-m ft-lb Unit
N•m kg-m ft-lb
Motor assembly
Front bracket to rear bracket fixing 11 1.12 8.1 Motor assembly
through bolt Front bracket to rear bracket fixing 15 1.53 11.1
Terminal fixing nut 13 - 17 1.4 - 1.7 10 - 12 through bolt
Terminal fixing nut 13 - 17 1.4 - 1.7 10 - 12
Motor installation
Motor installation
Motor-to-drive unit fixing bolt Short 38 - 52 3.9 - 5.3 29 - 38
bolt Mounting bracket fixing bolt Frame 38 - 52 3.9 - 5.3 29 - 38
side
Long 38 - 52 3.9 - 5.3 29 - 38
bolt Motor 39 - 50 4.0 - 5.0 29 - 36
side
Drive unit fixing bolt M14 150 - 16 - 19 111 -
bolt 190 140
M8 19 - 25 2.0 - 2.5 14 - 18
bolt
MM-3
TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
• The following tables list only typical examples. To perform an accurate diagnosis, carefully listen to the
user's complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
• The same symptoms as the following may occasionally be caused by the control system. Perform the
trouble diagnosis for not only mechanical cause but also control system cause. For the trouble diagnosis
of control system, refer to the CS section.
If it is no-load • Gap between stator iron core and • Disassemble and check. Repair or
Whining noise
condition, rotor iron core is unbalanced replace as necessary.
motor turns • Disassemble and check. Repair or
Yoke overheats • Partially short circuit in stator coil
replace as necessary.
• Disassemble and replace with new
Bearing noise • Bearing malfunction
ones.
MM-4
TROUBLE DIAGNOSES AND CORRECTIONS
MM-5
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• When removing or installing motor assembly, be sure to turn
the key switch OFF and disconnect battery plug to cut power
supply in advance. This prevents motors from unexpectedly
rotating, avoiding danger.
• Always assemble parts in a clean work place to prevent
foreign matter from entering assembly.
• Before disassembling, be sure to clean off the parts.
• Do not use water or cleaning oil to clean any part. Use
compressed air or wipe with dry rag.
• Carefully handle removed motor so as not to drop or impact
the motor.
NOTE:
Be sure to use the special service tool when lifting and supporting
traction motor.
MMT0001 M8×1.25
MM-6
TRACTION MOTOR
TRACTION MOTOR
COMPONENT PARTS
1N1 series
MMM0013
Removal
1. Remove battery from vehicle. Refer to BC section.
2. Remove floor mat and floor panel. Refer to BF section.
3. Remove pedal bracket. Refer to BR section.
4. Disconnect cables connected to traction motor.
5. Remove traction motor and drive unit as a unit. Refer to DU
section. Then remove traction motor from drive unit.
MMM0014
MM-7
TRACTION MOTOR
COMPONENT PARTS
A1N1 series
Removal
1. Remove battery from vehicle. Refer to BC section.
2. Remove floor mat and floor panel. Refer to BF section.
3. Remove pedal bracket. Refer to BR section.
4. Disconnect cables connected to traction motor.
5. Remove traction motor and drive unit as a unit. Refer to DU
section. Then remove traction motor from drive unit.
MM-8
TRACTION MOTOR
Installation 1N1
To install, reverse the order of removal. Observe the following:
For inspection of revolution sensor and temperature sensor, refer to
CS section.
Traction motor-to-drive unit securing bolt:
Long bolt
: 39 - 50 (4.0 - 5.0, 29 - 36)
Short bolt
: 38 - 52 (3.9 - 5.3, 28 - 38)
CAUTION:
When installing motor to drive unit, be careful not to damage oil
seal of front bracket at shaft spline and drive unit.
MMM0017
MM-9
TRACTION MOTOR
Installation A1N1
To install, reverse the order of removal. Observe the following:
For inspection of revolution sensor and temperature sensor, refer to
CS section.
Traction motor-to-drive unit securing bolt:
Long bolt
: 38 - 52 (3.9 - 5.3, 29 - 38)
Short bolt
: 38 - 52 (3.9 - 5.3, 28 - 38)
CAUTION:
When installing motor to drive unit, be careful not to damage oil
seal of front bracket at shaft spline and drive unit.
MMM0017
MM-10
PUMP MOTOR
PUMP MOTOR
COMPONENT PARTS
(A)1N1 series
MMM0021
CAUTION:
• Always relieve oil pressure remaining in hydraulic lines.
• When cutting off pipes, be careful to avoid splashing
hydraulic fluid to other parts by covering with waste cloths
around the cutting areas.
• When connecting pipes, be careful that foreign material does
not enter into pipes.
• Clamp suction hose so that the hydraulic fluid does not leak.
Removal
1. Remove floor mat and floor board. Refer to BF section.
2. Remove brake pedal bracket. Refer to BR section
3. Remove piping from hydraulic pump.
4. Disconnect motor cables.
5. Lift up the motor with hydraulic pump.
6. Remove bracket hydraulic pump from motor.
MM-11
PUMP MOTOR
Installation 1N1
To install, reverse the order of removal. Observe the following:
Pump motor mounting bracket fixing bolt:
Frame side
: 39 - 52 N•m (4.0 - 5.3 kg-m, 29 - 38 ft-lb)
Pump motor side
: 39 - 50 N•m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Oil pump fixing bolt:
: 24.5 - 31.3 N•m (2.5 - 3.1 kg-m, 18 - 23 ft-lb)
CAUTION:
When installing the oil pump to the pump motor, apply the
molybdenum disulfide grease to the oil pump shaft spline.
Installation A1N1
To install, reverse the order of removal. Observe the following:
Pump motor mounting bracket fixing bolt:
Frame side
: 39 - 52 N•m (3.9 - 5.3 kg-m, 29 - 38 ft-lb)
Pump motor side
: 39 - 50 N•m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Oil pump fixing bolt:
: 25 - 31 N•m (2.6 - 3.1 kg-m, 19 - 23 ft-lb)
CAUTION:
When installing the oil pump to the pump motor, apply the
molybdenum disulfide grease to the oil pump shaft spline.
MM-12
MOTOR DISASSEMBLY AND ASSEMBLY
MOTOR DISASSEMBLY AND ASSEMBLY
Disassembly 1N1
COMPONENT PARTS
1N1 series
MMM0015
MM-13
MOTOR DISASSEMBLY AND ASSEMBLY
Disassembly (Cont’d)
1. Remove sensor cover.
2. Remove revolution sensor.
MMM0016
Assembly
To assemble, reverse the order of disassembly. Observe the
following:
Terminal fixing screw:
: 5.1 - 6.6 N•m (0.52 - 0.67 kg-m, 3.8 - 4.8 ft-lb)
Front bracket to rear bracket fixing through bolt:
Traction motor
: 11 - 14 N•m (1.2 - 1.4 kg-m, 9 - 10 tf-lb)
Pump motor
: 19 - 23 N•m (2.0 - 2.3 kg-m, 14 - 16 ft-lb)
CAUTION:
When heating the bearing with a heater, be careful not to
increase the bearing temperature to above 60 to 80°C.
MMM0018
MM-14
MOTOR DISASSEMBLY AND ASSEMBLY
Assembly (Cont’d)
Install the oil seal in the front bracket of traction motor.
Ensure that the oil seal is pressed against the endstop.
The flat face of the oil seal should be faced towards the inside.
MMM0019a
MMM0019
MMM0020
Inspection
For inspection of revolution sensor and temperature sensor, refer to
CS section.
MM-15
MOTOR DISASSEMBLY AND ASSEMBLY
Disassembly A1N1
COMPONENT PARTS
MM-16
MOTOR DISASSEMBLY AND ASSEMBLY
Disassembly (Cont’d)
9. Remove the cover.
10. Remove the revolution sensor and spur wheel.
(1) Revolution sensor
(2) Spur wheel
(3) Tolerance ring
Assembly
Assemble in the reverse order of disassembly. Observe the
following:
Terminal fixing screw:
: 13 - 17 N•m (1.4 - 1.7 kgf-m, 10 - 12 ft-lb)
Front bracket to rear bracket fixing through bolt:
Traction motor
: 11 N•m (1.12 kgf-m, 8.1 ft-lb)
Pump motor
: 15 N•m (1.53 kgf-m, 11.1 ft-lb)
Inspection
For inspection of revolution sensor and temperature sensor, refer to
CS section.
MM-17
MOTOR DISASSEMBLY AND ASSEMBLY
MM-18
DRIVE UNIT
SECTION DU
CONTENTS
SERVICE DATA AND SPECIFICATIONS ......... DU-2 DRIVE UNIT ....................................................... DU-5
General Specifications 1N1 ........................... DU-2 Reduction Gear Assembly ............................. DU-5
Tightening Torque 1N1 .................................. DU-2 Removal ........................................................ DU-6
General Specifications (J)A(G)1N1 ............... DU-2 Installation ..................................................... DU-7
Tightening Torque (J)A(G)1N1 ...................... DU-2 Component Parts .......................................... DU-8
TROUBLE DIAGNOSES AND Disassembly ................................................ DU-10
CORRECTIONS ................................................. DU-3 Assembly ..................................................... DU-12
Trouble Diagnoses ........................................ DU-3 Inspection .................................................... DU-15
PRECAUTIONS AND PREPARATION ............. DU-4
Precautions ................................................... DU-4
Special Service Tool ...................................... DU-4
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
DU-2
TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
Trouble Diagnoses
REDUCTION GEAR
Oil leakage Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper
corrective action.
• Worn, faulty, or improperly installed oil seal. Repair or replace.
• Loose gear carrier mounting bolts. Retighten, or replace gasket.
• Faulty gasket. Replace gasket.
• Loose filler plug or drain plug. Retighten.
• Worn, faulty, or improperly installed axle hub oil Repair or replace.
seal.
Seizure Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if
necessary.
• Bearing seizure. Replace.
• Insufficient oil, or use of improper oil. Add or replace as specified.
Unusual noise • Pitted or worn gear tooth surface, or broken Replace.
tooth.
• Loose pinion nut, or any other bolts or nuts. Retighten.
• Insufficient oil, or use of improper oil. Add or change oil as specified.
• Abnormally worn or broken gear. Replace.
DU-3
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation.
• Be careful not to drop heavy components or parts. Always
use a lifting device.
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Always clean working area to prevent foreign matter from
getting into parts being assembled or serviced.
• Use a paper rag rather than a cloth when wiping clean parts.
Use of a cloth rag may leave lint or other foreign matter on
parts being wiped.
DUM0001
DU-4
DRIVE UNIT
DRIVE UNIT
DUM0002
DU-5
DRIVE UNIT
Removal
• Remove the carriage.
• Turn the ignition switch OFF, and then disconnect the battery
connector.
• Jack up the vehicle and support it using a piece of wood.
• Remove the following parts.
• Mast (if necessary) (Refer to the LM section)
• Side panel (LH) (Refer to the BF section)
• Floor mat, floorboard (Refer to the BF section)
• Brake pedal (Refer to the BR section)
• PS piping (PS valve side)(Refer to the HD section)
• Mast piping (Refer to the HD section)
• Horn (Refer to the EL section)
• Brake cable, brake piping (drive unit side)
(Refer to the BR section)
• Traction motor cables (Refer to the EL section)
• Tire (Refer to the TR section)
• Drain the gear oil from the drive unit.
• Remove the spacer (between the drive unit and the frame).
• Remove the drive unit with a traction motor as unit. (Disconnect
the connections of the revolution sensor and the temperature
sensor.)
• Remove the motor.
DUM0003
DUM0004
DU-6
DRIVE UNIT
Installation
Install in the reverse order of removal.
Tightening Torque:
CAUTION:
• Always bleed air from the brake piping.
• When installing the motor to drive unit, be careful not to
damage the oil seal of front bracket at shaft spline and drive
unit.
MMM0017
DU-7
DRIVE UNIT
Component Parts
DUM0006
DU-8
DRIVE UNIT
DU-9
DRIVE UNIT
Disassembly
CAUTION:
For disassembly of wet type brake, refer to the BR section.
DUM0007
DUM0026
Remove the snap ring (25). To remove the second reduction gear
(26) use an extractor.
DUM0009
DU-10
DRIVE UNIT
Disassembly (Cont’d)
DISASSEMBLY OF THE RING GEAR (18) AND OF
THE DRIVE AXLE HUB (1)
1. In order to pull out the pinion gears (22) and their bearings (23),
remove the retaining ring (24) and use a special extractor.
DUM00010
DUM00011
3. Unscrew the 10 bolts (17) and pull out the ring gear (18).
DUM00012
DU-11
DRIVE UNIT
Assembly
After the worn-out parts have been replaced, to assemble the unit
again follow the disassembling process steps in reverse order.
DUM00013
2. Place the sun gear (38) on a chock on the press surface. Insert
the gear cover (33) on the pinion, then using a pipe [diameter =
35 mm (1.38 in) and diameter = 41 mm (1.61 in)] placed on the
bearing (29) inner ring, press down the cover.
DUM00014
3. Place the rectangular key (27) into its own slot and insert the
second reduction gear (26) on the sun gear (38).
Insert the snap ring (25).
DUM0027
DUM00016
2. Introduce the dust cover (5) in its own housing on the gear
carrier (7) the wheel side.
Introduce the pre-assembled hub into the casing, insert the
spacer (13) into the shaft and then place the cone of the bearing
(6), pressure-keying it in.
CAUTION:
In order to respect the max end play [0.04 mm (0.0016 in)] it is
possible to ask for a kit with calibrated pieces including 2
bearings (6), spacer (13) and all the required spacers.
DUM00017
DU-12
DRIVE UNIT
Assembly (Cont’d)
3. Insert the ring-gear washer (16) into the ring gear (18) and fix it
introducing the spring (15) in its housing.
DUM00018
4. Place the disk in the gear carrier (7) and tighten the 10 bolts
(17) with a 80 Nm torque wrench setting.
Torque:
80 N•m (8.2 kg-m, 59 ft-lb)
DUM00019
DUM00020
DUM00021
DU-13
DRIVE UNIT
Assembly (Cont’d)
ASSEMBLING THE INPUT SHAFT (36)
1. Key the bearing (35) onto the input shaft (36), then place the
rectangular key (32) into its own slot on the shaft, insert the
reduction gear (31), and finally lock all with the snap ring (30).
DUM0026
DUM00023
DUM00024
DU-14
DRIVE UNIT
Inspection
The drive unit is supplied without oil. For oil filling operations, follow
these specifications:
Use refill plug for filling, oil level check plug for checking the oil level
and drain plug for draining (see the figure).
MAM0158
DU-15
MEMO
DU-16
FRONT TIRE AND REAR TIRE
SECTION TR
CONTENTS
SERVICE DATA AND SPECIFICATIONS ......... TR-2 TROUBLE DIAGNOSES AND CORRECTIONS TR-5
General Specifications 1N1 ........................... TR-2 TIRE AND ROAD WHEEL ................................. TR-6
Tightening Torque ......................................... TR-2 Tire and Road Wheel Assembly .................... TR-6
SERVICE DATA AND SPECIFICATIONS ......... TR-3 Replacing Tires ............................................. TR-9
General Specifications (J)A(G)1N1 ............... TR-3 Inspection ...................................................... TR-9
Tightening Torque ......................................... TR-3
PRECAUTIONS AND PREPARATION ............. TR-4
Precautions ................................................... TR-4
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
Tire size
18x7-8 18x7-8 18x7-8 200/50-10 18x7-8 200/50-10 200/50-10
(Pneumatic solid)
Pneumatic
solid
Type
Clean (White)
Cushion — — —
Tire size
15x4.5-8 15x4.5-8 140/55-9 140/55-9 16x6-8 16x6-8 16x6-8
(Pneumatic solid)
Rim size
3.00D-8 3.00D-8 4.00E-9 4.00E-9 4.33R-8 4.33R-8 4.33R-8
(Pneumatic solid)
Rear
Pneumatic
solid
Type
Clean (White)
Cushion — — — — — —
Cushion
Tire size (Pneumatic solid) 15×4.5-8 140/55-9 140/55-9
Rim size (Pneumatic solid) 3.00D-8 4.00E-9 4.00E-9
Tire size (Cushion) 15×5×11-1/4 15×5×11-1/4
Rear
Cushion
Tightening Torque
TR-2
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
Pneumatic
solid
Type
Clean (White)
Cushion – – –
Tire size
15×4.5-8 140/55-9 15×4.5-8 140/55-9 140/55-9 16×6-8 16×6-8 16×6-8
(Pneumatic solid)
Rim size
3.00D-8 4.00E-9 3.00D-8 4.00E-9 4.00E-9 4.33R-8 4.33R-8 4.33R-8
(Pneumatic solid)
Rear
Pneumatic
solid
Type
Clean (White)
Cushion – – – – – –
Cushion
Tire size (Pneumatic solid) 15×4.5-8 140/55-9 140/55-9
Rim size (Pneumatic solid) 3.00D-8 4.00E-9 4.00E-9
Tire size (Cushion) 15×5×11-1/4 15×5×11-1/4
Rear
Cushion
Tightening Torque
TR-3
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation and follow all safety precautions.
• Be careful not to drop heavy components or parts. Always
use a lifting device.
TR-4
TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user's complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
TR-5
TIRE AND ROAD WHEEL
TIRE AND ROAD WHEEL
TRM0001
TRM0002
TR-6
TIRE AND ROAD WHEEL
TRM0002EU
TR-7
TIRE AND ROAD WHEEL
TR-8
TIRE AND ROAD WHEEL
Replacing Tires
1. Before removing a tire, loosen wheel nuts slightly. Then raise
vehicle using a jack. For jacking information, refer to GI section.
2. Remove wheel nuts, then remove tire.
3. To install tire, reverse the order of removal. Always observe the
torque specifications and instructions outlined above.
Inspection
CHECKING WHEEL NUTS
Before each day's operation, check wheel nuts for looseness.
Check wheel nuts for torque specification at specified regular
intervals.
Front and rear wheel nuts:
157 - 196 N•m (16 - 20 kg-m, 116 - 145 ft-lb) for 1N1
167 - 226 N•m (17 - 23 kg-m, 123 - 166 ft-lb) for A1N1
CAUTION:
Always tighten wheel nuts in a criss-cross fashion.
TRM0003
CHECKING TIRE WEAR
Check all tires for tread groove depth. Visually check for appearance
of tread wear indicator (slip-sign mark) on the tire.
MAT0006
MAT0007
MAT0008
TR-9
TIRE AND ROAD WHEEL
TR-10
BRAKE SYSTEM
SECTION BR
CONTENTS
SERVICE DATA AND SPECIFICATIONS ......... BR-2 MASTER CYLINDER ....................................... BR-15
General Specifications .................................. BR-2 Removal ...................................................... BR-16
Tightening Torque ......................................... BR-2 Installation ................................................... BR-16
TROUBLE DIAGNOSIS AND Disassembly ................................................ BR-16
CORRECTIONS ................................................. BR-3 Assembly ..................................................... BR-16
Service Brake ................................................ BR-3 Inspection .................................................... BR-17
Parking Brake ................................................ BR-4 RESERVOIR TANK ......................................... BR-18
PRECAUTIONS AND PREPARATION ............. BR-5 Brake Fluid Level ......................................... BR-19
Precautions ................................................... BR-5 BRAKE PIPING ............................................... BR-20
CONSTRUCTION ............................................... BR-6 Brake Piping ................................................ BR-20
Brake System ................................................ BR-6 Brake Line Air Bleeding ............................... BR-21
SERVICE BRAKE .............................................. BR-7 PARKING BRAKE ........................................... BR-22
Removal ........................................................ BR-7 Removal ...................................................... BR-22
Installation ..................................................... BR-7 Installation ................................................... BR-23
Disassembly .................................................. BR-9 Disassembly and Assembly ........................ BR-24
Assembly ..................................................... BR-10 Inspection .................................................... BR-24
Inspection .................................................... BR-10
BRAKE PEDAL ................................................ BR-11
Removal ...................................................... BR-11
Installation ................................................... BR-12
Disassembly and Assembly ........................ BR-13
Inspection .................................................... BR-13
Adjustment .................................................. BR-14
General Specifications
Item (A)1N1 series
Tightening Torque
Unit N•m kg-m ft-lb
Service Brake cartridge cover 15 1.5 11
brake fixing bolt
Air bleeder 2-3 0.2 - 0.3 1.5 - 2.2
Master Master cylinder fixing 9 -11 1.0 - 1.1 7-8
cylinder bolt
Push rod lock nut 16 - 22 1.7 - 2.2 12 - 16
Brake Brake pedal bracket 36 - 50 3.7 - 5.0 27 - 36
pedal fixing bolt
Pedal stopper lock nut 12 - 15 1.3 - 1.5 9 -11
Brake switch 12 - 15 1.3 - 1.5 9 -11
Accel unit attaching 9 -12 1.0 - 1.2 7-8
bolt
Reservoir Reservoir tank fixing 4-5 0.4 - 0.5 3.0 - 3.6
tank bolt
Brake Brake tube flare nut 15 -18 1.6 - 1.8 11 - 13
tube
BR-2
TROUBLE DIAGNOSIS AND CORRECTIONS
TROUBLE DIAGNOSIS AND CORRECTIONS
Service Brake
BRM0066
BR-3
TROUBLE DIAGNOSIS AND CORRECTIONS
Parking Brake
BRM0067
BR-4
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• When servicing, be sure to chock rear wheels and lift up front
of vehicle using a jack. Refer to GI section.
• Never get under the vehicle while it is supported only by
wooden blocks.
• When disassembling or replacing the brake system, always
perform operational check after servicing.
• To avoid splashing the brake fluid on painted surfaces such
as the body, always protect them with a rag during operation.
• When brake tube is disconnected, brake fluid may leak.
Attach a cap to the flare nut.
• Never reuse brake fluid.
• Use only genuine brake fluid or equivalent. Never mix
different types of brake fluid.
• When disconnecting or replacing brake piping, be sure to
perform leak check after servicing.
• Do not discard used brake fluid or cleaning oil without
permission. Dispose of them in accordance with the legal
procedure.
BR-5
CONSTRUCTION
CONSTRUCTION
Brake System
BR-6
SERVICE BRAKE
SERVICE BRAKE
BRM0069
Removal
For removing the drive unit, refer to DU section.
CAUTION:
Drain the fluid from the brake piping. Refer to “BRAKE PIPING”.
NOTE:
Disconnect the brake cables. Refer to “PARKING BRAKE”.
Installation
For installing the drive unit, refer to DU section.
CAUTION:
Refill the brake fluid and bleed the air from the brake piping.
NOTE:
For connection and installation of the brake cable, refer to “PARKING
BRAKE” section.
BR-7
SERVICE BRAKE
BRM0070
BR-8
SERVICE BRAKE
Disassembly
1. On the gear cover of the brake cartridge four hexagon socket
headcup plugs are symmetrically placed. These plugs may
be used for any possible topping-up/checking of the brake disk
oil level. The level is indicated by the top plug.
BRM0071
2. Remove the plugs and drain the oil off, at least in part;
unscrew the 14 bolts and .
BRM0072
BRM0097
BRM0073
BR-9
SERVICE BRAKE
Assembly
Wash down the cartridge thoroughly, then to assemble the parts
again following the next steps:
1. Insert the reaction disk .
2. Insert disk plate, wear brake disk , 4 springs one spacer
on each locking pin.
3. Repeat step 2 for 5 times.
4. Place the last disk plate and the 2 springs in the pins .
5. Insert the disk pusher device + onto the pins , then
pressing down all of them, place the 2 snap rings into the
seat on the pins .
BRM0073
BRM0074
Refill the brake disk unit with brake disk oil using the refill plug, fill
with the advised quantity (for oil level A1N1 see page BR-7).
BRM0071aEU
Inspection
Inspection of brake piston stroke.
It is necessary to check every 2,400 working hours or 1 year that the
stroke of the brake piston is not over 3 mm, otherwise it is necessary
to replace the brake disk.
BRM0071
BR-10
BRAKE PEDAL
BRAKE PEDAL
BRM0076
Removal
1. Disconnect battery connector.
2. Remove floor mat and floor panel. Refer to BF section.
3. Remove master cylinder fixing nuts.
4. Disconnect harness connectors for brake switch and
accelerator unit.
5. Remove snap pin and clevis pin or the push rod of master
cylinder.
6. Remove pedal bracket fixing bolts, then remove pedal bracket
assembly (with brake pedal and accelerator unit).
CAUTION:
Suspend master cylinder from instrument panel, etc. using
string so as not to allow the master cylinder to swing.
BRM0077
BR-11
BRAKE PEDAL
Installation
1. To install, reverse the order of removal.
Pedal bracket fixing bolt:
36 - 50 N•m (3.7 - 5.0 kg-m, 27 - 36 ft-lb)
Master cylinder fixing bolts:
9 - 11 N•m (1.0 - 1.1 kg-m, 7 - 8 ft-lb)
Brake switch lock nut:
12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
2. After installation, adjust brake pedal. Refer to “Adjustment”.
CAUTION:
Install clevis pin connecting brake pedal and push rod in
correct direction. Be sure to install snap pin.
BRM0077
BR-12
BRAKE PEDAL
BRM0078
NOTE:
• Assembly is to be smoothly separated without foreign parts, and
there is to be no parts missing, incorrect assembly, etc.
• Chassis grease (NCS-1 or equivalent) shall be applied properly to
sliding area of shaft hole. It is to be free from non-standard
conditions such as unusual noise when the pedal is actuated to
the full stroke.
• Chassis grease (NCS-1 or equivalent) must be applied on return
spring during assembly.
Inspection
Check for deformation or damage of each part, looseness of pedal
movable area, and malfunction of pedal return. Replace if
necessary.
BRAKE SWITCH
Refer to CS section for inspection.
BR-13
BRAKE PEDAL
Adjustment
1. Adjust pedal height (distance between floor panel and pedal
pad surface) to the standard by adjusting pedal stopper. Then,
securely tighten lock nut.
Standard:
122 mm (4.80 in)
: 12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
BRM0079
BRM0080
CAUTION:
Always properly adjust play. If play is much less than standard,
push rod is continuously applied with load. This results in
blocking master cylinder return port, causing brake dragging.
Also, excessive play may cause push rod to come out of place.
BR-14
MASTER CYLINDER
MASTER CYLINDER
BRM0082
BRM0083
BR-15
MASTER CYLINDER
Removal
CAUTION:
Drain brake fluid in brake line before removing master cylinder.
Refer to BRAKE PIPING for draining brake fluid.
1. Remove floor mat and floor panel. Refer to BF section.
2. Loosen left and right flare nuts and disconnect brake piping.
3. Remove master cylinder fixing bolt snap pin, clevis pin and
remove master cylinder from pedal bracket assembly.
NOTE:
Always remove master cylinder together with push rod.
Installation
CAUTION:
• After installation, bleed the air from brake piping.
• Install clevis pin connecting brake pedal and push rod in
correct direction. Be sure to install snap pin.
To install, reverse the order of removal. Observe the following:
Master cylinder attaching bolt:
: 9 - 11 N•m (1.0 - 1.1 kg-m, 7 - 8 ft-lb)
• Tighten brake piping flare nut with special service tool.
: 15 - 18 N•m (1.6 - 1.8 kg-m, 11 - 13 ft-lb)
• After installation, refill brake fluid and bleed air. Refer to
“BRAKE PIPING” and MA section.
BRM0077
Disassembly
1. Remove nipple and gasket.
2. Remove dust cover.
3. Remove stopper ring and piston stopper. Then remove push
rod, piston assembly, return spring and spring retainer.
4. Remove primary and secondary piston cups and spacer from
piston assembly.
CAUTION:
Disassemble parts in a clean place. Place disassembled parts
in order for easier reassembly.
Assembly
CAUTION:
• Clean all parts in clean brake fluid.
• Apply brake fluid to sliding surfaces before assembly.
• Be careful not to damage cylinder or piston during assembly.
• Replace piston cup with a new one. Do not reuse.
• Be sure to use the same manufacturer's item for replacement
of cylinder main body and inner parts.
• When installing a new piston cup, make sure the
manufacturer’s name and size is on the back of the lip.
BR-16
MASTER CYLINDER
Assembly (Cont’d)
1. Install secondary piston cup with the lip (recess) facing return
spring side.
2. Insert spring retainer in cylinder body. Install spacer, primary
piston cup, spring seat and return spring to piston assembly,
then insert the assembly into cylinder body.
CAUTION:
• Install primary piston cup with the lip (recess) facing return
spring side.
• Install spring seat with its flange surface (recess) attached to
primary piston cup.
BRM0084
3. Install push rod, piston stopper and stopper ring.
CAUTION:
Make sure that stopper ring is properly engaged with the
groove.
Inspection
CAUTION:
• Check each part after cleaning in brake fluid. Do not use any
cleaning solvent other than brake fluid.
• Be sure to use the same manufacturer's item for
replacement.
PISTON
• Measure clearance between cylinder inner diameter and piston
outer diameter. If it exceeds the limit, replace piston.
Limit:
0.15 mm (0.0059 in)
Cylinder inner diameter (for reference):
19.05 mm (3/4 in)
• Check sliding surface of piston for scratches or uneven wear. If
necessary, replace piston.
PISTON CUP
Always replace when disassembling.
RETURN SPRING
• Check for weakening or deformities. Replace if necessary.
BR-17
RESERVOIR TANK
RESERVOIR TANK
BRM0085
CAUTION:
• Make sure that there is no fluid leakage from the piping.
• Make sure that there is no deformation, damage, and fluid
leakage of reservoir tank.
• Insert the hose and install the clamp as shown in the figure,
and then tighten them securely.
BRM0086
BR-18
RESERVOIR TANK
BR-19
BRAKE PIPING
BRAKE PIPING
Brake Piping
BRM0088
CAUTION:
Lift the carriage and support it with a wire or nylon sling to
facilitate work.
BR-20
BRAKE PIPING
BR-21
PARKING BRAKE
PARKING BRAKE
BRM0090
Removal
CAUTION:
• Securely block the rear wheels, and then jack up the front
wheels.
• Lift up the carriage, and then perform the safe operation.
1. Chock rear wheels and jack up front of vehicle. Refer to GI
section.
2. Disconnect parking brake switch harness.
3. Remove the three parking brake lever assembly attaching bolts
and remove the assembly from vehicle.
4. Loosen cable lock nut at the parking brake lever assembly side.
5. Pull out left and right parking brake cables from parking cable
lever.
6. Remove lock plates and cable clamp.
7. Pull out the end of parking brake cable from parking brake lever.
BRM0091
BR-22
PARKING BRAKE
Installation
To install, reverse the order of removal. Observe the following:
• Insert parking brake cable into bracket and fix it with lock plate.
CAUTION:
Do not reuse removed lock plate.
BRM0092
• Clamp the left side of parking brake cable facing it toward vehicle
front.
BRM0093
BRM0095
BR-23
PARKING BRAKE
Inspection
PARKING BRAKE LEVER ASSEMBLY
Check assembly parts for deformities or damage. Replace any
damaged part if necessary.
BR-24
REAR AXLE
SECTION RA
CONTENTS
SPECIFICATION ................................................ RA-2 STEERING AXLE HUB (4 - WHEEL) .............. RA-13
TROUBLE DIAGNOSES AND Removal ...................................................... RA-13
CORRECTIONS ................................................. RA-3 Inspection .................................................... RA-13
SERVICE DATA AND SPECIFICATIONS ......... RA-4 Installation ................................................... RA-13
Steering Axle Upper Surface (4 - wheel) ....... RA-4 Adjustment .................................................. RA-14
Steering Axle Front Surface (4 - wheel) ........ RA-5 KINGPIN (4 - WHEEL) ..................................... RA-15
Steering Axle Front Surface (3 - wheel) ........ RA-6 Details ......................................................... RA-15
CONSTRUCTION (4 - WHEEL) ......................... RA-7 Removal ...................................................... RA-16
Details of Rear Axle (4 - wheel) ..................... RA-7 Inspection .................................................... RA-16
PRECAUTIONS ................................................. RA-8 Installation ................................................... RA-17
AXLE CENTER (4 - WHEEL) ............................. RA-9 Construction of Tire Angle Sensor .............. RA-18
Removal ........................................................ RA-9 AXLE CENTRE (3 - WHEEL) .......................... RA-19
Installation ..................................................... RA-9 Details of Rear axle (3 - wheel) ................... RA-19
COMPONENT PARTS (4 - WHEEL) ............... RA-12 AXLE CENTRE (3 - WHEEL) .......................... RA-20
Disassembly and Assembly ........................ RA-12 Removal ...................................................... RA-20
Installation ................................................... RA-20
Assembly ..................................................... RA-22
SPECIFICATION
SPECIFICATION
(A)1N1 / except
Model Only J(A)G1N1
J(A)G1N1
Item series
Series
Camber (°) 0 X
Caster (°) 0 0
Wheel alignment
Toe-angle (°) 0 0
RA-2
TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
Heavy steering wheel Improperly sliding kingpin. Check thrust bearing and needle bearing and replace
operation faulty parts. Apply grease to kingpin.
Insufficient lubrication. Apply grease.
Malfunctioning steering system. Refer to ST section.
Unstable driving and vehicle Loose wheel nuts. Tighten.
vibration Different type tire or wheel on right and left. Replace.
Differently worn right and left tires. Check and replace.
Improperly adjusted spindle stopper. Adjust.
Excessive wheel bearing backlash. Adjust bearing preload. Replace worn wheel
bearings as a set.
Loose kingpin. Check kingpin-related parts (especially bearings).
If necessary, replace.
Adjust by replacing adjusting shims.
Loose axle mounting. Check rubber mount. If necessary, replace.
Adjust by replacing adjusting shims.
Improperly inclined vehicle on a slope. Adjust axle swing angle.
Others Dragging wheels. Check wheel bearing for rust formation. Adjust wheel
bearing preload.
Loose nuts and bolts. Tighten.
RA-3
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
RAM0026
Model
J(A)G1N1 series
Item
Toe-angle (°) 0
Caster (°) 0
Camber (°) 0
(1) Tie-rod bar connecting pin mounting bolt tightening torque N•m (kg-m, ft-lb) 7.2 - 10.8 (0.8 - 1.1, 6 - 7)
(2) Kingpin lock nut tightening torque N•m (kg-m, ft-lb) 31 - 42 (3.2 - 4.2, 23 - 30)
137 - 186
(3) PS cylinder mounting bolt tightening torque N•m (kg-m, ft-lb)
(14.0 - 18.9, 102 - 137)
39 - 43
(4) PS piping tightening torque N•m (kg-m, ft-lb)
(4.0 - 4.3, 29 - 31)
(5) Top and bottom clearance of axle center pin mm (in) There is no clearance.
(7) Axle mounting cap mounting bolt tightening torque N•m (kg-m, ft-lb) 50 - 70 (5.1 - 7.1, 37 - 51)
RA-4
SERVICE DATA AND SPECIFICATIONS
RAM0801EU
Model
J(A)G1N1
Item
(1) Spindle top and bottom clearance mm (in) 0.2 (0.008) or less
(3) Lock screw tightening torque N•m (kg-m, ft-lb) 4.4 - 6.6 (0.5 - 0.6, 4 - 5)
167 - 226
(4) Wheel nut tightening torque N•m (kg-m, ft-lb)
(17.1 - 23.0, 124 - 166)
24 - 32
(7) Stopper mounting bolt tightening torque N•m (kg-m, ft-lb)
(2.5 - 3.2, 18 - 23)
8.6 - 10.6
(8) Stopper and axle center clearance mm (in)
(0.34 - 0.42)
RA-5
SERVICE DATA AND SPECIFICATIONS
RAM0802EU
Model
(A)1N1 (Except J(A)G1N1)
Item
(1) Steering axle assy mounting bolts 240 - 320 (25 - 32; 177 - 236)
(4) Wheel nut tightening torque 157 - 196 (16 - 20, 116 - 145) 1N1 / 167 - 226 (17 - 23, 123 - 166) A1N1
(5) Tire angle sensor mounting bolt 1.2 - 1.8 (0.13 - 0.18; 0.9 - 1.3)
RA-6
CONSTRUCTION (4 - WHEEL)
CONSTRUCTION (4 - WHEEL)
RAM0028EU
RAM0029EU
RA-7
PRECAUTIONS
PRECAUTIONS
CAUTION:
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation and follow all safety precautions.
• Be careful not to drop heavy components or parts. Always
use a lifting device.
NOTE:
• Axle center assembly can be removed or installed after removing
tires. This RA section deals primarily with the disassembly and
reassembly of the axle center assembly.
• For information concerning wheels and tires, refer to MA section.
RA-8
AXLE CENTER (4 - WHEEL)
AXLE CENTER (4 - WHEEL)
Removal
NOTE:
When remove tire of for cushion model, refer to “STEERING AXLE
HUB”, “Removal”.
1. Loosen wheel nuts until possible to turn by hand. Raise rear
end of vehicle using a jack. Refer to GI section.
2. Remove tires together with rims.
CAUTION:
• When removing wheel nuts (large), do not confuse them with
rim bolts (small). Rim bolts are fixed by welding.
• Before removing pneumatic tires, bleed a slight amount of air
from tires.
3. Support axle center assembly with a jack.
CAUTION:
Properly place jack to prevent axle center assembly from tilting
or slipping during removal.
4. Disconnect tire angle sensor harness connector, then remove
harness mounting bolts.
RAM0030
5. Remove PS piping.
CAUTION:
• Since oil tends to spill when pipes are disconnected, cover
the surrounding area with rag.
• Stuff stoppers into disconnected pipes to prevent oil spills.
• Never allow foreign matter to enter PS cylinder or pipes.
6. Remove mounting cap bolts, then remove axle center assembly.
CAUTION:
After removing axle center, place it on a worktable.
RAM0050
7. Remove rubber mount together with adjusting shim(s).
Installation
Note the following, and install in the reverse order of removal.
CAUTION:
Be sure to prevent axle center from tilting or slipping off of jack
during installation.
RA-9
AXLE CENTER (4 - WHEEL)
RAM0032
RAM0033
CAUTION:
Tighten wheel nuts to the specifled torque evenly.
• Inflate pneumatic tires to specified air pressure (if so equipped).
RAM0034 NOTE:
Tire installation for cushion model is refer to “Wheel bearing
adjustment”.
Installation (Cont’d)
5. Axle swing angle adjustment.
• Locate vehicle on a solid and level surface.
• Turn key switch to ON position. Turn steering wheel fully in either
direction so stopper is visible.
• Select and install stopper with proper thickness between stopper
plate and axle center so that stopper plate upper surface-to-swing
stopper clearance “H” is within standard.
Unit: mm (in)
RAM0035
RA-10
AXLE CENTER (4 - WHEEL)
Unit: mm (in)
3.2 (0.13)
4.0 (0.16)
5.0 (0.20)
6.0 (0.24)
Available adjusting stoppers
7.0 (0.28)
8.0 (0.31)
9.0 (0.35)
16.0
RAM0036
RA-11
COMPONENT PARTS (4 - WHEEL)
COMPONENT PARTS (4 - WHEEL)
RAM0039
RA-12
STEERING AXLE HUB (4 - WHEEL)
STEERING AXLE HUB (4 - WHEEL)
Removal
• Jack up and securely support body with safety stands.
(Refer to GI section.)
• Remove tires, and then remove hub caps.
• Loosen lock screw, and then remove lock washer, wheel bearing
nut and outer bearing.
• Pull out steering axle hub.
CAUTION:
• Do not drop outer bearing.
• Pull out inner bearing.
• Do not damage grease seal.
• Drive out inner race remaining hub by using hub groove.
RAM0040
Inspection
Clean each disassembled part and check.
WHEEL BEARING
Check for damage, seizure, peeling, improper rotation and noise.
Replace if necessary.
HUB, SPINDLE
Check for cracks (by dye test). Replace if necessary.
GREASE SEAL
Check for damage and wear. Make sure that oil seal is removed from
spindle. Replace if necessary.
Installation
Note the following, and install in the reverse order of removal.
• Apply wheel bearing grease (NWB-2) to each roller, race surface
and grease seal lip of wheel bearing.
• Adjust wheel bearing. (Refer to “Wheel Bearing Adjustment”.)
• Do not apply grease to inside inner race (where it is engaged to
spindle).
RA-13
STEERING AXLE HUB (4 - WHEEL)
Adjustment
WHEEL BEARING
NOTE:
For the cushion model, the tires are installed instead of the steering
axle hub.
1. Rotate steering axle hub with one hand, and then tighten wheel
bearing nut until it is hard to rotate.
2. Return wheel bearing nut approximately 60°.
3. Rotate steering axle hub several turns under this condition to fit
bearing.
4. Rotate steering axle hub with one hand again, tighten wheel
bearing nut until it is hard to rotate, and then return it
approximately 60°.
5. Align lock washer protrusion with spindle groove and lock
washer hole with thread hole of wheel bearing nut, and then
RAM0041
tighten lock screws.
Lock screw:
: 4.4 - 6.6 N•m (0.45 - 0.67 kg-m, 3.3 - 4.8 ft-lb)
CAUTION:
Position lock screw so that both holes are close if the holes are
not aligned. And then, rotate wheel bearing nut so as to align
with the nearest hole.
6. Turn and return steering axle hub several times, and then make
sure that rotation starting force is within the standard.
Rotation starting force
(Reading of hub bolt spring balance) N•m (kg-m, ft-lb):
10 - 29 (1.1 - 2.9, 3 - 6) (1B1)
RAM0042
CAUTION:
Readjust if it is outside the standard.
7. Check steering axle hub axial direction for looseness.
Axial direction gap: 0.08 mm (0.003 in) or less
CAUTION:
Readjust if looseness is still detected.
RA-14
KINGPIN (4 - WHEEL)
KINGPIN (4 - WHEEL)
Details
RAM0043EU
RA-15
KINGPIN (4 - WHEEL)
Removal
1. Disassemble spindle and tie-rod bar.
2. Loosen lock nut, and then remove lock screw.
3. Remove grease nipple, dust cover, and tire angle sensor from
kingpin upper, and then drive out kingpin downward while
positioning a piece of metal on the kingpin.
CAUTION:
• Hold kingpin so as not to drop.
• Install the plate for tire angle sensor positioning to kingpin
RH. Do not deform the plate when installing.
RAM0044
RAM0045
Inspection
Clean each disassembled part and check.
SPINDLE
Check for cracks (by dye test). Replace if necessary.
GREASE SEAL
Check for cracks (by dye test). Replace if necessary. Also replace if
grease seal is removed from steering axle.
RA-16
KINGPIN (4 - WHEEL)
Installation
Note the following, and install in the reverse order of removal.
CAUTION:
• Assemble tire angle sensor correctly so as to correctly
operate knob position correction system function.
• See the following procedure for assembly.
RAM0046
RAM0047
RAM0046
RA-17
KINGPIN (4 - WHEEL)
RAM0048
Tire angle sensor fixes the kingpin plate to the kingpin as shown in
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the angle sensor by engaging
the shaft of the angle sensor. Therefore, it is necessary to assemble
the angle sensor correctly to make steering control system function
correctly. Notes concerning assembly are as follows.
• When the kingpin plate is installed in the kingpin, it is necessary to
insert the plate vertically in the direction shown in the above
figure.
• When the sensor shaft is engaged in the kingpin plate, it is necessary
to set the plane part of the sensor shaft to the spring and the other
side of the kingpin plate (left side in the above figure).
• Securely insert plate into side groove of king pin hole.
CAUTION:
When the tire angle sensor is removed, installed and replaced,
the neutral level adjustment must be performed for the new
sensor.
Refer to CS section for neutral level adjustment.
RAM0049
RA-18
AXLE CENTRE (3 - WHEEL)
AXLE CENTRE (3 - WHEEL)
RA0079EU
RA-19
AXLE CENTRE (3 - WHEEL)
AXLE CENTRE (3 - WHEEL)
CAUTION:
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines is completely bled off.
• To prevent foreign material from entering, always maintain a
clean workplace.
• When disconnecting pipes, cover the surrounding area with
waste cloths and ensure that oil does not contaminate other
parts.
• Never allow foreign material to enter pipes when connecting.
• Put disassembled parts on clean paper or waste cloths and
use care so as not to contaminate, scratch or dent them.
• Turn the key switch to OFF and disconnect the battery cables
before removal.
Removal
1. Jack up and support the bottom of the frame around the
steering axle assy.. (Refer to the GI section.)
2. Remove the battery. (Refer to the BC section.)
3. Remove the counterweight. (Refer to the BF section.)
4. Remove the controller assembly. (Refer to the CS section.)
5. Remove the rear tire. (Refer to the TR section.)
6. Disconnect the tire angle sensor harness connector.
7. Disconnect the PS piping connection.
8. Remove the steering axle mounting bolt.
9. Remove the steering axle assy. from the vehicle.
NOTE:
The rear tire interferes with the frame if it is removed together with
the steering axle assy.. Therefore, the steering axle assy. cannot be
removed.
10. Disconnect the PS hose from the PS cylinder and drain the oil.
STM0078
Installation
Install in the reverse order of removal.
Steering axle mounting bolt
Tightening torque
[N•m (kg-m)]: 240 - 320 (25 - 32), 177 - 236 ft-lb
RA-20
AXLE CENTRE (3 - WHEEL)
STM0086
CAUTION:
Always replace the cotter pin with new one.
CAUTION:
Always replace the seals with new ones.
RA-21
AXLE CENTRE (3 - WHEEL)
Disassembly (Cont’d)
ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
• Always replace the cotter pin and the seal (if removed) with
new ones.
• Be careful of the direction of the seal when assembling the
seals to the hub.
• Apply the bearing grease to 4 positions shown in the figure.
PRELOAD ADJUSTMENT
1. Tighten the lock nut once.
2. Loosen the lock nut.
3. Tighten the lock nut again.
Preload torque [N•m (kg-m)]: 2 - 6 (0.2 - 0.6), 18 - 53 in-lb
4. Assemble the cotter pin and lock the lock nut within the above
torque.
STM0087
Assembly
1. Assemble the steering axle mounting assembly and the
steering axle bracket.
Tightening torque [N•m (kg-m)]: 280 (29), 207 ft-lb
2. Install the tire angle sensor.
3. Apply the chassis grease to the steering axle mounting
assembly.
STM0088
RA-22
MEMO
RA-23
AXLE CENTRE (3 - WHEEL)
RA-24
HYDRAULIC SYSTEM
SECTION HD
CONTENTS
SERVICE DATA AND SPECIFICATIONS ......... HD-2 TILT CYLINDER .............................................. HD-40
General Specifications .................................. HD-2 Construction ................................................ HD-40
Inspection and Adjustment ........................ HD-2 Removal ...................................................... HD-40
Adjusting Shim .............................................. HD-3 Disassembly ................................................ HD-41
Tightening Torque ......................................... HD-3 Inspection .................................................... HD-42
TROUBLE DIAGNOSES AND Assembly ..................................................... HD-42
CORRECTIONS ................................................. HD-4 Installation ................................................... HD-43
PRECAUTIONS AND PREPARATION ............. HD-8 LIFT CYLINDER .............................................. HD-44
Precautions ................................................... HD-8 Construction ................................................ HD-44
Special Service Tool ...................................... HD-9 Removal ...................................................... HD-48
HYDRAULIC SYSTEM ..................................... HD-10 Installation (2W, 2F, 3F, 3V) ........................ HD-52
Hydraulic Circuit Diagram ............................ HD-10 Disassembly ................................................ HD-53
Disassembly and Assembly ........................ HD-12 Inspection .................................................... HD-53
Inspection .................................................... HD-25 Assembly ..................................................... HD-54
OIL PUMP (GEAR PUMP) ............................... HD-26 Adjustment .................................................. HD-54
Removal ...................................................... HD-26 FULL-FREE CYLINDER .................................. HD-55
Installation ................................................... HD-26 Construction ................................................ HD-55
Disassembly ................................................ HD-27 Removal ...................................................... HD-58
Inspection .................................................... HD-28 Disassembly ................................................ HD-58
Assembly ..................................................... HD-29 Inspection .................................................... HD-59
Test Procedures .......................................... HD-30 Assembly ..................................................... HD-59
HYDRAULIC CONTROL LEVER ..................... HD-32 Installation ................................................... HD-60
Mechanical Control System ......................... HD-32 Adjustment .................................................. HD-60
CONTROL VALVE ........................................... HD-33 OIL TANK (3-WHEEL) ..................................... HD-61
Removal ...................................................... HD-33 Disassembly ................................................ HD-61
Installation ................................................... HD-34 OIL TANK (4-WHEEL) ..................................... HD-62
Disassembly ................................................ HD-34 Disassembly ................................................ HD-62
Inspection .................................................... HD-37
Assembly ..................................................... HD-37
Hydraulic Test ............................................. HD-37
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
General Specifications
Oil pump (Gear pump) Tilt cylinder
(A)1N1 series Applied model (A)1N1 series
Applied model Regular Large Stroke mm (in) 81 (3.19)
capacity capacity Cylinder I.D.mm (in) 65 (2.56)
KFS 2320 KFS 2324 Cylinder O.D.mm (in) 80 (3.15)
Pump type Piston rod diametermm (in) 30 (1.18)
CSNS CSNS
Drive type Direct coupled to motor Tilt angle 2W, 2F 4°/ 6°
(Forward-
Gear system Single, Zero-backlash type
backward) 3F, 3V 5°/ 5°
Normal discharge 20.2 24.0
m (US fl oz, lmp fl oz)/rev. (0.68, 0.71) (0.81, 0.84)
Lift (mast) cylinder
Maximum pressure
20.6 (205.9, 210, 2,986)
MPa (bar, kg/cm2, psi) Mast name 2W 2F 3F and 3V
Cylinder I.D. mm (in) 45 (1.77) 45 (1.77) 45 (1.77)
Control valve Cylinder O.D mm (in) 52 (2.05) 52 (2.05) 52 (2.05)
Piston rod diameter
(A)1N1 series 35 (1.38) 32 (1.26) 35 (1.38)
mm (in)
Applied model Mechanical
Joystick type
type Full-free cylinder
KVSF- KVSB-
Valve type Mast name 2F and 3F 3V
65VPFLS 65PSL
Main relief set pressure Cylinder I.D. mm (in) 70 (2.76) 50 (1.97)
16.7 (167.0, 170.34, 2,421) Cylinder O.D mm (in) 84 (3.31) 60 (2.36)
MPa (bar, kg/cm2, psi)
Piston rod diameter
Tilt relief set pressure 50 (1.97) 40 (1.57)
9.3 (93.0, 94.86, 1,348) mm (in)
MPa (bar, kg/cm2, psi)
The 3rd and 4th relief set pressure
11.8 (118.0, 120.36, 1,711) Suction filter
MPa (bar, kg/cm2, psi)
Power steering relief set pressure Applied model (A)1N1 series
6.9 (69.0, 70.38, 1,000)
MPa (bar, kg/cm2, psi) Filter type Wire gauze
Relief valve type Cartridge Diameter mm (in) 100 (3.94)
Plunger type Cylinder, spring return Filtration accuracy (mesh) 150
Rated flow rate Filter area cm2 (sq in) 620 (96.1)
65 (17-1/8, 14-1/4)
(US gal, lmp gal)/min.
Micron filter
Applied model (A)1N1 series
Filter type Filter paper (cartridge) type
Filtration sizeμm 20
HD-2
SERVICE DATA AND SPECIFICATIONS
Clearance between
cylinder head
0.2 (0.008) —
bushings and piston
rod
Clearance between
cylinder tube and 0.7 (0.028) —
piston ring
Adjusting Shim
Unit: mm (in)
Tightening Torque
Part name N•m (kg-m, ft-lb)
Cylinder head 2W, 3F and 3V 197 - 245 (20 - 25, 145 - 180)
(Lift Cylinder) 2F 197 - 225 (20 - 23, 145 - 166)
Cylinder mounting bolt 44 - 54 (4.4 - 5.6, 32 - 40)
U-bolt lock nut 26 - 32 (2.6 - 3.3, 19 - 24)
Lift cylinder Adjusting bolt lock nut 74 - 94 (7.5 - 9.6, 54 - 69)
HD-3
TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
For malfunctions closely related to pump motor, refer to MM section for diagnosis.
For malfunctions closely related to control system, refer to CS section for diagnosis.
No oil supplied from oil pump • Low oil level in tank • Fill up oil to specified level.
• Clogged suction pipe or filter • Clean. If oil is dirty, replace with new.
Low oil pump pressure • Worn gear shaft bushing or faulty packing • Replace with new one.
ring
• Improperly adjusted relief valve • Readjust to specified pressure using
pressure gauge.
• Air in the system • Retighten suction side piping.
• If oil level in tank is too low, add oil to
specified level.
• Do not operate pump until air bubbles in
tank are removed.
Abnormal noise caused by oil pump • Cavitation due to crushed suction hose or • Remove foreign matter and repair crushed
clogged filter hose.
• Air sucked from lose suction side joint • Retighten each joint.
• Excessive viscosity of oil • Replace with new oil having proper
viscosity.
• Air bubbles in hydraulic oil • Discharge air, remove foreign matter and
replace oil.
Oil leakage from oil pump • Faulty oil seal or body seal • Replace seal with new one.
• Worn sliding surfaces of gears (Increased • Replace oil pump with new one.
inner leakage)
HD-4
TROUBLE DIAGNOSES AND CORRECTIONS
CONTROL VALVE
Fluctuation of steering side oil pressure • Malfunctioning plunger • Clean foreign matter in hydraulic oil, or
change oil.
• Pump discharging oil is less than specified • Check pump performance and if necessary
amount. replace the damaged parts.
• Relief valve pressure set too low • Check and correct relief valve set pressure.
[Standard: 6.9 MPa (68.6 bar, 70 kg/cm2,
995 psi)] (Refer to ST section.)
• Broken spring • Replace.
• Foreign matter caught in fixed orifice of • Disassemble and clean foreign matter.
plunger
Poor steering response until specified oil • Clogged plunger damper orifice • Disassemble and check.
pressure is attained.
• Malfunctioning plunger • Clean foreign matter from hydraulic oil, or
change oil.
Oil leaking • Damaged or scratched O-ring • Replace faulty O-ring.
Pump pressure does not rise. • Lift lock valve does not operate. • Disassemble and clean the valve. In case of
solenoid operation failure, replace the
solenoid.
• Shuttle of proportional solenoid pressure- • Disassemble and clean the valve. However,
reducing valve or plunger of proportional when the plunger of the proportional
solenoid is stuck. solenoid is stuck, replace the valve because
it cannot be disassembled.
• Lead wire or solenoid coil is broken. • Repair or replace the wire or coil.
• Input current of solenoid is small. • Check if the specified maximum current is
applied.
• Lift lock valve is open. • Check the operation of the lift lock solenoid.
• Check the operation of the lift lock valve.
• Spool of flow priority valve is stuck. • Disassemble and clean the valve.
Plunger sticks • Foreign matter between sliding surfaces of • Clean valve housing and plunger.
valve housing and plunger
• Deteriorated oil • Change oil with new.
• Damaged return spring • Replace.
• Distorted valve housing mounted • Loosen mounting bolts and check.
• Bent plunger • Replace valve housing and plunger as an
assembly.
• Shuttle of proportional solenoid pressure- • Disassemble and clean the valve. However,
reducing valve or plunger of proportional when the plunger of the proportional
solenoid is stuck. solenoid is stuck, replace the valve because
it cannot be disassembled.
Oil leakage from oil seal • Paint dust or dirt caught in oil seal • Remove seal and clean.
• Distorted seal plate • Clean seal plate and retighten bolts.
• Worn or damaged seal • Replace.
• Damaged plunger • Replace.
Lowered or tilted forward cylinder without • Worn valve housing and plunger • Replace valve housing and plunger as an
control lever operation assembly.
• Oil leaking from cylinder • Check cylinder and replace faulty parts.
Load drops when changing control lever from • Foreign matter caught in load check valve • Disassemble check valve and clean.
NEUTRAL to RAISE position.
• Damaged poppet or check valve seat • Replace or repair by lapping.
Mast tilts forward when control lever is moved • Worn or damaged tilt lock plunger • Replace plunger and tilt valve housing as
forward and backward while key switch is OFF. an assembly.
• Broken tilt lock plunger spring • Replace.
• Oil leakage from O-ring in tilt cylinder piston • Replace.
HD-5
TROUBLE DIAGNOSES AND CORRECTIONS
Cylinder speed is too slow or cylinder does not • Worn relief valve or damaged seat • Replace relief valve assembly.
operate.
• Foreign matter caught in relief valve • Clean or replace relief valve.
• Faulty oil pump • Refer to “OIL PUMP”.
Mast is unstable or does not operate when • Stuck or damaged tilt lock plunger • Replace plunger and tilt valve housing as
control lever is moved to forward while key an assembly.
switch is ON.
• Foreign matter caught between valve and • Disassemble and clean.
plunger, making valve inoperative
RELIEF VALVE
Pressure does not rise at all. • Main poppet or pilot poppet is stuck and • Check for foreign objects in the engaged
kept open. area of the poppet.
• Foreign object is caught in poppet seat. • The poppet should slide freely.
• Clean all the parts thoroughly.
Relief pressure is unstable. • Poppet seat is damaged. • Replace the damaged part.
• Clean all the parts thoroughly.
• Poppet is stuck.
• Remove the flaw on the surface.
Relief pressure is abnormal. • Wear caused by foreign object • Replace the damaged part.
• Perform readjustment.
• Lock nut or adjusting screw is loosened.
Oil leakage • Damage to seat • Replace the damaged part or the worn part.
• Wear of O-ring • Each part should move smoothly.
• Each part is stuck due to foreign objects. • Check for scratch, scoring, and foreign
objects.
Pressure rise is delayed. • Air is trapped in relief valve. • Bleed air.
TILT CYLINDER
HD-6
TROUBLE DIAGNOSES AND CORRECTIONS
Mast swings to and fro when brakes are • Air in cylinder • Operate cylinder for about five minutes (10 -
applied while driving. 20 strokes).
• Oil leak from piston seal • Replace seal or cylinder.
LIFT/FULL-FREE CYLINDER
HD-7
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
WITH MECHANICAL SYSTEM
• For lift piping, fully tilt the masts forward, operate the control lever
several times forward, and turn key switch OFF. Operate the
control lever several times backward, and release the residual
pressure from piping.
• For lift piping, place the fork at the lowest position, and operate
the lift lever several times downward.
HD-8
PRECAUTIONS AND PREPARATION
HDT0001
HD-9
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HD-10
HYDRAULIC SYSTEM
HDM01
HD-11
HYDRAULIC SYSTEM
HD-12
HYDRAULIC SYSTEM
HDM02EU
HD-13
HYDRAULIC SYSTEM
HDM03
HD-14
HYDRAULIC SYSTEM
HDM04
HD-15
HYDRAULIC SYSTEM
HDM05
HD-16
HYDRAULIC SYSTEM
HDM06
HD-17
HYDRAULIC SYSTEM
HDM07
HD-18
HYDRAULIC SYSTEM
HDM08
HD-19
HYDRAULIC SYSTEM
HDM09
HD-20
HYDRAULIC SYSTEM
HDM010
HD-21
HYDRAULIC SYSTEM
HDM011
HD-22
HYDRAULIC SYSTEM
HDM012
HD-23
HYDRAULIC SYSTEM
HDM013
HD-24
HYDRAULIC SYSTEM
HDM014
Inspection
HOSES
• Leaking, degraded or damaged hoses should be replaced.
• Leaking or damaged connectors should be replaced.
HD-25
OIL PUMP (Gear pump)
OIL PUMP (GEAR PUMP)
Removal
HDM015
CAUTION:
• Clean the area surrounding the pump and remove dust.
• Because oil tends to spill, cover the area surrounding the
pipes with rag. (Especially opening for pump motor fan)
• Never allow foreign matter to enter pump or pipes.
Installation
CAUTION:
Apply molybdenum disulfide grease to the pump shaft.
HDM0164
Install in the reverse order of removal.
HD-26
OIL PUMP (Gear pump)
Disassembly
HDM016
CAUTION:
• Before disassembling, thoroughly clean dirt from outside of
pump body.
• Before disassembling, prepare new parts such as packings
and oil seals that are not reusable.
• When loosening bolt (1), be careful not to drop the pump
from the vise, and loosen the bolt slowly.
HDM0130
• Insert a slotted screwdriver into the back of oil seal, and then pry
the oil seal upward.
HDM0131
HD-27
OIL PUMP (Gear pump)
Inspection
Clean all disassembled parts in cleaning oil and check for cracks
and damage.
BODY
Suction Check the sliding mark of the gear teeth tip on the inner surface (at
chamber
Discharge the suction side).
side Suction Limit “a”:
side
Sliding mark
More than half-circumference
Depth of sliding mark
More than 0.20 mm (0.0079 in)
Gear hole
Sliding
mark
HDM0063
GEAR
Check the shaft and gear teeth face. In case of the following, replace
with a new one.
• The side face is rough to the extent that fingernails get caught.
• The teeth face is abnormally worn.
• The shaft diameter is less than the limit value.
Limit “d”: 20.961 mm (0.8252 in) dia.
HDM0064
SIDE PLATE
Check the side plate. In case of the following, replace with new ones.
• Severe roughness has been caused by many flaws which can be
felt by fingernails.
• The thickness of the side plate is less than the limit value.
Thickness of pressure plate:
Limit 2.927 mm (0.1152 in)
HDM0132
HDM0133
HD-28
OIL PUMP (Gear pump)
Assembly
1. Wash each part.
2. Secure the cast surface of mounting bracket in a vise with the
mounting surface facing downward.
3. Securely insert seal plate and backup into the groove of
mounting bracket so as not to protrude from outer surface. Be
careful about the insertion direction of backup.
4. Install dowel pin to mounting bracket, and then install pump
body to mounting bracket while aligning it with dowel position.
At this time, dowel pin is the positioning pin. If it is hard to insert
dowel, tap and insert it using a plastic hammer.
HDM0134
5. Insert side plate into the bottom of pump body with the copper
alloy side facing up. Be careful about the intake side/exhaust
side of side plate.
When the side plate cannot be moved because it tilted, hold the
drive shaft end of drive gear and slightly push the higher side of
side plate to insert it easily.
6. Insert the drive gear and driven gear while aligning the
matching marks with it put on shaft end surface. Be careful
about the drive gear and driven gear.
After inserting gear, apply clean hydraulic fluid of 2 to 3 m
HDM0135 (0.07 to 0.10 US fl oz, 0.07 to 0.11 Imp fl oz) to the tooth groove.
7. Insert side plate into the pump body with the copper alloy side
facing down. Be careful about the intake side/exhaust side.
8. Securely insert seal plate and backup into the groove of cover
so that they do not protrude from outer surface.
9. Install dowel pin to pump body, and then install cover while
aligning it with dowel position.
Be careful to prevent the seal plate and backup from dropping
or protruding. If the cover protrudes approximately 2 to 3 mm
(0.08 to 0.12 in) between the pump body and cover after
installing, the cover might not be installed correctly in step 8.
Check again.
10. Insert and temporarily tighten flanged bolt to the tightening
torque of 2.0 to 4.9 N•m (0.2 to 0.5 kgf-m, 2 to 3 ft-lb). The
thread should be in the wet condition.
HD-29
OIL PUMP (Gear pump)
Assembly (Cont’d)
11. After temporarily tightening, remove the pump from the vise.
Place the pump body horizontally with intake side facing up on
the stand under the mounting bracket and the cover. Tap the
pump body using a plastic hammer to adjust to the proper
position. This procedure should always be performed because it
is necessary to keep the performance after assembly,
12. Secure the pump on a vise again, and then tighten the bolt to
the specified torque.
Flange bolt
: 88 - 98 N•m (9 - 10 kgf-m, 65 - 72 ft-lb)
CAUTION:
Always tighten bolts to the specified torque.
If the tightening torque is outside the specified torque, it may
cause damage to the bolt and the hydraulic fluid spouting from
pump matching surface, which may cause accident.
13. Remove the pump from the vise, and then rotate the shaft end
of drive gear using a tool. If it rotates lightly, there are no foreign
materials and no seal getting caught. (If any seal gets caught,
the shaft cannot rotate manually. Perform disassembly and
assembly again.)
HDM0136
14. Install oil seal to mounting bracket. Apply a thin film of clean
lithium grease to lip of oil seal.
When pressing in the oil seal, be careful not to damage the lip
and do not press in the oil seal obliquely. Wrap the front drive
gear shaft end with seal tape to prevent the lip from being
damaged. Always wipe off the tape.
15. Insert the snap ring for stopping the missing oil seal. Always use
a new snap ring.
HDM0137
Test Procedures
NOTE:
Perform the test under the following conditions.
• Heat the hydraulic oil to approximately 50°C
• Set to P mode in POWER MODE (refer to the CS section)
• Set to 8 in PUMP ACCELERATION LEVEL (refer to the CS
section)
• Set to 100% in PUMP POWER LIMIT (refer to the CS section)
• Set to 100% in LIFT SPEED (refer to the CS section)
HD-30
OIL PUMP (Gear pump)
L13Q
(A)S1N1 500 (19.69) 550 (21.65)
L15Q
L15Q
(A)1N1 500 (19.69) 550 (21.65)
L18Q
L16Q
600 (23.62)
(A)G1N1 L18Q 550 (21.65)
L20Q 580 (22.83)
L15V
(A)1N1
L18V 515 (20.28) 550 (21.65)
(36V)
L20V
L15V
(A)1N1 600 (23.62)
L18V 550 (21.65)
(48V)
L20V 580 (22.83)
5. Move fork up and down with and without load, and check that it
operates correctly.
HD-31
HYDRAULIC CONTROL LEVER
HYDRAULIC CONTROL LEVER
HDM0138
ADJUSTMENT
Adjust the opened/closed area of control lever cover with the
following procedure.
1. Secure the striker on the center of long hole.
2. Connect the catcher and striker of control lever cover, and then
adjust the striker position so that there is no looseness on
control lever cover.
HDM0139
HD-32
CONTROL VALVE
CONTROL VALVE
Removal
CAUTION:
• Before discharging remaining pressure, lower lift fully and tilt
completely forward. Next, turn control lever toward backward
tilt side.
• When disconnecting pipes, turn key switch to OFF and
discharge remaining pressure in pipes.
• Never allow foreign matter to enter pipes or control valve.
• Because oil tends to spill, cover the area surrounding the
pipes with a shop cloth. (Especially opening for pump motor
fan)
HDM0166
HDM0140
HDM0141
HD-33
CONTROL VALVE
Installation
To install, reverse the order of removal. Pay attention to the following
points.
• Never allow foreign matter to enter pipes or control valve.
• After connecting pipes, apply relief pressure to check for any oil
leaks.
• After connecting lever and control valve, adjust the clearance
between control valve switch and dog and implement centering by
referring to CS section.
Disassembly
MECHANICAL CONTROL VALVE
HDM0142
HDM0143
HD-34
CONTROL VALVE
Disassembly (Cont’d)
Inlet spool
HDM0167
Lift spool
HDM0168
HD-35
CONTROL VALVE
Disassembly (Cont’d)
Tilt spool
HDM0169
HDM0170
HD-36
CONTROL VALVE
Disassembly (Cont’d)
1. Remove bracket containing control valve switch from control
valve assembly. (for mechanical)
2. Remove relief valves from control valve assembly.
CAUTION:
• Do not disassemble relief valve assemblies because they are
replaced as an assembly.
• Do not loosen lock nut. If lock nut is loosed, be sure to adjust
set pressure after assembling.
3. Remove the tie rod, and disassemble the control valve to each
section.
Be careful not to lose poppets and poppet springs that are
between each section.
Inspection
• Clean the disassembled parts with detergent oil, and bleed air to
remove foreign objects thoroughly.
• Replace the parts with deformation, cracks, or other damage.
• Replace the O-ring and wiper ring with new ones.
Assembly
• Assemble in the reverse order of disassembly.
• Check for smooth operation.
Hydraulic Test
CAUTION:
• When performing hydraulic test, wear protective eyeglasses.
High pressure oil leaks can cause loss of vision or other eye
damage.
• Perform the test in an appropriate place to allow lifting of the
mast.
NOTE:
Perform the test under the following conditions.
• Heat the hydraulic oil to approximately 50°C
• Set to P mode in POWER MODE (refer to the CS section)
• Set to 8 in PUMP ACCELERATION LEVEL (refer to the CS
section)
• Set to 100% in PUMP POWER LIMIT (refer to the CS section)
• Set to 100% in LIFT SPEED (refer to the CS section)
HD-37
CONTROL VALVE
Standard pressure
HDM0165 MPa (bar, kg/cm2, psi)
Main relief pressure 16.7 (167.0, 170.34, 2,421)
Tilt relief pressure 9.3 (93.0, 94.86, 1,348)
3rd, 4th relief pressure 11.8 (118.0, 120.36, 1,711)
Power steering relief pressure 6.9 (69.0, 70.38, 1,000.5)
PRESSURE ADJUSTMENT
• Turn key switch to OFF, and then disconnect the battery
connection.
• Disconnect seat switch harness connection, and then connect the
seat switch harnesses on body harness side.
• Relief valve on control valve upper side
1. Remove control valve switch (for mechanical).
2. Loosen lock nut of relief valve assembly.
3. Connect battery cable, and then turn key switch to ON.
4. Push control valve switch to ON (for mechanical). Operate
control lever (for joystick).
5. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard, turn clockwise.
• If greater than the standard, turn counterclockwise.
CAUTION:
• One rotation of the adjusting screw corresponds to a
pressure change of 6.9 - 7.8 MPa (68.6 - 78.5 bar, 70 - 80 kg/
HDM0144
cm2, 995 - 1,138 psi), so do not turn carelessly.
• Carefully adjust pressure, observing the pressure gauge
reading.
6. After completing adjustment, hold adjusting screw in place and
tighten lock nut.
7. Implement the pressure test again to check whether the set
pressure is correct.
• Relief valve on control valve lower side
1. Remove battery from the vehicle.
2. Connect battery cable to the vehicle using an extension cable.
3. Turn key switch to ON and operate control lever.
4. Turn adjusting screw of relief valve to set standard pressure.
• If lower than the standard: Turn clockwise.
• If greater than the standard, turn counterclockwise.
HD-38
CONTROL VALVE
SHUT-OFF VALVE
• When the forks and masts cannot be lowered with/without load.
• First of all, check the following:
If the above steps are OK, the forks and masts can be lowered with
the following procedure.
1. Turn key switch to OFF, disconnect the battery connection, and
then remove battery from the vehicle.
2. Remove the floor mat and floor board.
HDM0171
Return
1. Screw in the screw until it stops.
2. Loosen lock nut.
3. Install the floor board and floor mat, and then install the battery.
CAUTION:
Always return to the lift lock function after repair.
HDM0172
HD-39
TILT CYLINDER
TILT CYLINDER
Construction
HDM0145
Removal
CAUTION:
• When removing tilt cylinder, lift mast with wire or nylon string
and support cylinder with a block of wood so that it does not
fall.
• During work, be sure to keep your hands and feet out of
danger.
HD-40
TILT CYLINDER
Removal (Cont’d)
1. Lower fork fully.
2. Remove pivot pin attaching bolt from the joint of outer mast and
pull out pivot pin.
3. Turn key switch to ON and set tilt cylinder to the maximum
backward tilt, then tilt forward to extend cylinder by about 10 mm
(0.39 in). Turn key switch to OFF and disconnect battery plug.
4. Disconnect two pipes connected to tilt cylinder at pipe
connectors.
CAUTION:
• Since oil tends to spill when pipes are disconnected, cover
the surrounding area with rag.
• Stuff stoppers into disconnected pipes to prevent oil spills.
5. Remove pivot pin attaching bolt from joint of body frame and
pull out pivot pin to remove tilt cylinder.
NOTE:
To separate left tilt cylinder on body side, first remove tilt cylinder
cover, then go to next step.
HDM0146
Disassembly
1. Hold cylinder in a vise with piping port down and put a plate
under port. Apply compressed air alternately to two ports and
activate piston rod to discharge oil from cylinder.
2. Loosen head lock nut, then remove rod head from piston rod
assembly.
3. Loosen cylinder head, then remove cylinder head from cylinder
tube assembly.
CAUTION:
Use care not to damage O-ring.
HD-41
TILT CYLINDER
Disassembly (Cont’d)
5. Remove O-ring from piston rod assembly.
CAUTION:
Do not disassemble piston rod assembly.
Inspection
CYLINDER HEAD
• Measure inside diameter of cylinder head and outside diameter of
piston rod and calculate the clearance. If the clearance is greater
than usable limit, replace cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Usable limit: 0.2 mm (0.008 in)
CYLINDER TUBE
• Measure inside diameter of cylinder tube and outside diameter of
piston and calculate the clearance. If the clearance is greater than
usable limit, replace cylinder tube.
Standard: 0.03 - 0.15 mm (0.0012 - 0.0059 in)
Usable limit: 0.2 mm (0.008 in)
• Check whether the interior is damaged. If damage is minor, repair
using oilstone. If serious, replace cylinder tube.
• If welded part is damaged, replace cylinder tube.
PISTON ROD
• Check whether sliding surface is damaged. If damage is minor,
repair using oilstone. If serious, replace piston rod.
• If hard chromium plate flakes, replate piston rod or replace.
• If rod is bent, replace.
Assembly
To assemble, reverse the order of disassembly. Pay attention to the
following points.
• Lubricate each part with clean hydraulic oil.
• Never allow foreign matter to enter parts.
• Use new O-ring, U-rings, backup ring and wiper ring.
• Use care not to twist or damage O-ring.
HD-42
TILT CYLINDER
Assembly (Cont’d)
• Use care not to damage O-ring and wiper ring with threads of
piston rod.
Rod head lock nut:
: 108 - 147 N•m (11 - 15 kg-m, 80 - 108 ft-lb)
Cylinder head:
: 350 - 400 N•m (36 - 40 kg-m, 259 - 295 ft-lb)
NOTE:
To prevent O-ring and wiper ring from being damaged, wrap vinyl
tape around threads of piston rod, then attach cylinder head
assembly.
Installation
To install, reverse the order of removal. Pay attention to the following
points.
Pivot pin attaching bolt:
: (M10 4T) 26 - 32 N•m (2.6 - 3.3 kg-m, 18 - 24 ft-lb)
(M10 7T) 43.1-54.9 N•m (4.4 - 5.6 kg-m, 32-40 ft-lb)
• After installing, operate cylinder for about five minutes (10 - 20
strokes).
HD-43
LIFT CYLINDER
LIFT CYLINDER
Construction
2W MAST
HDM0147
HD-44
LIFT CYLINDER
Construction (Cont’d)
2F MAST, RIGHT HAND
HDM0148
HD-45
LIFT CYLINDER
Construction (Cont’d)
2F MAST, LEFT HAND
HDM0149
HD-46
LIFT CYLINDER
Construction (Cont’d)
3F AND 3V MAST
HDM0150
HD-47
LIFT CYLINDER
Removal
CAUTION:
Be sure to keep hands and feet out of danger.
PREPARATION
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of
clearance from lower end of outer mast to floor (refer to GI
section).
3. After setting mast vertical and lower lift cylinder at the lower
end, turn key switch OFF and disconnect the battery cable.
CAUTION:
Be sure to lower lift cylinder fully to discharge remaining
pressure in pipes.
2W LIFT CYLINDER
1. Remove lift hose from lift cylinder.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
2. Disconnect the hose between the lift cylinders.
LMM0232
HDM0152
HD-48
LIFT CYLINDER
Removal (Cont’d)
5. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
CAUTION:
• Because lift cylinder is very heavy, two people should
perform this task.
• When removing U-bolt, support lift cylinder to prevent it from
falling.
HDM0153
2F LIFT CYLINDER
1. Remove lift hose from lift cylinder.
2. Disconnect the hose between the lift cylinders.
3. Disconnect the piping between the lift cylinder and full-free
cylinder.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
HDM0089
HDM0175
6. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
CAUTION:
• Because lift cylinder is very heavy, two people should
perform this task.
• When removing U-bolt, support lift cylinder to prevent it from
falling.
HDM0154
HD-49
LIFT CYLINDER
Removal (Cont’d)
3F LIFT CYLINDER
1. Lift up the inner mast until the inner mast lower beam comes to
the position of the upper section of the outer mast tilt beam.
CAUTION:
Because the chain and lift hose become saggy, make sure that
they are not caught while lifting up the inner mast.
2. Remove the chain anchor on the inner mast side, and remove
the mast chain from the inner mast.
3. Remove the hydraulic piping on the lower section of the full-free
cylinder.
4. Remove the hose pulley support on the upper section of the
Inner mast middle mast, and remove the chain wheel.
5. Place a square timber of approximately 100 mm (3.94 in) height
under the inner mast, and lower the inner mast.
6. Fix the lifting tool to the upper beams of both the inner mast and
middle mast.
7. Remove the mounting bolt on the mast cylinder upper surface.
8. Lift up the inner mast and middle mast together, and remove the
upper section of the mast cylinder.
9. Disconnect the lift cylinder hose from the mast cylinder, remove
the lift hose clamp mounting bolt, and remove the cylinder from
the mast.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
10. Remove the bolt at the bottom end of the mast cylinder (lower
face of the outer mast support).
HDM0155
11. Remove the U-bolt, and remove the mast cylinder toward the
front of the vehicle.
CAUTION:
• When removing U-bolt, support lift cylinder to prevent it from
falling.
• Because lift cylinder is heavy, two people should perform
this task.
HD-50
LIFT CYLINDER
Removal (Cont’d)
3V LIFT CYLINDER
1. Remove the mast assembly from the forklift.
WARNING:
After removing the mast assembly, the middle and inner rails
will easily slide. Use ropes to firmly fasten the outer, middle and
inner rail top beams together.
2. Disconnect the high pressure hose at the lower end of the lift
cylinder.
HDM0156
Lock nut
Lift cylinder
LMM0055
4. Remove the securing bolt from the upper end of the lift cylinder.
WARNING:
After removing the mast assembly, the middle and inner rails
Securing will easily slide. Use ropes to firmly fasten the outer, middle and
bolt
inner rail top beams together.
Lift
cylinder
LMM0070
5. Slide the middle rail together with the inner rail 250 mm (9.84 in)
in the upper direction.
CAUTION:
Record the thickness and location of the adjusting shim used
to adjust the lift cylinder height in advance. The adjustment
shim is installed to the upper end of the lift cylinder.
WARNING:
The middle and inner rails easily slide. Use ropes to firmly
fasten the outer, middle and inner rail top beams together.
HD-51
LIFT CYLINDER
Removal (Cont’d)
6. Remove the bolt from the lower end of the lift cylinder.
HDM0157
U-bolt
Lock nut
LMM0073
• Fit the U-bolt into the cylinder, tighten the adjusting nut by hand,
Stopper and fix with the lock nuts.
Adjusting nut U-bolt : 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
Lock nut • Fit the stopper into the hole at the end of the adjusting bolt.
• Tighten the adjusting bolt, and check that the stopper contacts
Adjusting bolt with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten
the lock nut.
: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
Lock nut • When tightening the lock nut, make sure that the adjusting
Cylinder nut does not turn.
HDM0094
• For 2W mast, tighten the stud bolts on the set nuts to the bottom
of the threads. Apply thread lock to the threads of the stud bolt on
the cylinder side. And then tighten and fasten the stud bolt on the
top of the lift cylinder. So that the set nut does not become loose,
secure the stud bolt with a cotter pin.
HDM0158
HD-52
LIFT CYLINDER
Disassembly
1. Loosen cylinder head and remove from cylinder tube.
2. Disassemble cylinder head.
• Tap out wiper ring/dust seal using a screwdriver.
CAUTION:
Replace removed wiper ring/dust seal with new one. (Never
reuse a wiper ring/dust seal after tapping it out because outside
diameter is reduced.)
Inspection
CYLINDER HEAD
Measure inside diameter of cylinder head and outside diameter of
piston rod and calculate the clearance. If the clearance is greater
than usable limit, replace cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Usable limit: 0.2 mm (0.008 in)
PISTON ROD
• Check for bent. If excessive, replace with new one.
• Check whether sliding surface is damaged. If damage is minor,
repair using oilstone. If serious, replace piston rod.
• If hard chromium plating flakes, re-plate or replace piston rod.
CYLINDER TUBE
If the interior is damaged, replace cylinder tube.
HD-53
LIFT CYLINDER
Assembly
To assemble, reverse the order of disassembly. Pay attention to the
following points.
• Before assembling, lubricate each part with new hydraulic oil.
• Clean packings in petroleum-base hydraulic oil.
• During assembly, never allow foreign matter such as dust to enter
parts.
Cylinder head:
2W, 3F, 3V mast : 197 - 245 N•m (20 - 25 kg-m, 145 -
180 ft-lb)
2F mast : 197 - 225 N•m (20 - 23 kg-m, 145 - 166 ft-lb)
Adjustment
BLEEDING AIR
1. Add hydraulic oil up to the upper limit of level gauge.
2. Raise and lower mast slowly.
3. Lower mast fully and check the hydraulic oil capacity in tank. If
hydraulic oil level is reduced, fill up to the upper limit of level
gauge.
4. Repeat steps 2 and 3 until the hydraulic oil capacity is not
reduced.
5. Check that cylinder moves smoothly up and down.
HDM0158
6. For 2W mast, tighten the lock nut until it reaches the incomplete
thread of the stud bolt. At this time, the difference between the
upper beam and the lock nut is 1 mm (0.0394 in) or more.
HDM0173
HD-54
FULL-FREE CYLINDER
FULL-FREE CYLINDER
Construction
2F AND 3F MAST
HDM0160
HD-55
FULL-FREE CYLINDER
Construction (Cont’d)
3V MAST, RIGHT HAND
HDM0161
HD-56
FULL-FREE CYLINDER
Construction (Cont’d)
3V MAST, LEFT HAND
HDM162
HD-57
FULL-FREE CYLINDER
Removal
CAUTION:
Be sure to keep hands and feet out of danger.
PREPARATION
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of
clearance from lower end of outer mast to floor (refer to GI
section).
3. After setting mast vertical and lower full-free cylinder at the
lower end, turn key switch OFF and disconnect the battery
cable.
CAUTION:
Be sure to lower full-free cylinder fully to discharge remaining
pressure in pipes.
PROCEDURES
1. Disconnect the hydraulic piping from the full-free cylinder.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
2. Lift up the full-free cylinder using a nylon sling or a lifting wire.
3. Remove the full-free cylinder mounting bolt. Lift up the full-free
cylinder, and remove it.
Disassembly
1. Loosen the cylinder head, and remove the cylinder head from
the cylinder tube.
2. Disassemble the cylinder head.
• Push the wiper ring out by hitting with a screwdriver.
CAUTION:
Replace a removed wiper ring with a new one. (Because the
outer diameter of the removed wiper ring has been reduced, it
cannot be reused.)
• Remove the U-ring by prying with a screwdriver.
CAUTION:
Replace removed U-rings with new ones.
3. Remove the piston rod assembly from the cylinder tube.
CAUTION:
Do not disassemble the piston rod assembly.
HD-58
FULL-FREE CYLINDER
Inspection
CYLINDER HEAD
Measure the cylinder head inner diameter and piston rod outer
diameter, and calculate the clearance. When the clearance exceeds
the limit value, replace the cylinder head.
Standard: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
Limit: 0.2 mm (0.008 in)
PISTON ROD
• Check the piston rod for bending. When excessive bend is found,
replace the piston rod.
• Check the sliding face for damage. In case of minor damage,
repair with oil stone. In case of severe damage, replace the piston
rod.
• When the hard chromium plating is peeled off, plate again, or
replace the piston rod.
CYLINDER TUBE
When the inner face is damaged, replace the cylinder tube.
Assembly
Assemble in the reverse order of disassembly. Pay attention to the
following:
• Before assembling, moisten the parts with Nissan Hydraulic Oil.
• Clean the packing with a petroleum hydraulic fluid.
• Prevent foreign objects from entering into the inside during
assembly.
• Tighten the cylinder head to the specified torque.
Cylinder head:
2F, 3F mast : 300 - 370 N•m (31 - 37 kg-m, 202 - 272 ft-
lb)
3V mast : 246 - 274 N•m (25 - 28 kg-m, 181 - 202 ft-lb)
HD-59
FULL-FREE CYLINDER
Installation
Inner mast
Install in the reverse order of removal. Pay attention to the following:
Shim • 2F, 3F MAST:
Adjust with the shim so that the inner mast becomes parallel to
the full-free cylinder.
Shim thickness: 1.0 mm (0.039 in)
Then tighten the mounting bolt.
: 128 - 156 N•m (13 - 16 kg-m, 95 - 115 ft-lb)
Full-free cylinder
HDM0098
• 3V MAST:
Mounting bracket of full free cylinder to be inserted into the notch
of inner mast 2nd-beam. After surface A of 2nd-beam touches
surface B of mounting bracket, bolt is to be tightened. (3V mast)
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
HDM0163
• Seal the taper threads of the piping with seal tape securely.
Prevent chips of the seal tape or other foreign object from entering
into the hydraulic piping.
• O-rings are used at the connectors which connect the hydraulic
units. When assembling, insert the connector with a guide on the
threads so that the O-ring is not damaged.
• Screw in the connector by hand. When the connector is
positioned, tighten the lock nut to the specified torque. (For the
tightening torque, refer to “Mast Piping”.)
Adjustment
BLEEDING AIR
1. Add hydraulic fluid to the upper limit of the level gauge.
2. Lift the mast slowly, then lower it slowly.
3. Lower the mast fully, and check the hydraulic fluid amount in the
tank. When the hydraulic fluid amount is low, add to the upper
limit of the level gauge.
4. Perform the operations mentioned in steps 2 and 3 above
repeatedly until the hydraulic fluid amount does not decrease.
5. Move the cylinder up and down, and check for smooth
operation.
HD-60
OIL TANK (3-wheel)
OIL TANK (3-wheel)
Disassembly
HDM0174
HD-61
OIL TANK (4-wheel)
OIL TANK (4-wheel)
Disassembly
HDM0801EU
HD-62
STEERING SYSTEM
SECTION ST
CONTENTS
SERVICE DATA AND SPECIFICATIONS ......... ST-2 Construction ................................................. ST-14
General Specifications .................................. ST-2 Specification ................................................. ST-14
Tightening Torque ......................................... ST-2 Removal ....................................................... ST-15
PRECAUTIONS AND PREPARATION ............. ST-3 Installation .................................................... ST-15
Special Service Tool ...................................... ST-3 Troubleshooting ........................................... ST-16
STEERING COLUMN ASSEMBLY ................... ST-4 Disassembly ................................................. ST-18
Installation ..................................................... ST-5 Assembly ...................................................... ST-20
Inspection After Installation ........................... ST-5 Periodical Inspection and Maintenance ........ ST-24
PS VALVE .......................................................... ST-6 PS CYLINDER. (3 - WHEEL) ............................ ST-26
Parts Construction ......................................... ST-6 Construction ................................................. ST-26
Disassembly .................................................. ST-7 Removal ....................................................... ST-29
Inspection ...................................................... ST-8 Installation .................................................... ST-29
Assembly ....................................................... ST-9 PS PIPING ........................................................ ST-33
Trouble Diagnosis and Corrections ............. ST-12
PS CYLINDER (4 - WHEEL) ............................ ST-14
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
General Specifications
(A)1N1 J(A)G1N1
Power steering relief pressure MPa (kg/cm 2) (psi) 6.9 (70.38) (1,000.5) 8
Tightening Torque
Unit N•m kg-m ft-lb
Steering wheel nut 18 – 22 1.9 – 2.2 14 – 16
Steering column cover bolt 1.5 – 2.0 0.16 – 0.20 1.1 – 1.4
Steering column shaft upper joint pinch bolt 16 – 22 1.7 – 2.2 12 – 16
Steering column bracket bolt 27 – 36 2.8 – 3.6 20 – 26
Tilt lock lever securing bolt 8 – 11 0.9 – 1.1 6–8
PS valve bolt 30 – 40 3.1 – 4.0 23 – 29
Steering axle mounting bolt 240 – 320 25 – 32 177 – 236
ST-2
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
STM0075
ST-3
STEERING COLUMN ASSEMBLY
STEERING COLUMN ASSEMBLY
STM0067
CAUTION:
• Turn the key switch to OFF and disconnect the battery cables
before removing and installing the steering column.
• For removal, do not tap the steering wheel mounting nut with
a hammer. It causes the damage of the combination switch.
• Neutral knob position must be redetected after removing and
installing or replacing the steering wheel angle sensor of the
steering axle.
• Apply grease to the specified position shown on the
illustration above.
ST-4
STEERING COLUMN ASSEMBLY
Installation
STM0076
ST-5
PS VALVE
PS VALVE
Parts Construction
STM0070
ST-6
PS VALVE
Disassembly
Be careful the following when repairing PS valve.
• Work in a clean place.
• Clean unit around the port before disconnecting piping.
• Remove dust or dirt on the joint of circumference of unit using
wire brush.
• Be careful so as not to dent and damage because parts drop and
contact.
CAUTION:
Take care not to be injured by any sharp, machined edges in the
sleeve, spool and housing.
1. Hold the main body with a vise with end cap side facing up.
Make sure to hold it at the mounting flange of the housing by
applying moderate pressure. Do not apply excessive pressure.
Use copper plates between the component and the vise as
necessary.
2. Remove the six screws and one retainer screw assembly.
3. Remove the end cap.
4. Remove the O-ring from the end cap.
5. Remove the plug and O-ring from the gerotor.
6. Take out the spacer from the inner spline of the gerotor.
STT0100L
NOTE:
Depending on the gerotor’s displacement, some units have no
spacers and others have two spacers, etc.
7. Remove the gerotor. Do not allow the star to drop from the
gerotor.
8. Remove the O-ring from the gerotor.
9. Remove the drive.
10. Remove the spacer plate.
11. Remove the O-ring from the housing.
12. Remove the adapter screw from the housing.
13. Remove the housing from the vise and remove the ball by
turning the housing upside down.
CAUTION:
Do not drop or lose the ball.
14. Place the housing on a clean fabric with the flange side facing
up so that the finished faces are not damaged. Lift the end of
the retaining ring with a screwdriver and remove it from the
housing.
CAUTION:
Always wear safety goggles. The retaining ring may pop out of
the housing.
15. Place the housing on a clean fabric so that the axial direction of
the main body is held in a horizontal direction. After setting the
STT0101L
pin to a level position by turning the spool and sleeve assembly,
slightly push out the spool and sleeve assembly to remove the
seal gland bushing from the housing.
NOTE:
The spool and sleeve assembly mentioned above includes the
sleeve, spool, pin, centering spring and flat spring.
ST-7
PS VALVE
Disassembly (Cont'd)
16. Remove the oil seal from the seal gland bushing.
17. Remove the dust seal from the seal gland bushing.
18. Remove the two race bearings, thrust needle and oil seal.
19. Press the inner spline of the spool with thumb and pull off the
spool and sleeve assembly from the opposite side to the
housing flange. At that time, ensure that the sleeve outer wall is
not caught in the housing inner wall.
CAUTION:
Depending on the spool/sleeve combinations, even a 180° shift
in position may render the unit inoperative. To prevent such a
symptom, put alignment marks at the positions shown in figure
on the spool and sleeve assembly during this step.
STT0102L
20. Pull out the pin from the spool and sleeve assembly.
CAUTION:
Always wear safety goggles. The centering spring may pop out
of the spool.
21. Slightly push forward the spool in the sleeve and carefully
remove the centering spring from the spool with fingers.
22. Pull out the sleeve from the spool. To do so, gently turn the
sleeve while pulling it.
Inspection
Inspect the fitting faces of all parts. Any parts with scratches or burrs
must be replaced. These may cause oil leakage.
Clean all metal parts with clean solvent and dry them by blowing air.
Do not use cloth or paper. Lint or particles from these materials may
enter the main body, resulting in contamination of the hydraulic
system and subsequent symptoms.
Do not use files or sandpaper on the parts.
CAUTION:
Take care not to be injured by any sharp, machined edges in the
sleeve, spool and housing.
ST-8
PS VALVE
Assembly
CAUTION:
• Assemble a new O-ring and seal when assembling.
• Apply a small amount of clean grease to O-rings before
assembly.
• Do not confuse O-rings and because they are sizes very
near.
1. Slowly insert the spool in the sleeve while turning the spool.
After that, hold the spool spline and try to turn it. The spool
should turn smoothly in the sleeve.
WARNING:
Make sure to align the two parts correctly by referring to the
alignment marks that have been placed during disassembly.
Misalignment may cause malfunctions, resulting in serious
accidents.
STM0077
3. Slightly lift the spool from the sleeve. While pressing and
holding the opposite end of the centering spring, push them into
the grooves of the spool and sleeve. At that time, make sure to
slide the inserting tool at the same speed as pushing the
springs. After inserting the springs, align the spring ends to the
sleeve periphery.
CAUTION:
Always wear safety goggles. The centering spring may pop up
from the spool.
STT0104L
4. Insert the pin in the sleeve hole and align both ends of the pin
with the sleeve periphery.
5. Place the housing on a clean fabric so that the axial direction of
the main body is held in a horizontal direction. Insert the spool
and sleeve assembly from the opposite end to the housing
flange.
Verify that the spool and sleeve assembly can turn smoothly in
the housing in this status.
ST-9
PS VALVE
Assembly (Cont'd)
CAUTION:
• When inserting the spool and sleeve assembly, ensure that
they are not slanted and caught by the housing inner wall.
During the insertion process, turn the assembly left and right
to a small stroke while keeping the pin in a horizontal
position.
• After insertion, the spool and sleeve assembly must be flush
with the housing end face. Do not insert the assembly
further. Any excessive insertion may cause the pin to drop in
the inner portion of the housing.
6. Place the housing on a clean flat surface and install the O-ring.
7. Install the two race bearings and thrust needle bearing. Make
sure to insert the thrust needle bearing between the race
bearings.
(In the order of race bearing, thrust needle bearing, and then
race bearing)
8. Install the dust seal into the seal gland bushing. Ensure that the
flat face of the dust seal comes to the seal gland bushing side.
9. Attach the oil seal to the seal gland bushing.
CAUTION:
Ensure that the oil seal is not twisted and deformed.
10. Insert the seal gland bushing in the spool while turning the
bushing. Lightly tap on the bushing with a plastic hammer to
insert it to the specified position.
11. Install the retaining ring into the housing.
CAUTION:
• Expand the retaining ring with a flat-bladed screwdriver so
that the entire periphery of the ring fits into the housing
groove.
• Always wear safety goggles. The retaining ring may pop out
of the housing.
3. Install the adapter screw into the hole in which the ball has been
put.
STT0105L
ST-10
PS VALVE
Assembly (Cont'd)
NOTE:
The bolt hole differs from the oil hole in pitch and diameter.
6. Turn the spool and sleeve assembly so that the pin and the
housing port are parallel. Insert the drive and engage the drive
yoke and the pin.
For accurate positioning, draw a line on the drive end face
parallel to the pin using a marker pen.
7. Attach the O-ring to the gerotor.
CAUTION:
There are two O-rings. Ensure that the correct one is selected.
8. Position the O-ring side of the gerotor toward the spacer plate
and assemble it while aligning the concaves of the gerotor star
gear to the line marked. At that time, ensure that the pin, drive
and star concaves are all aligned parallel as shown in the figure.
Turn the gerotor ring to align the bolt holes while keeping the
drive and the gerotor star engaged with each other.
WARNING:
Make sure to restore the correct positional relation. Incorrect
combinations will cause a malfunction, which may lead to
serious accidents.
CAUTION:
STT0106L
• Be sure to perform above steps 6 to 8 because they are
important procedure for mating valve timing.
• The bolt hole differs from the oil hole in pitch and diameter.
STT0108L
ST-11
PS VALVE
ST-12
PS VALVE
ST-13
PS CYLINDER (4 - WHEEL)
PS CYLINDER (4 - WHEEL)
Construction
STM0091
Specification
Vehicle model
Items J(A)G1N1
ST-14
PS CYLINDER (4 - WHEEL)
Removal
1. Jack up the vehicle and support it securely with a rigid rack.
2. Disconnect the hydraulic tube from the PS cylinder.
STM0099EU
3. Remove the tie-rod clevis pin connecting the piston rod and tie
rod bar.
STT0112L
Installation
Note the following, and install in the reverse order of removal.
• Clean the inner wall of the spherical bushing mounting hole to
prevent risk of seizure due to foreign objects.
• Apply grease to the sliding faces and dust cover lips.
PS cylinder mounting bolt
: 137 - 186 N•m (14 - 18 kg-m, 101 - 137 ft-lb)
Tie-rod clevis pin mounting bolt:
: 7.2 - 10.8 N•m (0.74 - 1.10 kg-m, 6 - 7 ft-lb)
Flare nut:
: 39 - 59 N•m (4.0 - 6.0 kg-m, 29 - 43 ft-lb)
PS cylinder connector
: 39 - 43 N•m (4.0 - 4.4 kg-m, 29 - 32 ft-lb)
ST-15
PS CYLINDER (4 - WHEEL)
Troubleshooting
Condition Possible causes Corrective action
Oil leakage from piston Piston 1. Eliminate the scratches and smoothen the sliding face
rod sliding face rod (1.5s or less) using oilstone. If the oil still leaks, the sealing
*: Refer to “Inspection • Rust or scratches on parts such as U-ring may be damaged by the scratches.
After Assembly” for sliding face, which can be Overhaul the piston.
judgement. felt by fingernails. 2. If the scratches and rust zone is too wide to repair with
oilstone, replace the piston rod, U-ring, seals such as the
wiper ring, and piston rod bearings.
1. Replace.
2. The packing may have reached its end of life or the fluid
• Packing deteriorated in
may have been deteriorated or overheated.
elasticity and shredded in
• Replace the fluid.
pieces
• Check the fluid temperature. [The desirable temperature
• Lip faces widely lost
is 80°C (176°F) or less.]
• Check for any partially heated portion.
1. Replace.
2. The packing may be subject to excessive high pressure.
• Excessive projection of
• Check the operation pressure.
packing heel
• If equipped with a buffer ring, the buffer ring may be the
cause. Check the buffer ring.
Oil leakage from piston Cylinder • Cylinder head used in 1. Remove the scratches and rust with oilstone.
rod sliding face head piston rod contains rust or 2. If not repairable, replace the cylinder head.
*: Refer to “Inspection scratches on seal fitting
After Assembly” for face. Refer to “Bearing
judgement. materials” above.
ST-16
PS CYLINDER (4 - WHEEL)
Troubleshooting (Cont’d)
Condition Possible causes Corrective action
Inappropriate functioning Piston rod • Excessive bending 1. Replace with a new one.
No smooth operation or cylinder deformation over specified Also inspect the seals and sliding parts, which may be
tube limit damaged. Replace them if necessary.
(Bending deformation:
Refer to “Disassembly”,
“Maintenance criteria”.)
Cylinder 1. Replace with a new one. As in the above, also inspect the
• Dent
tube seals and sliding parts.
Piston rod • Excessive wear and 1. Replace with a new one. As in the above, also inspect the
Cylinder damage of sliding faces, seals and sliding parts.
tube Sliding foreign objects in piston 2. Remove the foreign objects. As in the above, also inspect
part and cylinder head sliding the seals and sliding parts.
materials faces
Internal oil leakage Piston seal 1. Replace with a new one. Also inspect the inside of the
• Scratches or wear
Piston rod moves cylinder tube.
spontaneously during
operation or specified Cylinder 1. Remove scratches and rust by honing or with oilstone to
speed output is not tube smoothen the surfaces. If the damaged area is too large to
• Scratches or rust inside
available. repair, replace the cylinder tube.
2. Replace the piston seal.
Too much impact at a Pin bushing 1. Measure the dimensions of the pin and pin bushing.
changeover point Pin • Too large gap between Replace the parts if the dimensions exceed the allowable
between expansion and mounting and pin bushing limits.
retraction.
ST-17
PS CYLINDER (4 - WHEEL)
Troubleshooting (Cont’d)
CAUTION:
• The hydraulic fluid expands or shrinks due to changes in the
ambient temperature and pressure. The resultant cylinder
stroke may be recognized incorrectly as internal oil leakage.
• When checking for any internal oil leakage, ensure that the
temperature and pressure do not change during the check.
Disassembly
PREPARATION
Before starting disassembly work, make the following preparations.
• Work bench
Prepare a wide and robust workbench so that the components on
the bench are supported stably and securely.
GENERAL PRECAUTIONS
• Before disassembling the cylinder, remove soil and dust from the
cylinder outside wall.
• All components are precision-made. Always handle the
components with great care. Do not allow the components to hit
other parts or drop on the floor.
• When working, do not use excessive force. Tapping strongly or
prying forcibly may create burrs or damage the components,
rendering the component unusable and causing oil leakage and
performance deterioration. Always work with patience.
• Do not interrupt disassembly or assembly work in the interim
wherever possible. Moisture and dust may enter the exposed
components and rust may develop later. If it is inevitable to
interrupt the work, take appropriate measures for rustproofing and
dustproofing.
MAINTENANCE CRITERIA
The sliding parts and sealing parts must be replaced according to
the following criteria.
• Bushing
When one-fourth of the periphery is worn out and turned copper
brown
• Seals
Whenever the cylinder is disassembled
• Spherical bearing
If a significant bite is observed
• Piston rod
If a bend of 0.5 mm (0.020 in)/1 m (3 ft) or more is observed
ST-18
PS CYLINDER (4 - WHEEL)
Disassembly (Cont’d)
DISASSEMBLY
1. Extract fluid.
2. Place the cylinder on a horizontal surface.
3. Set the piston rod in the neutral position.
4. Loosen the nut and remove the tie rod.
5. Remove the cylinder heads.
CAUTION:
There are two cylinder heads. Before removing each cylinder
head, prepare an appropriate container to collect oil drained
from the joint between cylinder head and cylinder tube.
STT0113L
STT0114L
STT0115L
ST-19
PS CYLINDER (4 - WHEEL)
Disassembly (Cont’d)
10. Remove the pin bushing.
• Remove the snap ring.
Insert the tip of a screwdriver in the open end of the snap ring,
and pry out the ring from the groove.
If the ring is the C-snap type, use pliers to remove it.
• To remove the pin bushing, push it out by using a press as shown
in the figure.
Assembly
CAUTION:
The paint of the components may flake off and enter inside the
cylinder, resulting in oil leakage. When assembling, exercise
extreme caution not to allow any paint to come off.
STM0101
ST-20
PS CYLINDER (4 - WHEEL)
Assembly (Cont’d)
2. Install the wiper ring using an impact block.
STT0118L
STT0119L
3. Assembly of U-ring.
• Attach the backup ring and U-ring in order into the U-ring groove.
• Ensure that the U-ring is correctly positioned and free from
damage.
• Reverse installation will lead to oil leakage.
• After attaching the rings, verify that no permanent deformation,
such as wrinkles, is created.
4. Install the snap ring to retain the bushing.
STT0120L
STT0121L
ST-21
PS CYLINDER (4 - WHEEL)
Assembly (Cont’d)
ASSEMBLY OF PISTON SEALS
1. Attach the O-ring into the groove.
• Ensure that the O-ring is not twisted.
2. Push the slip seal onto the piston while stretching the seal. The
slip seal insertion jig will help to attach it safely. Heating the slip
seal to approximately 80°C (176°F) also facilitates the assembly
work.
STT0122L
3. If the slip seal is still stretched when fitted onto the piston,
straighten it with the straightening jig.
• The stretched slip seal will prevent subsequent assembly work.
STM0092
STT0124L
ST-22
PS CYLINDER (4 - WHEEL)
Assembly (Cont’d)
INSTALLATION AND TIGHTENING OF TIE ROD
1. Install the tie rod and nut and hold the two cylinder heads in
place.
CAUTION:
Ensure that the cylinder heads are positioned correctly.
TEST OPERATION
1. Turn the key switch to ON position while lifting up rear wheels.
2. Turn the handle left/right rapidly or slowly, and then repeat
several times. However, do not turn the handle to full stroke at
first, increase the stroke gradually.
Do not move the cylinder rapidly from the beginning.
Doing so will cause aeration.
3. Repeat above operations to fill the cylinder with oil.
4. Lubricate both end bushings.
ST-23
PS CYLINDER (4 - WHEEL)
Response
Internal leakage
ST-24
PS CYLINDER (4 - WHEEL)
STM0093
ST-25
PS CYLINDER. (3 - WHEEL)
PS CYLINDER. (3 - WHEEL)
Construction
STM0801EU
ST-26
PS CYLINDER. (3 - WHEEL)
Construction (Cont’d)
STM0080
ST-27
PS CYLINDER. (3 - WHEEL)
STM0071
•
CAUTION:
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines is completely bled off.
ST-28
PS CYLINDER. (3 - WHEEL)
Removal
1. Jack up and support the bottom of the frame around the
steering axle assy.. (Refer to the GI section.)
2. Remove the battery. (Refer to the BC section.)
3. Remove the counterweight. (Refer to the BF section.)
4. Remove the controller assembly. (Refer to the CS section.)
5. Remove the rear tire. (Refer to the TR section.)
6. Disconnect the tire angle sensor harness connector.
7. Disconnect the PS piping connection.
8. Remove the steering axle mounting bolt.
9. Remove the steering axle assy. from the vehicle.
NOTE:
The rear tire interferes with the frame if it is removed together with
the steering axle assy.. Therefore, the steering axle assy. cannot be
removed.
10. Disconnect the PS hose from the PS cylinder and drain the oil.
STM0078
Installation
Install in the reverse order of removal.
Steering axle mounting bolt
Tightening torque
[N•m (kg-m)]: 240 - 320 (25 - 32), 177 - 236 ft-lb
Disassembly
1. Remove the tire angle sensor together with the bracket.
2. Remove the bolt, and then separate the steering axle mounting
assembly and the steering axle bracket.
ST-29
PS CYLINDER. (3 - WHEEL)
STM0081
ST-30
PS CYLINDER. (3 - WHEEL)
Disassembly (Cont’d)
ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
• Be careful of the direction of the seal when assembling the
seals.
• Always use the Loctite 620 when assembling the upper seal
and the lower ring to the steering axle mounting.
• Assemble the steering axle mounting to the steering
mounting plate so that the center tooth of the rack is
positioned between two teeth of the steering mounting plate
shaft.
STM0082
PRELOAD ADJUSTMENT
1. Tighten the lock nut once.
2. Loosen the lock nut.
3. Tighten the lock nut again.
Preload torque (with rack and without PS cylinder)
[N•m (kg-m)]: 15 - 25 (1.6 - 2.5), 11 - 18 ft-lb
4. Securely lock the lock nut using the lock washer within the
above torque.
STM0083
ST-31
PS CYLINDER. (3 - WHEEL)
Disassembly (Cont’d)
PS CYLINDER
DISSASEMBLY
STM0084
ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
• Always use new O-ring, seal, and bushing.
• Turn the end gap of the bushing by 180 degrees, and then
assemble the bushing to the piston.
• Face the flat surface of the piston to the rack side, and then
assemble the piston.
STM0085
ST-32
PS PIPING
PS PIPING
STM0071EU
ST-33
PS PIPING
STM0802EU
ST-34
PS PIPING
STM0072
CAUTION:
• When installing the connector, make sure that electrical line
is free from foreign materials, and no deformation or crush
occurs.
• When fixing hoses, make sure that the direction and position
of hoses should be correct to protect them from twist and
tension.
• Before bleeding the air, turn the key switch to ON and turn
the steering wheel fully from left to right (lock to lock) 15
times.
• Make sure that steering system is free from oil leakage and
other defects when keeping the steering wheel at relief
pressure position (left and right) over 3 seconds.
• Install hose clamps as shown in the figure.
STM0089
ST-35
MEMO
ST-36
LOADING MECHANISM
SECTION LM
SERVICE DATA AND SPECIFICATIONS ......... LM-2 CARRIAGE ASSEMBLY ................................ LM-10
TROUBLE DIAGNOSES AND Removal ...................................................... LM-10
CORRECTIONS ................................................. LM-4 Inspection .................................................... LM-11
PRECAUTIONS AND PREPARATION ............. LM-5 Adjustment .................................................. LM-11
Precautions ................................................... LM-5 Installation ................................................... LM-13
FORK ................................................................. LM-6 MAST ............................................................... LM-14
Removal ........................................................ LM-6 Mast Assembly ............................................ LM-14
Inspection ...................................................... LM-6 Removal ...................................................... LM-18
Installation ..................................................... LM-6 Disassembly ................................................ LM-19
LIFT CHAINS ..................................................... LM-7 Inspection .................................................... LM-22
Removal ........................................................ LM-7 Assembly ..................................................... LM-22
Installation ..................................................... LM-7 Installation ................................................... LM-29
Adjustment .................................................... LM-7 Adjustment .................................................. LM-30
Inspection ...................................................... LM-8 Mast bushing ............................................... LM-31
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
LM-2
SERVICE DATA AND SPECIFICATIONS
Tightening Torque
LM-3
TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
The following table lists only typical examples. To perform an
accurate diagnosis carefully listen to the user's complaints and
check the actual vehicle to fully understand under what
conditions the symptoms occur.
Forks do not raise or lower smoothly. • Improperly adjusted carriage bracket assembly • Adjust clearances between parts (such as inner
mast, side roller, thrust metal, carriage roller).
Replace faulty parts with new ones.
• Improperly adjusted inner mast-to-outer mast • Adjust using shim(s) or liner.
clearance or roller-to-mast clearance
• Insufficient lubrication • Apply grease to contacting/sliding surfaces of
parts.
• Caught foreign matter in functional parts • Remove foreign matter.
• Deformed inner mast • Adjust.
• Bent carriage bracket assembly • Adjust or replace.
Forks rising unstable • Improperly adjusted lift chain(s) • Adjust lift chain tension.
Lift rollers fail to rotate. • Solidified grease on rollers or sliding surfaces • Clean lift rollers and grease.
or accumulated dirt/dust
• Lift roller(s) are improperly installed. • Check and adjust lift rollers.
• Roller(s) are broken or damaged. • Replace faulty rollers.
Mast assembly emits noise. • Insufficient lubrication • Apply grease.
• Improperly adjusted lift rollers, side rollers and/ • Adjust.
or liners
• Worn chain wheels, lift rollers and/or liners • Replace worn parts.
• Damaged lift rollers and/or mast rollers • Replace damaged rollers.
LM-4
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
• Most of the loading mechanism parts such as forks, mast,
carriages, etc. are heavy. The hoisting and movement of
those objects are inherently dangerous. Therefore, be
extremely careful and always employ an assistant when you
remove them.
• When removing/installing cylinder, always perform the
procedure with two persons because of heavy weight,
paying attention not to catch hands by components.
• Be extremely careful to protect your hands, feet, etc., when
performing maintenance work on or moving heavy objects.
• Always assign lifting operations to qualified operators
trained in slinging or hoisting procedures.
• Before removing hydraulic lines or piping, the oil pressure
remaining in hydraulic lines must be completely bled off.
NOTE:
• The fork assembly must be removed as required to make
maintenance work easier to perform.
• Disassembly of the carriage bracket assembly requires the
removal of the forks. Following the removal of forks, remove the
carriage bracket assembly from the mast assembly.
• If the carriage bracket assembly needs not be disassembled upon
removal, remove it with the forks installed to it. This will prevent
the carriage assembly from toppling over.
• When the mast assembly and carriage bracket assembly are to
be removed as a unit, remove the fork assembly beforehand.
LM-5
FORK
FORK
Removal
CAUTION:
For removal of the fork assembly and carriage assembly as a
unit, refer to “CARRIAGE ASSEMBLY”.
1. Raise the forks approximately 100 to 200 mm (3.94 to 7.87 in)
above the ground.
2. Turn the lock levers 90° at the upper ends of the forks, then
move the forks to the notched portion located in the center of
the carriage assembly.
LMM0204
3. While lifting the tips of the forks, disengage the jaws from the
carriage (finger bar). Lift the upper portions of the forks up and
away from the carriage assembly. Always remove one fork at a
time.
LMM0134
Inspection
• Check the forks for wear (as shown in the figure). If wear exceeds
specifications, replace the forks with new ones.
Standard wear limit:
More than 3 mm (0.12 in)
• Visually check the forks for cracks, deformation or separation of
welds. If necessary, replace with new fork assembly.
• Check the forks using a dye penetration method. If they are
cracked, replace with new ones.
LMM0227
Installation
To install the forks, reverse the order of removal.
CAUTION:
After installing both forks, check to ensure that the lock levers
are properly locked.
LM-6
LIFT CHAINS
LIFT CHAINS
Removal
1. Support the carriage assembly by placing a wooden block
under it or using a crane.
2. Retract the lift cylinders to loosen the lift chains, then remove
the chain anchor bolts from the carriage.
3. Disengage the lift chains at the lift chain joint links and
adjustment bolts on the mast side. Refer to the illustration of
mast assembly.
4. Removal the lift chains from the chain wheel.
LMT0077J
Installation
To install the lift chains, reverse the removal procedures.
CAUTION:
• Before installing the chain anchor bolts, ensure that the lift
chain is not twisted.
• Discard old cotter pins; replace with new ones.
Lock nut:
: 92 - 124 N•m (9.4 - 13.0 kg-m, 69 - 93 ft-lb)
Adjustment
CAUTION:
• Before adjusting lift chain tension, park the vehicle on flat
and solid ground.
• On pneumatic tire models, inflate the tires to the specified
pressure.
• As for the 3F and 3V mast, adjust the mast chain and lift
chain.
1. Set the mast assembly in the vertical position and lower the
carriage assembly all the way down.
2. Turning the adjustment nut in or out, adjust the carriage
assembly until its lower end above the ground is within
specifications.
Standard clearance:
76 mm (2.99 in)
LMT0079J
3. For the 3F and 3V mast, after the adjustment of the lift chain
mentioned above, raise the carriage gradually to adjust the
adjustment nut of the mast chain so that the difference between
the inner mast lower end and the outer mast lower end
conforms to the standard value.
Standard: 0 mm (0 in)
LMT0078J
LM-7
LIFT CHAINS
Adjustment (Cont’d)
4. With the fork assembly attached to the carriage, adjust the lift
chain adjustment nut so the midpoint of the lift chain can be
pulled (2W mast) or pressed (2F/3F/3V mast) 25 to 30 mm
(0.98 to 1.18 in). The left and right lift chains must be equally
adjusted.
CAUTION:
Check to ensure that the left and right chains are tensioned
equally.
Lock nut:
: 92 - 124 N•m (9.4 - 13 kg-m, 69 - 93 ft-lb)
5. After making the mast and lift chain tension adjustments, move
the carriage assembly up and down to ensure it moves
smoothly.
NOTE:
Every 200 hours of operation or once a month, whichever occurs
first, apply a coat of Nissan Motor Oil to the lift chains requiring
lubrication.
LMM0228
LMM0209
Inspection
• Visually inspect the lift chains for cracks, breaks or damage. If
necessary, replace the left and right lift chains as a unit.
• To check the lift chain for elongation, raise the forks approximately
20 to 30 mm (0.79 to 1.18 in) above the ground.
LM-8
LIFT CHAINS
Inspection (Cont’d)
NOTE:
• Balance the tension between left and right chains.
• Cracks or breakages often occur at the ends of the lift chains. If
necessary, replace both chains as a unit.
• Elongation often occurs in portions of the lift chain which
experiences contact with the chain wheel.
How to count number of links. 4. Apply the chain gauge and measure the chain length counting
the appropriate number of links for the chain type.
Replace the fork chain when the length exceeds the limit.
LM-9
CARRIAGE ASSEMBLY
CARRIAGE ASSEMBLY
LMM0210
Removal
NOTE:
Removal of the carriage assembly and fork assembly as a unit
prevents the carriage assembly from toppling to the ground.
1. Set the mast assembly in the vertical position, then lower the
forks to the ground.
NOTE:
When removing the carriage assembly without forks, attach a lifting
wire/nylon sling, then support the carriage assembly using a hoist or
crane.
2. Disengage the lift chains at the adjusting bolt and lift chain joint
links on the mast side, then drape the lift chains over the
backrest.
3. Slowly raise the inner mast, then remove the carriage assembly
from the mast assembly.
CAUTION:
Be careful to prevent the mast from catching the removed
lifting chain.
LMT0083J
LMT0084J
LM-10
CARRIAGE ASSEMBLY
Inspection
LIFT ROLLERS, SIDE ROLLERS AND SHIMS
Check for unsmooth rotation, deformation, stepped wear or damage.
Replace faulty parts with new ones if necessary.
CARRIAGE ASSEMBLY
• Visually check for cracks, deformation or separation at welds. If
necessary, replace with new ones.
• Check the carriage assembly using a dye penetration method. If it
is cracked, replace with a new one.
Adjustment
1. Select suitable rollers so that the clearance between the rolling
contact surface of the inner mast rail and the carriage roller are
within specifications.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes:
97.0, 97.5 and 98.0 mm (3.819, 3.839 and 3.858 in)
Center mast roller diameter (2W/2F/3F mast):
97.0 mm (3.819 in)
LMT0085J
2. Measure the inner wall width (A) of the inner mast at three
points (two at upper and lower ends of the inner mast and one
in the center of the inner mast at the cross beam location).
LMT0086J
LM-11
CARRIAGE ASSEMBLY
Adjustment (Cont’d)
LMM0211
3. Measure the pitch of the left and right carriage side rollers,
carriage rollers and thrust metals (at points “B”, “B'” and “B"”).
NOTE:
• The upper and middle carriage rollers for 2W/2F/3F mast are
used only for lift rollers. The lower carriage roller is guided and
rolls to the right and left within the rail race.
• Independent side rollers are located on the upper portion of the
carriage assembly.
4. Calculate carriage clearances by subtracting the maximum
pitch values of the carriage side rollers, carriage rollers and
thrust metals (B) from the measured minimum inner wall width
of the inner mast (A).
5. Whenever possible, use the same number of adjustment shims
to equalize left and right clearances.
Standard carriage clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available adjustment shims:
For use with carriage side rollers and thrust metals
0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)
For use with carriage rollers
0.5, 1.0 and 2.0 mm (0.020, 0.039 and 0.079 in)
CAUTION:
Be extremely careful when adjusting carriage clearances.
Improper adjustment may cause the carriage bracket to deviate
either to the left or right, or tilting of the finger. These
conditions will result in unequal heights for the left and right
forks.
LM-12
CARRIAGE ASSEMBLY
Adjustment (Cont’d)
6. After carriage clearance adjustment, check to ensure that the
carriage assembly moves smoothly without binding.
CAUTION:
Apply a coat of grease to the roller rolling contact surfaces and
thrust metal contacting surfaces (indicated by arrows in the
figure).
LMM0231
LMM0212
Installation
To install the carriage assembly, reverse the order of removal.
Observe the following:
CAUTION:
Discard old cotter pins; replace with new ones.
LM-13
MAST
MAST
Mast Assembly
2W MAST
LMM0213
LM-14
MAST
LMM0214
LM-15
MAST
LMM0215
LM-16
MAST
LMM0216
LM-17
MAST
Removal
CAUTION:
When removing the mast assembly, ensure the forks are
removed beforehand. This is a precaution to ensure the safest
possible maintenance procedure.
NOTE:
• If the carriage assembly need not be disassembled, remove the
carriage assembly together with the forks prior to removing the
mast assembly. Refer to “CARRIAGE ASSEMBLY” for
instructions.
1. Remove the hoses (lift hose, attachment hoses, etc.), then plug
their openings to prevent foreign matter from getting into the
hydraulic lines.
CAUTION:
The oil pressure remaining in hydraulic lines must be
completely bled off.
NOTE:
When removing the lift hose together with the carriage assembly,
relieve oil pressure in the hydraulic lines beforehand. Attach a lifting
LMM0232 wire or nylon sling to the carriage, then suspend it in the air with a
hoist to facilitate access to the mast assembly.
2. Attach a lifting wire or nylon sling to the upper beam of the mast
assembly, then support the mast assembly using a hoist.
CAUTION:
Be sure to support mast assembly, failure to do so may cause
serious injury or costly damage to the mast or other equipment.
LMT0094J
3. Remove the mast support cap bolts; remove the mast support
cap from the mast support, located at the frame by the inner
sides of the front tires.
LMM0233
LM-18
MAST
Removal (Cont’d)
4. Remove the pivot pin lock bolts, then remove the pivot pins
securing the tilt cylinder to the mast assembly.
5. Turn the key switch to the ON position, retract the tilt cylinder all
the way (tilting the mast assembly backward).
CAUTION:
Be sure to retract the tilt cylinder all the way, failure to do so
may interfere with the tilt bracket when installing the mast
assembly.
LMM0234
6. Using a hoist, lift the mast assembly up and away from the
vehicle, then lower it horizontally onto blocks.
CAUTION:
• Be careful not to damage brake pipes, etc. while lifting or
moving the mast assembly away from the vehicle.
• When removing the mast assembly and carriage assembly
from the vehicle as a unit, securely fasten the tilt beam and
carriage assembly (finger bar) with a rope or wire. This
prevents carriage assembly movement when mast assembly
is transferred to the ground.
LMT0097J
• Always ensure the mast assembly rests on a flat and solid
surface after it has been removed.
• When positioning the mast assembly on the block, be careful
not to damage the mast support.
7. When the mast assembly and carriage assembly are removed
as a unit, remove the carriage assembly from the mast
assembly as follows:
• Attach a lifting wire or nylon sling to the carriage assembly and lift
using a hoist.
• Disengage the lift chains at the lift joint link and adjustment bolt on
the mast side, then place the disengaged lift chains on the
carriage.
• Slide the carriage down and extract it from the lower side of the
inner mast.
CAUTION:
Do not allow the mast assembly to snag or catch the lift chain
when removing the carriage assembly from the inner mast.
Disassembly
2W MAST
1. Remove the hydraulic lines from the lift cylinders.
2. Remove the fixing nuts from the upper ends of the lift cylinders.
LMM0217
LM-19
MAST
Disassembly (Cont’d)
3. Draw out the inner masts from the upper end of the outer mast,
then remove the bolts from the lower ends of the lift cylinders
and the U-bolts. Remove the lift cylinders.
LMT0100J
LMM0235
7. Attach a lifting wire or nylon sling. Using a hoist, lift the lifting
wire or nylon sling until the inner mast is lifted free of the outer
mast.
CAUTION:
Be sure to remove the mast rollers in advance, otherwise, inner
mast cannot be removed from the outer mast with the mast
rollers installed in position.
LMT0102J
LM-20
MAST
Disassembly (Cont’d)
2F/3F/3V MAST
1. Remove the piping connected to the head block (with the chain
wheel) and full-free cylinder.
• Remove the chain wheel from the head block if necessary.
LMM0219
LMM0220
6. Slide the inner mast and middle mast (3F/3V mast) downward,
and remove the mast roller.
CAUTION:
• Do not remove the rollers of the 3F/3V mast at one time.
Remove the rollers of the inner mast first, then those of the
middle mast in this order.
• Be careful not to pinch your hand when the mast slides.
• Be careful not to pinch your hand when the roller is removed
from the mast.
LMT0100J
7. Remove the liner from the outer mast and middle mast (3F/3V
mast).
8. Pass nylon slings or wires in the mast of the inner mast first,
then the middle mast (3F/3V mast) in this order. While lifting
them by a hoist, etc., pull them upward over the outer mast.
CAUTION:
Because the inner mast and the middle mast (3F/3V mast)
cannot be pulled out if the mast roller has not been removed,
special care should be taken.
LMT0104J
LM-21
MAST
Inspection
LIFT ROLLERS
Check for unsmooth rotation, deformation, stepped wear or damage.
If necessary, replace with new ones.
LINERS
Check for wear or damage. If necessary, replace with new ones.
CHAIN WHEELS
Check for cracks or damage. If necessary, replace with new ones.
PIPING
Check for cracks, breakage or damage. If necessary, replace with a
new one.
MAST ASSEMBLY
Check for cracks, damage or breakage at welds. If necessary,
replace with new one as an assembly.
Assembly
CAUTION:
Assemble the mast assembly while adjusting various parts.
2W MAST
1. Attach a lifting wire or nylon sling to the inner mast. Using a
hoist, lift the inner mast and guide it into position for
reinstallation to the outer mast.
2. Slide the inner mast down, then install the liner and mast rollers.
CAUTION:
Be sure to install mast rollers in the correct places, since the
inner and outer mast rollers are different in diameter.
Outer mast roller diameter:
97.0 mm (3.819 in)
3. Select suitable mast rollers so the clearances between the
rolling contact surfaces of the inner mast roller and outer mast
rail are within specifications.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes:
Mast height: 3,500 or more mm (137.80 or more in):
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
Mast height: 2,700 - 3,300 mm (106.30 - 129.92 in):
105.0 mm (4.13 in)
LMT0105J • Apply a coat of grease to the rolling contact surface of the mast
rail.
CAUTION:
After adjustment, ensure that the mast assembly moves
smooth.
LM-22
MAST
Assembly (Cont’d)
4. According to the following procedures, adjust the liners.
• Using a thickness gauge, measure the inner mast-to-liner
clearance on each side.
• If the clearance is outside specifications, use the same number
and thickness of shims on each side to adjust the clearance.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available shims:
0.5 and 1.0 mm (0.020 and 0.039 in)
CAUTION:
LMT0106J
When installing the liners after making shim adjustments, apply
a coat of bearing grease to the sliding surfaces of the liners and
mast assembly.
NOTE:
The liners are push-in type for easy positioning in the mast
assembly.
<Adjustments with the mast assembly installed to the vehicle>
• For removal procedure of carriage assembly, refer to “CARRIAGE
ASSEMBLY”. For removal procedure of lift cylinder, refer to HD
section.
• Lower the inner masts approximately 120 mm (4.72 in), then
adjust the shim of liner in the same manner as previously
described.
5. To adjust the mast rollers using adjustment shims, proceed as
follows:
• Adjust the roller pitch (Dimension “L”) for the inner and outer mast
rollers according to the forklift model series, as shown in the table
below.
Unit: mm (in)
• Move the inner mast all the way to either side of the inner wall of
the outer mast.
• Using a thickness gauge, measure the clearance between the
mast and mast roller on the opposite side.
CAUTION:
The mast-to-mast roller clearance must be measured at four
points (upper, lower, left and right).
• Lower the inner mast, then measure the mast-to-mast roller
clearance at or near the center cross beam of the outer mast.
• Using the same number and type of outer mast roller adjustment
shims, equally adjust the outer mast roller-to-inner mast
clearance on the left and right sides of the mast assembly until the
LMT0108J
clearance is within specifications.
LM-23
MAST
Assembly (Cont’d)
• Using the minimum clearance value of the measurements
obtained from the upper and middle (at cross beam) portions,
select suitable inner mast roller adjustment shims. The left and
right inner mast roller clearances must be adjusted equally as
much as possible.
Standard clearance:
0.1 - 0.6 mm (0.004 - 0.024 in)
Available adjustment shims:
0.50, 1.00 and 2.00 mm (0.020, 0.039 and 0.079 in)
LMT0109J
HDM0158
9. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
with the lock nuts.
: 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
10. Fit the stopper into the hole at the end of the adjusting bolt.
11. Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and
tighten the lock nut.
: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
• When tightening the lock nut, make sure that the adjusting
nut does not turn.
LMM0218
LM-24
MAST
Assembly (Cont’d)
2F/3F/3V MAST
CAUTION:
When adjusting the 3F/3V masts, do not adjust them at one
time. Adjust the middle mast first, then the inner mast in this
order.
1. Pass nylon slings or wires in the mast of the middle mast (3F/3V
mast) first, then the inner mast in this order. While lifting them by
a hoist, insert them from over the outer mast.
2. Slide the inner mast and the middle mast (3F/3V mast) toward
the bottom of the outer mast, and install the liner, outer mast
roller, and middle mast upper roller.
CAUTION:
The roller diameters of the mast rollers differ on the inner mast
side, middle mast upper and lower sides (3F/3V mast), and
outer mast side. When installing the mast rollers, be sure to
install them in the proper positions.
Middle mast upper side roller diameter (3F/3V mast):
97.0 mm (3.819 in)
Outer mast roller diameter:
97.0 mm (3.819 in)
• As for the adjustment of other mast rollers, refer to step 4. on the
next page.
LMT0112J
LM-25
MAST
Assembly (Cont’d)
<Adjustment of the mast installed to the vehicle>
2F mast
• Hang the mast using wire, etc., and remove the carriage
assembly and lift cylinder. (As for the removal of the carriage
assembly, refer to “CARRIAGE ASSEMBLY”. As for the removal of
the lift cylinder, refer to HD section.)
• Lower the inner mast by approximately 120 mm (4.72 in), and
perform the shim adjustment mentioned above, and then replace
the liner.
3F/3V mast
• Hang the mast using a wire, etc., and remove the carriage
assembly. (Refer to “CARRIAGE ASSEMBLY”.)
• Remove the mast chain.
• Remove the mast cylinder. (Refer to HD section.)
• Lower the inner mast by approximately 120 mm (4.72 in), replace
the liner of the middle mast side, and then perform the shim
adjustment.
• Lower the inner mast and middle mast simultaneously for
approximately 120 mm (4.72 in), replace the liner of the outer
mast side, then perform the shim adjustment.
4. Install the inner mast roller, mast roller of the middle mast lower
side, and perform the shim adjustment using the following
procedure.
• Set the roller pitches (Dimension “L”) of the inner mast, middle
mast (3F/3V mast), and outer mast to the dimensions indicated in
the table according to the mast lifting height.
Unit: mm (in)
LM-26
MAST
Assembly (Cont’d)
LMM0222
CAUTION:
• For the 3F/3V mast, setting the roller pitches of the inner
mast, middle mast, and outer mast at one time may cause
instability. Adjust in two steps, first for the inner and middle
masts, then for the middle and outer masts.
• Fix the mast with a rope or a wire to prevent it from sliding.
• Select the mast rollers so that the clearances between the mast
roller of the inner mast side and the outer mast (middle mast for
3F/3V mast), and between the mast roller of the middle mast
lower side and the rail and roller sliding surface of the outer mast
(for 3F/3V mast only) conform to the standard values.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
2F mast roller types (Inner mast):
Mast height: 3,500 or more mm
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
LMT0105J Mast height: 2,700 - 3,300 mm,
105 mm (4.13 in)
3F/3V mast roller types (Middle mast lower side):
105.0, 105.5, 106.0 mm (4.13, 4.15, 4.17 in)
3F/3V mast roller types (Inner mast):
97.0, 97.5, 98.0 mm (3.82, 3.84, 3.86 in)
• Place the inner mast or the middle mast (for 3F/3V mast only) to
the end of the side, and measure the clearance between the mast
and the mast roller of the reverse side using a thickness gauge.
CAUTION:
Perform measurement for the mast rollers at four points: upper,
lower, right, and left sides (eight points for 3F/3V mast).
• Adjust the shim of the mast roller to the right and left as equally as
possible, so that the closest clearance between the mast roller of
the outer mast side and inner mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast upper side
LMT0108J
and the inner mast (for 3F/3V mast only) conform to the standard
values.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in)
LM-27
MAST
Assembly (Cont’d)
• Adjust the shim of the mast roller to the right and left as evenly as
possible, so that the closest clearance between the mast roller of
the inner mast side and outer mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast lower side
and the outer mast (for 3F/3V mast only) conform to the standard
valves.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0, 2.0 mm (0.020, 0.039, 0.079 in)
LMT0109J
LMM0231
LMM0212
5. Set the mast cylinder to the hole of the lower beam on the outer
mast, and set the piston rod to the cylinder setting bracket on
the inner mast. Tighten the mounting bolts at the upper and
lower ends of the cylinder.
Cylinder upper end:
: 78 - 98 N•m (7.9 - 10.0 kg-m, 58 - 72 ft-lb)
Cylinder lower end:
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
6. Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
with the lock nuts.
: 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
7. Fit the stopper into the hole at the end of the adjusting bolt.
LMM0218
LM-28
MAST
Assembly (Cont’d)
8. Tighten the adjusting bolt, and check that the stopper contacts
with the cylinder. Then, further tighten for 1/2 to 1 turn and
tighten the lock nut.
: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
• When tightening the lock nut, make sure that the adjusting
nut does not turn.
9. Install the piping to the mast cylinder.
10. Install the chain wheel and mast chain (3F/3V mast).
LMM0226
11. Install the full-free cylinder. At this time, perform the shim
adjustment so that the inner mast and full-free cylinder become
parallel (2F/3F mast).
Shim: 1.0 mm (0.039 in)
: 128 - 156 N•m (13 - 16 kg-m, 94 - 115 ft-lb)
LMT0119J
HDM0163
12. Install the piping of the head block (with the chain wheel) and
full-free cylinder.
13. When the mast assembly is removed with the carriage
mounted, adjust the lift roller of the carriage, lift the carriage
assembly by a nylon sling or wire, then install to the inner mast.
(As for the adjustment of the lift roller, refer to “CARRIAGE
ASSEMBLY”.)
14. Pass the lift chain in the chain wheel, connect the adjusting bolt
to the chain joint linking section, and then install it to the full-free
cylinder.
CAUTION:
Replace the cotter pin with a new one.
Installation
1. Attach a lifting wire or nylon sling to the mast assembly, then lift
the mast assembly using a hoist.
CAUTION:
• Before lifting the mast assembly (if equipped with the
carriage assembly), lower the carriage assembly all the way
down. Securely fasten the carriage finger bar to the tilt beam.
• Make sure the lift chains are placed on the chain wheels.
• Make sure the lift chains are not twisted.
LM-29
MAST
Installation (Cont’d)
2. Apply a coat of multi-purpose grease to the mast mounting
shafts. Then install the bushings.
3. Apply a coat of multi-purpose grease to the outer walls of the
bushings. Place the mast mounting shaft onto the mast support
at the frame, then install the mast support caps.
: 89 - 118 N•m (9.1 - 12.0 kg-m, 66 - 87 ft-lb)
4. Turn the key switch to the ON position. Extend the tilt cylinder
using the tilt lever until the pivot pin holes in the tilt cylinders and
mast are aligned. Insert the pivot pins into the holes, then
secure with the bolts.
LMM0237 : 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
CAUTION:
Be careful not to catch your hands by the tilt cylinder and mast
assembly when the tilt lever is operated.
5. Install the lift hoses to their connections.
CAUTION:
Ensure that the lift hoses shall not be twisted during
installation.
6. Apply a coat of multi-purpose grease to the mast supports and
tilt cylinder pivot pins.
7. Lift and tilt the mast assembly several times. Check that no oil
leaks occur at or around the hydraulic lines, and that the mast
assembly operates smoothly without binding.
8. Check the lift chains for proper tension. If necessary, adjust the
chain tension. For chain tension adjustments, refer to “LIFT
CHAINS”.
LMM0223
Adjustment
ADJUSTING OF CYLINDER HEIGHT
NOTE:
To prevent mast from being twisted and deformed, adjust the
cylinder height. Be sure to adjust when reassembling the mast
assembly, especially when replacing only one cylinder.
1. Check that forklift is placed horizontally.
2. Remove upper mounting nuts/bolts of right and left cylinder.
3. Slowly raise mast without load, and then check that right and
left cylinders reach to their stroke end simultaneously.
4. If one cylinder is delayed, adjust delayed cylinder by inserting
shims.
Thickness of shim: 1.0 mm (0.039 in)
5. Repeat the adjustment above until there is no difference
between the right and left cylinders.
6. Ensure that the top of the cylinders are set firmly to the bracket
HDM0158 on the inner (middle) mast, and secure by tightening the
mounting bolts.
Apply Thread Lock to the threads of cylinder mounting bolts.
(2W mast only)
: 78 - 98 N•m (7.9 - 10.0 kg-m, 58 - 72 ft-lb)
LM-30
MAST
Adjustment (Cont’d)
MAST TILT ANGLE ADJUSTMENT
1. Park the vehicle on flat and solid ground.
2. Tilt the mast assembly all the way forward, then check the left
and right sides of the mast assembly to ensure that the forward
tilt angle is within specifications.
Forward/Backward
2W, 2F 4°/6°
3F, 3V 5°/5°
LMM0225
3. Loosen the lock nuts and turn the tilt cylinder rods using a
wrench until their stroke lengths are within specifications.
CAUTION:
• Adjust the piston rod stroke lengths so the lengths of the
piston rod thread portions do not exceed.
• Adjust the piston stroke lengths so that the tilt angle of the
left and right masts are identical.
• Tilt the mast assembly forward and backward. If the left and
right masts are improperly adjusted, make fine adjustments
of the tilt cylinder stroke lengths as required.
LMT0123J
•NOTE:
The backward tilt angle of the mast is automatically set by adjusting
the forward tilt angle.
4. After adjusting the forward-backward tilt angle of the mast
assembly, tighten the lock nuts on the tilt cylinders.
: 108 - 147 N•m (11 - 15 kg-m, 80 - 108 ft-lb)
5. Paint alignment marks on mating areas between the tilt cylinder
rod and rod head, and the rod head and lock nut.
6. Operate the mast assembly several times to ensure that it
moves smoothly without binding.
LMT0124J
Mast bushing
MAST BUSHING GREASING
• Jack the mast slightly to make sure the grease will go all
around the mast pin.
• Add grease until the new grease comes out all around the
mast pin.
• Clean the exceeding grease.
CHECKING WEAR
LMM0223
To check the wear of the mast bushing, measure the thickness of the
bushing in different places. If the wear limit is reached at one of the
places, replace the bushing.
Wear limit is: 3.38mm (0.133in)
LM-31
MEMO
LM-32
BODY & FRAME
SECTION BF
CONTENTS
SERVICE DATA AND SPECIFICATIONS ......... BF-2 Floor Board and Mat ....................................... BF-6
General Specifications .................................. BF-2 Overhead Guard and Rearview Mirror ........... BF-7
Tightening Torque ......................................... BF-3 Seat and Top Panel ....................................... BF-8
PRECAUTIONS AND PREPARATION ............. BF-4 Panels and Counterweight ........................... BF-10
Precautions ................................................... BF-4
BODY AND FRAME ........................................... BF-5
Instrument Covers ......................................... BF-5
SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS
General Specifications
COUNTERWEIGHT
Applied model
Identifica Weight kg
(A)S1N1 (A)1N1 (A)G1N1
tion mark (lb)
13 15 15 18 16 18 20
820 (1808)
H – – – – –
MH
659 (1453) – – – – – –
(A1N1)
M 630 (1389) – – – –
L 520 (1147) – – – – –
BFM0031
Applied model
Identifi-
Weight kg
cation J(A)G1N1
(lb)
mark
16 18 20
L 520 (1147) – –
M 600 (1323) – –
H 730 (1609) – –
BFM0801EU
BF-2
SERVICE DATA AND SPECIFICATIONS
Tightening Torque
Unit N•m kg-m ft-lb
Instrument covers bolt 1.5 – 2.0 0.16 – 0.20 1.1 – 1.4
Floor board, FR bolt 5.0 – 6.0 0.51 – 0.61 3.7 – 4.4
Instrument frame bolt 93 – 108 9.5 – 11 69 – 79
Rear pillar bolt 137 – 196 14 – 20 101 – 144
Overhead guard bolt 78 – 98 7.9 – 10 58 – 72
Rearview mirror 13 – 15 1.3 – 1.6 10 – 11
Top panel hinge bolt (Pillar side) 56 – 64 5.7 – 6.6 42 – 47
Top panel hinge bolt (Top panel side) 9.3 – 10 0.95 – 1.1 6.9 – 7.3
Gas stay bolt 9.3 – 10 0.95 – 1.1 6.9 – 7.3
Side panel bracket bolt 16 – 17 1.6 – 1.8 11.8 – 12.5
Counterweight bolt 490 – 620 50 – 63 362 – 457
BF-3
PRECAUTIONS AND PREPARATION
PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Use a hoist and lifting wire/nylon sling which is capable of
sufficiently withstanding the weight of objects being
handled.
• When disassembling or servicing units or parts of a vehicle,
park it on a solid and level ground and chock the wheels.
Failure to do so may cause the vehicle to move unexpectedly.
Also, be sure to disconnect battery plug in advance.
• Always assign lifting operations to qualified operators
trained in slinging or hoisting procedures.
• Turn the key switch to OFF and disconnect the battery cables
before removing the components.
NOTE:
• For battery removal and installation procedures, refer to BC
section.
• For pedal bracket removal and installation procedures, refer to BR
section.
• For steering system and rear axle removal and installation
procedures, refer to ST section.
• For reduction gear removal and installation procedures, refer to
DU section.
• For front and rear tires removal and installation procedures, refer
to TR section.
• For removal and installation of traction motor and oil pump motor,
refer to MM section.
• For mast assembly removal and installation procedures, refer to
LM section.
• For hydraulic system removal and installation procedures, refer to
HD section.
• For electrical system removal and installation procedures, refer to
EL section.
BF-4
BODY AND FRAME
BODY AND FRAME
Instrument Covers
BFM0032
BF-5
BODY AND FRAME
BFM0033
BF-6
BODY AND FRAME
BFM0034
CAUTION:
Be sure to attach the lifting wire / nylon sling so as not to allow
it to slide off the overhead guard.
BF-7
BODY AND FRAME
BFM0035
CAUTION:
• Be careful not to drop the operator’s seat during removal.
• Have someone assist in removal of the battery hood.
• When opening or closing the battery hood, be careful not to
catch your hands or fingers between the battery hood and
the case.
1. Release the lock lever on the console box and tilt the console
box forward (if equipped with the mechanical control type).
2. Unlock the top panel latch.
BFM0036
BF-8
BODY AND FRAME
CAUTION:
Since the top panel is heavy, exercise caution in handling it.
4. While pressing down the gas stay lock button, close the top
panel.
CAUTION:
BFM0037 Since the top panel is heavy, exercise caution in handling it.
WARNING:
• Close the top panel slowly, keeping a firm hold on the handle.
Never place your hand under the top panel. This is very
dangerous.
• Make sure that the top panel latch is securely locked.
BFM0038
BF-9
BODY AND FRAME
BFM0039
BF-10
BODY AND FRAME
BF-11
MEMO
BF-12
OPTION
SECTION OP
CONTENTS
OPTION .............................................................. OP-2 Cabin Option
Cabin Option Location of Electrical Component Parts ........ OP-5
Assembly of Front Window and Door ............ OP-2 Cabin Option
Cabin Option Outline ........................................................... OP-6
Assembly of Rear Window ............................ OP-3 Cabin Option
Cabin Option Cabin Harness Layout ................................... OP-7
Location of Electrical Component Parts
(3 - wheel) ..................................................... OP-4
Location of Electrical Component Parts
(4 - wheel) ..................................................... OP-4
OPTION
OPTION
Cabin Option
Assembly of Front Window and Door
Bracket frame upper
Grommet
Front window
Panoramic mirror
Self-tapping screws
1.3-1.4
(0.13-0.14, 0.94-1.01)
Room light
Bulb
9.3-10
(0.95-1.1, 6.9-7.3)
9.3-10
(0.95-1.1, 6.9-7.3)
78-98
(7.9-10, 58-72) Bracket frame lower
9.3-10
Bracket gas stay (0.95-1.1, 6.9-7.3)
Gas stay
Striker
Protrusion rod
Handle rod
9.3-10
Shim (0.95-1.1, 6.9-7.3)
9.3-10
(0.95-1.1, 6.9-7.3)
Door assembly
OP-2
OPTION
Cabin Option
Assembly of Rear Window
9.3-10
(0.95-1.1, 6.9-7.3)
Patrol lamp
19-21
(2.0-2.1, 14-15) Insulator upper, RH
Grommet
9.3-10
Insulator upper, LH (0.95-1.1, 6.9-7.3)
Door assembly-
back, outer
Insulator lower, RH
Insulator lower, LH
Sheetmetal back, lower
OPM0002
OP-3
OPTION
Cabin Option
Location of Electrical Component Parts (3 - wheel)
Patrol lamp
Wiper motor rear(STD: Except for
NORTH AMERICA)
(OPT: For NORTH AMERICA)
Controller
Fusible link
DC - DC converter (OPT)
Back buzzer Contactor ASSY
OPM0003
OPM0801EU
OP-4
OPTION
Cabin Option
Location of Electrical Component Parts
OPM0004EU
OP-5
OPTION
Cabin Option
Outline
ELM0252EU
OP-6
OPTION
Cabin Option
Cabin Harness Layout
: To FR wiper (E)
: To FR wiper (+)
: To connector for extra options
: To body harness connector B14
: To cabin relay
: To cabin relay
: To diode (cabin)
: To D/C D/C converter (output)
: To D/C D/C converter (input)
: To RR wiper (E)
: To R/R wiper (+)
Front
OPM0005
OP-7
MEMO
OP-8
ELECTRICAL SYSTEM
1N1 SECTION EL
CONTENTS
PRECAUTIONS ................................................. EL-2 SWITCHES ....................................................... EL-19
Precautions .................................................... EL-2 Key Switch ................................................... EL-19
LOCATION OF ELECTRICAL UNITS ............... EL-3 Battery Switch .............................................. EL-19
Electrical Component Parts (3 - wheel) .......... EL-3 Combination Switch ..................................... EL-20
Electrical Component Parts (4 - wheel) .......... EL-3 Back Operation Lamp Switch (Option) ......... EL-21
HARNESS LAYOUT .......................................... EL-5 Seat Switch .................................................. EL-21
Outline ............................................................ EL-5 Seat Belt Switch ........................................... EL-22
Body Harness for Mechanical Control System . EL- Parking Brake Switch ................................... EL-22
6 MISCELLANEOUS ELECTRICAL PARTS ...... EL-23
Body Harness for Joystick Control System .... EL-9 Horn Switch .................................................. EL-23
Tail Harness ................................................. EL-12 Horn Relay ................................................... EL-23
Guard Harness ............................................. EL-12 Tail Lamp, Auto Power Off, Battery Switch,
Hydraulic Control Valve Switch Harness for Joystick Control System Relay ..................... EL-24
Mechanical Control System .......................... EL-13 Horn ............................................................. EL-24
Sub-harness for Joystick Control System Warning Buzzer ............................................ EL-25
(Option) ........................................................ EL-13 Back Buzzer ................................................. EL-25
FUSES ............................................................. EL-14 BATTERY CABLES AND MOTOR CABLES ... EL-26
Fuse and Fuse Box ...................................... EL-14 Battery Cables and Moter Cables ................ EL-26
Fusible Link .................................................. EL-15 LOCATION OF OPTIONAL PARTS ................. EL-28
LIGHTING SYSTEM ........................................ EL-16 Earth Band ................................................... EL-28
Lamps ........................................................... EL-16
Headlamp ..................................................... EL-17
Back operation lamp (Option) ....................... EL-17
Patrol lamp (Option) ..................................... EL-18
Bulletin issued:
Service Bulletins Issue date
SB-TX-EL-0701-02 RPM sensor error with new motor 12-112007
PRECAUTIONS
PRECAUTIONS
Precautions
CAUTION:
• When performing removal and installation procedures, be
sure to turn key switch to OFF and disconnect battery plug.
• When replacing a fuse or a bulb for accessories, alway use
one of specified capacity.
EL-2
LOCATION OF ELECTRICAL UNITS
LOCATION OF ELECTRICAL UNITS
ELM0250EU
ELM0801EU
EL-3
LOCATION OF ELECTRICAL UNITS
ELM0251EU
EL-4
HARNESS LAYOUT
HARNESS LAYOUT
Outline
ELM0252EU
EL-5
HARNESS LAYOUT
ELM0253
*: For EUROPE only
**: Except for NORTH AMERICA
EL-6
HARNESS LAYOUT
ELM0254
***: For NORTH AMERICA only
EL-7
HARNESS LAYOUT
B10 : To brake fluid level switch B49 : To revolution sensor (Pump motor)
B11 : To brake fluid level switch B50 : To revolution sensor (Shield earth)
B12 : To lighting and turn signal lamp switch B51 : To revolution sensor (Shield earth)
B14 : To cabin harness (Option) B53 : To PS correction solenoid (Except for NORTH AMERICA)
B32 : To electrical horn (For NORTH AMERICA) B71 : To patrol lamp (Option)(Except for NORTH AMERICA)
B33 : To electrical horn (For NORTH AMERICA) B72 : To patrol lamp (Option)(Except for NORTH AMERICA)
EL-8
HARNESS LAYOUT
ELM0255
EL-9
HARNESS LAYOUT
ELM0256
***: For NORTH AMERICA only
EL-10
HARNESS LAYOUT
EL-11
HARNESS LAYOUT
Tail Harness
ELM0257
Guard Harness
ELM0258
EL-12
HARNESS LAYOUT
ELM0259
ELM0260
EL-13
FUSES
FUSES
ELM0261
INSTALLATION
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in
reverse order of removal.
NOTE:
• When removing fuse box, remove fuse box cover. Insert a small
screwdriver into hook to unlock, then remove fuse box from
bracket.
• When installing fuse box, insert part to be fitted into bracket and
securely lock with hook.
EL-14
FUSES
6 5 Option
7 5 Meter
Fusible Link
INSPECTION
Check for blown fusible link using circuit tester.
CAUTION:
If fusible link is blown, replace with a new one of specified
capacity. Also, check related electrical parts to determine the
cause of problem, and repair if necessary.
ELM0263
EL-15
LIGHTING SYSTEM
LIGHTING SYSTEM
Lamps
REMOVAL AND INSTALLATION.
ELM0265
EL-16
LIGHTING SYSTEM
Lamps (Cont’d)
SPECIFICATIONS
Headlamp 25 25 2
Front turn signal lamp 25 25 2
Stop/tail 25/10 25/10 2/2
Rear combination
Turn 25 25 2
lamp
Reverse 10 8 2
Back operation lamp (option) 25 25 1
CAUTION:
In checking, make sure that resistance between connector
terminal and case/screw is 100 kor more using circuit tester.
Headlamp
CAUTION:
Install lens with water-drain hole facing down.
ADJUSTMENT
Adjust headlamp aim so that axis of light is 6 degrees below
horizontal line.
CAUTION:
• Place vehicle and tester on the same horizontal plane.
• Keep all tires inflated to correct pressure.
ELM0266
EL-17
LIGHTING SYSTEM
ELM0267
EL-18
SWITCHES
SWITCHES
Key Switch
REMOVAL
1. Disconnect harness connector.
2. Remove ring nut and remove key switch from rear cover.
INSTALLATION
Install key switch in reverse order of removal.
ELM0268
INSPECTION
Check continuity between terminals using circuit tester ( range).
Switch position
Terminal Remarks
OFF ON RE-START
1 To fuse
2 From fuse
3
4 Re-start
ELM0269
Battery Switch
CAUTION:
Remove battery switch after turning off key switch,
disconnecting battery plug and making battery switch off
(pushed state).
INSPECTION
Check continuity between terminals using circuit tester ( range).
Switch condition
Terminal
ELM0270 Pulled Pushed
For battery cables Continuity
ELM0271
EL-19
SWITCHES
Combination Switch
ELM0272
DESCRIPTION
• The turn signals and forward-reverse switches were integrated
into a single unit. Also, a lighting switch structure was adopted.
• An auto return function was adopted for the turn signal lever.
• Turn signal switch is installed left side for joystick control system
(option) vehicle.
NOTE:
Please refer to control system (CS) section for forward-reverse
switch (lever) and steering angle sensor.
ELM0273
Lighting switch
ELM0274
INSPECTION
Check continuity between terminals using circuit tester ( range).
T-1
T-2
T-3
ELM0275
EL-20
SWITCHES
L-1
L-2
L-3
Switch OFF
Switch ON
BET0141L
ELM0277
Seat Switch
INSPECTION
Check continuity.
When sitting on the seat: Continuity should exist.
When not sitting on the seat: Continuity should not exist.
VCT0023L
EL-21
SWITCHES
INSPECTION
Check continuity.
When insert buckle: Continuity should exist.
When disconnect buckle: Continuity should not exist.
VCT0031L
INSPECTION
Check continuity between terminals using circuit tester ( range).
1
VCT0037L
2
3
EL-22
MISCELLANEOUS ELECTRICAL PARTS
MISCELLANEOUS ELECTRICAL PARTS
Horn Switch
INSPECTION
• Check horn sound by pushing horn switch while turning steering
wheel from lock to lock.
• Remove steering wheel (Refer to ST section) and visually check
horn brush for wear or damage.
Horn Relay
SPECIFICATIONS
ELM0276
INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals and
using circuit tester ( range) while applying or releasing battery
voltage to/from coil side terminals and .
ELM0278
EL-23
MISCELLANEOUS ELECTRICAL PARTS
ELM0279
INSPECTION
• Check for broken coil using circuit tester.
• Check continuity between contacting side terminals using circuit
tester ( range) while applying or releasing battery voltage to/
from coil side terminals.
Terminal
Coil - Continuity
Contacting point - Continuity
ELM0280
Horn
SPECIFICATIONS
Horn
ELM0281
EL-24
MISCELLANEOUS ELECTRICAL PARTS
Warning Buzzer
SPECIFICATIONS
Warning buzzer
ELM0282
INSPECTION
A warning buzzer sounds when the driver stands up from the seat
without applying the parking brake.
– –
– –
ON
– –
– –
–
– –
OFF
– –
– –
• 3-second delay is implemented for detection of unseated status.
Back Buzzer
SPECIFICATIONS
Back buzzer
ELM0283
EL-25
BATTERY CABLES AND MOTOR CABLES
BATTERY CABLES AND MOTOR CABLES
ELM0287
EL-26
BATTERY CABLES AND MOTOR CABLES
ELM0289
EL-27
LOCATION OF OPTIONAL PARTS
LOCATION OF OPTIONAL PARTS
Earth Band
DESCRIPTION
For normal tires (black tires), the carbon is contained as a material.
Therefore, if the vehicle is charged with electricity, it will be
discharged from the tires.
For non-marking tires (colored tires), the carbon is not contained as
a material. Therefore, if the vehicle is charged with electricity, it
cannot be discharged.
The circuit board, element, or parts may be damaged by this
electrification.
To prevent this damage, install the earth band to the vehicle and
discharge the static electricity from the vehicle.
ELM0284
WIRING DIAGRAM
WIRING DIAGRAM
CIRCUIT DIAGRAM
EL-28
B
JOYSTICK CONTROLLER
1N1 -series CABIN ASSY
(OPTION FOR T'
RELAY (OPTION)
EUROPE ONLY)
Fingertip / mechanical controlled
JOYSTICK CONTROLLER (OPTION)
From serial number to serial
G1N1-721551 => G1N1-722977
1N1-721779 => 1N1-723538
S1N1-720481 => S1N1-721094
SEAT BELT SW SEAT BELT SW
688
L/GY
608 630 626 636 609 680 682 688 690 691
JOYSTICK CONTROL
SYSTEM (OPTION)
HARN-SUB HARN-SUB
PS CORRECTION
682
687
682
HARN-SUB HARN-SUB
W B 679
PUMP CONTROLLER
LIGHT SW
1 4 8 11 23 26 30 33 36 39 42 53 56 59 62 65 76 79 82 85 88 90 102 104 107
2 5 7 9 12 14 16 18 21 19
24 27 29 31 34 37 40 43 44 46 48 50 52 54 57 60 63 66 68 69 71 73 75 77 80 83 86 89 91 93 95 97 98 100 103 105 108
3 6 10 13 15 17 20 22 25 28 32 35 38 41 45 47 49 51 55 58 61 64 67 70 72 74 78 81 84 87 92 94 96 99 101 106 108
5
6 1
2
4
5
7
8
10 12 14 16 22 19 25 28 31 34 36 38 40 43 46
11 13 15 17 20 23 26 29 32 35 37 39 41 44 47
3 6 9 18 21 24 27 30 33 42 45 48
7 B
8 145 151 T' Vehicle side
B P
Combination meter
1 BATTERY VOLTAGE 11 POWER GND
151
2 BATTERY POWER + 12 NOT USED
145
PATROL LAMP 20 19 18 17 16 15 14 13 12 11
(OPTION) 10 9 8 7 6 5 4 3 2 1
Meter side
687
P S C OR R E C T ION
682
687
LIF T VALVE AS S Y
682
HAR N-S UB HAR N-S UB
680
P /M T E MP S E NS OR
P /M R E V S E NS OR
R H T /M T E MP S E NS OR
R H T /M R E V S E NS OR
R H T /M R E V S E NS OR
R H T /M T E MP S E NS OR
P /M R E V S E NS OR
671
P /M T E MP S E NS OR
670
P UMP C ONT R OLLE R
443
146
669 442 665 160
156
664
678
679
676
146 159
677
LIG HT S W
1 4 8 11 23 26 30 33 36 39 42 53 56 59 62 65 76 79 82 85 88 90 102 104 107
2 5 7 9 12 14 16 18 19 21 24 27 29 31 34 37 40 43 44 46 48 50 52 54 57 60 63 66 68 69 71 73 75 77 80 83 86 89 91 93 95 97 98 100 103 105 108
3 6 10 13 15 17 20 22 25 28 32 35 38 41 45 47 49 51 55 58 61 64 67 70 72 74 78 81 84 87 92 94 96 99 101 106 108
1 4 7 10 12 14 16 19 22 25 28 31 34 36 38 40 43 46
2 5 8 11 13 15 17 20 23 26 29 32 35 37 39 41 44 47
3 6 9 18 21 24 27 30 33 42 45 48
B
T' Vehicle s ide
C ombination meter
1 B AT T E R Y VOLTAG E 11 P OWE R G ND
2 B AT T E R Y P OWE R + 12 NOT US E D
LH T /M T E MP S E NS OR
3 NOT US E D 13 OP T R E LAY 2
LH T /M R E V S E NS OR
4 B R AK E F LUID LE V E L S W 14 OP T R E LAY 1
5 S E AT B E LT S W 15 WAR NING B UZZE R DR IV E R E LAY
6 PAR K ING B K K E Y INP UT 16 NOT US E D
7 NOT US E D 17 NOT US E D
8 NOT US E D 18 NOT US E D
9 PAR K ING B R AK E S W R E LE AS E 19 C ONT. TO ME T E R C OMMUNIC AT ION DATA
LH T /M R E V S E NS OR
LH T /M T E MP S E NS OR
PAT R OL LAMP 20 19 18 17 16 15 14 13 12 11
(OP T ION) 10 9 8 7 6 5 4 3 2 1
Meter s ide
E L M0285
540 541
000 101
542 543
000 102
900
910
129
128
280 281
101
280 281
127
126
671
670
761 661 661
670
763 663
762 662 662
979 979 671
660
664
740
SEAT
BELT
SW LIFT SOL. VALVE
380 480 311
722 722 732
380
381
746
GND
GND
POWER
POWER
746 733
EMG
RELAY
134 133 132 450 253 412 411 254 911 140 142 144 146 913 148 150 912 141 143 145 147 914 149 151 152 915 153 916 917 154 155 156 157 918 158 159 160 919 603 605 607 609 611 613 720 745 731
120 100
140 142 144 146 148 150 141 143 145 147 149 151 152 915 153 916 154 155 156 157 158 159 160 919
POWER
POWER
GND
GND
137 600
604 136 JOYSTICK CONT. 500 505 510 000 255
RELAY
601 135
608 631 520 505
680 680
501 506 511 000
681 681
608
682 682 954
410 221 442 405 465 409 220 441 404 464 212 213 969 241 361
686 624 624 625
PATROL BACK
431 LAMP OPERA- 687 687
(OPTION) TION
LAMP 688 688 634 634 635
125 727 (OPTION)
903
ELM0286
ELM0285 - WIRING DIAGRAM 2005-2006 MODELS
ne00479 Pagina 1 10-4-2008
Service Bulletin
Issue : SB-TX-CS-0501(Revision 2)
Date : January 2006
Model : TX
Subject : Prevention to damage Main Print Controller Board (PCB)
Caution:
Please turn key switch off and disconnect the battery plug before:
1. Removing or inserting main print board and/or meter panel connectors
2. If you need to disconnect the harness or you need to replace a light bulb
3. Installing electrical equipment
Failing to do so will result to damage the PCB.
Do not connect the battery plug, while connectors or fusible links are disconnected, doing
so will result to damage the PCB.
Error codes:
444 or 558 will normally appear after incorrect procedure.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-CS0601
Date : 05 May 2006
Model : TX
Subject : Power mode indication scrolling on meter panel
Introduction:
NFE has been made aware that you can create a scrolling power mode symbol on the meter
panel by pushing the function keys. As a result the modes can not be changed.
Outline:
Investigation learned that this scrolling of the power mode symbol sometimes occurs if the
key switch is on and you push the function keys FN1+FN3 simultaneously and keeping
them pushed for several seconds.
This scrolling of the power mode makes it impossible to change the power mode.
To stop the scrolling, the key switch should be switched off and on again.
The scrolling is caused by a software bug but does not influence the operation of the truck
or cause damage in the control system.
Modification:
The software will be changed in the next software release.
We advise not to change the meter panel or main PCB.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-CS0602
Date : 05 May 2006
Model : TX
Subject : Error code 558 occur with FN1+FN3
Introduction:
NFE has been made aware that you can create the error code 558 using the function keys.
Outline:
Investigation learned that sometimes an error code 558 “Meter panel communication error”
occurs if the key switch is on and pushing the function keys FN1+FN3 and keeping them
pushed for several seconds.
This error only disappears if you switch off and on the key switch.
The error itself is caused by a software bug but does not cause damage in the control
system.
Modification:
The software will be changed in the next software release.
We advise not to change the meter panel or main PCB.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-CS-0702
Date : October 2007
Model(s) : TX
Subject : Incorrect measurement with damaged controller
insulation
Outline:
It has come to our attention incorrect values can be read when measuring Drive FET board
(RH and LH) still installed on the truck. Cause of this problem is damaged insulation. The
insulation prohibits the Drive FET boards from making contact with the under laying frame.
Damaged insulation can result in a wrong diagnose.
(7): Insulator
To make sure there is no contact between Drive FET board and frame, perform an insulation
test.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
SB-TX-CS-0702 Incorrect measurement with damaged controller insulation.doc
Page 1 of 2 10/04/2008
ne00479 Pagina 2 10-4-2008
Service Bulletin
Issue : SB-TX-CS-0702
Date : October 2007
Insulation Test:
To make sure the insulation is not damaged; the following test has to be carried out before
proceeding Drive FET board test.
Frame
• For checking each Drive FET board, use circuit tester and measure resistance
between terminals listed in the table. There should be no continuity.
• The following table list resistance values measured across respective terminals (ref.
CS-49) and frame. Values are the same for both analog and digital tester.
Resistance
D1 ∞
S1D2 ∞
S2 FRAME ∞
G1 ∞
G2 ∞
• Above table is for checking 1 phase. Repeat the test for the other 2 phases. Perform
the test for both LH and RH FET board.
NOTE:
Disassembled FET boards need also to be tested on a non conductive surface, to avoid
similar problems.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
SB-TX-CS-0702 Incorrect measurement with damaged controller insulation.doc
Page 2 of 2 10/04/2008
Error code 406 “Contr. capacitor”
diagnostic procedure.
Issue : SB-TX-CS-0804-01
Date : October 2008
Instruction:
First make sure nothing is plugged between the main contactor and the controller,
such as lights, patrol light or any added device, since this can alter the
measurement of the tension of the capacitor.
Test procedure for error code 406 to check if main PCB is defect or
Mosfet/capacitor.
Measure
resistance
between
terminals
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-CS-0804-01
Date : October 2008
If this circuit tester is showing a gradually increasing resistance, the capacitors are
in good condition as the capacitor is charged.
The Mofset have to be checked following the procedure describe in the Service
manual page CS-48 and CS-49
The inverter and the PCB print board have to be visually checked for over heated
components.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-CS-0804-01
Date : October 2008
NOTE: It is important that nothing is plugged between the main contactor and the
controller because this may cause wrong measurement of the capacitor tension,
which will trigger a 406 error code
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Model :1N1
Issue : SB-TX-CS-1001
Date : January 2010 SERVICE
BULLETIN
Introduction:
This bulletin provides instruction on how to test the Drive mosfet (FET) boards and pump
mosfet (FET) modules.
The instructions in this bulletin do not replace the instructions from service manual, but are
to be followed in addition to the instructions from CS section and can be used when
resistance values seem to be OK, however the mosfet is suspected to be faulty.
Instruction:
When testing the mosfet Boards and modules please follow the steps describes in the
following pages.
THESE TESTS WERE VERIFIED WITH THE USE OF A DIGITAL METER IN THE
DIODE TEST MODE, USE OF AN ANALOG METER WILL PROVIDE INCORRECT
TEST VALUES.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
D1 +
STEP 5 OL
D2S1 -
D2S1 +
STEP 6 OL
S2 -
STEP 7
G2 SENSE + OL
S2 -
NOTE: STEP 8 MUST BE PERFORMED WITHIN 15 SECONDS OF STEP 7
STEP 8
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 8 FAILS VERIFY STEP 7 IS CORRECT AND RE TEST
STEP 9 S2 + OL
G2 SENSE -
STEP 10 D2S1 + OL
S2 -
STEP 11
D2S1 + CONTINUITY
S1 SENSE -
STEP 12
S2 + CONTINUITY
S2 SENSE -
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
SB-TX-CS-2010
FET BOARDS AND MODULES
Page 3 of 9
D1 +
STEP 3
D2S1 - CONTINUITY
STEP 4
D1 + OL
U PHASE
G1 SENSE -
STEP 5
D1 + OL
D2S1 -
STEP 6
D1 + CONTINUITY
D1 SENSE -
STEP 7
D2S1 + CONTINUITY
S1 SENSE -
STEP 8
D2S1 + OL
S2 -
STEP 9
G2 SENSE + OL
S2 -
NOTE: STEP 10 MUST BE PERFORMED WITHIN 10 SECONDS OF STEP 9
STEP 10
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 10 FAILS VERIFY STEP 9 IS CORRECT IS CORRECT AND RETEST
STEP 11
S2 + OL
G2 SENSE -
STEP 12
D2S1 + OL
S2 -
STEP 13
D2S1 + CONTINUITY
D2 SENSE -
S2 +
STEP 14
S2 SENSE - CONTINUITY
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
SB-TX-CS-2010
FET BOARDS AND MODULES
Page 5 of 9
STEP 3
D1 + CONTINUITY
D2S1 -
NOTE: IF STEP 3 FAILS VERIFY STEP 2 IS CORRECT IS CORRECT AND RETEST
STEP 4
D1 + OL
G1 SENSE -
V PHASE
STEP 5
D1 + OL
D2S1 -
STEP 6
D1 + CONTINUITY
D1 SENSE -
STEP 7
D2S1 + CONTINUITY
S1 SENSE -
STEP 8
D2S1 + OL
S2 -
STEP 9
G2 SENSE + OL
S2 -
NOTE: STEP 10 MUST BE PERFORMED WITHIN 10 SECONDS OF STEP 9
STEP 10
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 10 FAILS VERIFY STEP 9 IS CORRECT IS CORRECT AND RETEST
STEP 11
S2 + OL
G2 SENSE -
STEP 12
D2S1 + OL
S2 -
STEP 13
D2S1 + CONTINUITY
D2 SENSE -
STEP 14
S2 + CONTINUITY
S2 SENSE -
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
SB-TX-CS-2010
FET BOARDS AND MODULES
Page 6 of 9
STEP 3
D1 + CONTINUITY
D2S1 -
NOTE: IF STEP 3 FAILS VERIFY STEP 2 IS CORRECT IS CORRECT AND RETEST
STEP 4
D1 + OL
W PHASE
G1 SENSE -
STEP 5
D1 + OL
D2S1 -
STEP 6 D1 + CONTINUITY
D1 SENSE -
STEP 7
D2S1 + CONTINUITY
S1 SENSE -
STEP 8
D2S1 + OL
S2 -
STEP 9
G2 SENSE + OL
S2 -
NOTE: STEP 10 MUST BE PERFORMED WITHIN 10 SECONDS OF STEP 9
STEP 10
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 10 FAILS VERIFY STEP 9 IS CORRECT IS CORRECT AND RETEST
STEP 11
S2 + OL
G2 SENSE -
STEP 12
D2S1 + OL
S2 -
STEP 13
D2S1 + CONTINUITY
D2 SENSE -
STEP 14
S2 + CONTINUITY
S2 SENSE -
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
SB-TX-CS-2010
FET BOARDS AND MODULES
Page 7 of 9
STEP 3
D1 + CONTINUITY
D2S1 -
NOTE: IF STEP 3 FAILS VERIFY STEP 2 IS CORRECT IS CORRECT AND RETEST
STEP 4
D1 + OL
-
U PHASE
G1 SENSE
STEP 5
D1 + OL
D2S1 -
STEP 6
D1 + CONTINUITY
D1 SENSE -
STEP 7
D2S1 + CONTINUITY
S1 SENSE -
STEP 8
D2S1 + OL
S2 -
STEP 9
G2 SENSE + OL
S2 -
NOTE: STEP 10 MUST BE PERFORMED WITHIN 10 SECONDS OF STEP 9
STEP 10
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 10 FAILS VERIFY STEP 9 IS CORRECT IS CORRECT AND RETEST
STEP 11
S2 + OL
G2 SENSE -
STEP 12
D2S1 + OL
S2 -
STEP 13
D2S1 + CONTINUITY
D2 SENSE -
STEP 14
S2 + CONTINUITY
S2 SENSE -
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
SB-TX-CS-2010
FET BOARDS AND MODULES
Page 8 of 9
STEP 3
D1 + CONTINUITY
D2S1 -
STEP 4
D1 + OL
-
V PHASE
G1 SENSE
STEP 5
D1 + OL
D2S1 -
STEP 6
D1 + CONTINUITY
D1 SENSE -
STEP 7
D2S1 + CONTINUITY
S1 SENSE -
STEP 8
D2S1 + OL
S2 -
STEP 9
G2 SENSE + OL
S2 -
NOTE: STEP 10 MUST BE PERFORMED WITHIN 10 SECONDS OF STEP 9
STEP 10
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 10 FAILS VERIFY STEP 9 IS CORRECT IS CORRECT AND RETEST
STEP 11
S2 + OL
G2 SENSE -
STEP 12
D2S1 + OL
S2 -
STEP 13
D2S1 + CONTINUITY
D2 SENSE -
STEP 14
S2 + CONTINUITY
S2 SENSE -
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
SB-TX-CS-2010
FET BOARDS AND MODULES
Page 9 of 9
STEP 3
D1 + CONTINUITY
D2S1 -
NOTE: IF STEP 3 FAILS VERIFY STEP 2 IS CORRECT IS CORRECT AND RETEST
STEP 4
D1 + OL
-
W PHASE
G1 SENSE
STEP 5
D1 + OL
D2S1 -
STEP 6
D1 + CONTINUITY
D1 SENSE -
STEP 7
D2S1 + CONTINUITY
S1 SENSE -
STEP 8
D2S1 + OL
S2 -
STEP 9
G2 SENSE + OL
S2 -
NOTE: STEP 10 MUST BE PERFORMED WITHIN 10 SECONDS OF STEP 9
STEP 10
D2S1 + CONTINUITY
S2 -
NOTE: IF STEP 10 FAILS VERIFY STEP 9 IS CORRECT IS CORRECT AND RETEST
STEP 11
S2 + OL
G2 SENSE -
STEP 12
D2S1 + OL
S2 -
STEP 13
D2S1 + CONTINUITY
D2 SENSE -
STEP 14
S2 + CONTINUITY
S2 SENSE -
IF ANY OF THE ABOVE TEST VALUES DO NOT MATCH TEST HAS CONFIRMED A FAILURE
Prevent mosfet failures 1N1
Model : (JG)(G)(S)1N1
Issue : SB-TX-CS-1101
Date : march 2011 SERVICE
BULLETIN
1Description:
Investigation of defect parts show that in most the cases, the mosfet was damaged by static
electricity.
During repair / replacement of controller parts the mosfet is potential affected by static
electricity.
You will not notice any effect of this charging of mosfet by static electricity however the mosfet
is internal damaged/ weakened but can still operate.
After a certain operation time the mosfet finally get defect.
To avoid a weakened and finally defect mosfet every effort should be made to prevent static
electricity on controller parts during service / maintenance and repair work.
To avoid that you as mechanic are charged by static electricity, you should use a ground
cable to assure your body is connected to the earth.
Also the body/ frame of the truck should be connected to the earth.
Resistor (50-500Ω)
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
Model : (JG)(G)(S)1N1
Issue : SB-TX-CS-1101
Date : march 2011 SERVICE
BULLETIN
- You should earth yourself and the chassis of truck in the following cases:
o When there is a potential that your body / your tool is touching the electric
power cables or copper bars of pump/drive motor at the controller or at the
motor itself.
o When you are repairing or doing diagnosis on the controller.
- How to earth your body
o Use electric bracelet and connect the wire to the chassis frame of the truck
Connected
to chassis
of truck
Electric
bracelet
- Also assure that chassis of forklift is having good electric contact to earth by for
example putting a chain/cable from the truck to the ground.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
Issue : SB-TX-EL-0701-02
Date : November 2007
Revision
Model(s) : TX
Subject : RPM sensor error with new motors
Outline:
Since February 2007 the controller assy, traction motors and pump motor have been changed.
(See PI-TX-MM-0701-02 and PI-TX-CS-0701-02).
On TX models with new controller assy and motors it is possible to appear an error code on the
monitor. It will display a faulty revolution sensor of the motors.
This is caused by a changed pin layout on the controller and motor connectors and therefore
changing wire shielding in the body harness.
In case an error code is displayed as mentioned above, the following procedure has to be carried out.
Procedure:
Step 1:
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-EL-0701-02
Date : November 2007
Step 2:
1. Locate the revolution sensor connector for the traction motor (left and right side) and disconnect.
2. Locate the revolution sensor connector for the pump motor and disconnect.
T/Motor
P/Motor Connector of
Revolution sensor
3. Locate out terminal A and B from the connector at the chassis harness side. (traction motor
LH/RH and pump motor)
4. Change the terminals A and B at the connector. (See illustration 1 and Table 1).
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-EL-0701-02
Date : November 2007
Caution:
Make sure to lock the terminals in the connector.
Illustration 1.
5. Reconnect the connectors of the chassis harness to the respective revolution sensor connector.
6. Return the harness to the original position.
Caution:
Make sure to connect the harness connectors properly (LH and RH).
Table 1
Terminal of chassis harness
A (Colour) B (Colour)
T/Motor (RH) 150 (White) 144 (Black)
T/Motor (LH) 151 (Purple) 145 (Black)
P/Motor 159 (White) 156 (White)
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-EL-0701-02
Date : November 2007
Step 3:
1. Disconnect the connectors from the controller assy. (Traction controller and pump controller).
To Traction To Pump
controller controller
2. Locate the terminals A and B from the connector of the chassis harness
3. Change the terminals A and B at the connector. (See illustration 2 and Table 2).
Caution:
Make sure to lock the terminals in the connector.
Illustration 2
Table 2
Terminal of chassis harness
A (Colour) B (Colour)
T/Motor (RH) 150 (White) 144 (Black)
T/Motor (LH) 151 (Purple) 145 (Black)
P/Motor 159 (White) 156 (White)
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-EL-0701-02
Date : November 2007
Step 4:
¾ Caution:
Install clevis pin to connect brake pedal and push rod in the proper direction. Be sure
to install snap pin.
For 48V/36V:
1N1-721778 ~ 1N1-721991
G1N1-721459 ~ G1N1-721569
S1N1-720468 ~ S1N1-720516
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
Description:
In order to prevent PCB turn signal circuit damage by a short circuit, due for example to a damaged
bulb, the circuit of the turn signal can be changed preventively.
Modification:
In order to prevent high current through the PCB, two relays should be inserted in the turn signal
circuit. The turning signal function of the PCB is still used to control the relays which will provide the
current througho the bulbs.
Note: the modification is to be made on trucks with working PCB turn signal.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
1. Disconnect the left hand side connector (35pins) of main harness at Main
controller.
2. Cut the white and the red wire of the 35 pins connector (not too close from
the connector), which are located on the pin number 2 and 17. (view of the
connector wire side)
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
4. Install additional harness along main harness from Controller to relay tray as
shown below
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
5. connect the additional harness power line to the green wire from fuse box
(fuse number 8) and the additional harness earth to the white/red wire from
relay tray (tail lamp relay)
Fuse box
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0801
Date :
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
Description:
The PCB turn signal circuit can be damaged due to a short circuit occurs, for example by a
damaged bulb. The PCB is still working, only the turn signal circuit is damaged. To prevent high
repair costs by replacing the PCB, the turn signal circuit can be modified.
Modification:
In order to make the turn signal work, a flasher relay can be installed controlling the current to the
bulbs, replacing the PCB turn signal circuit.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
MODIFIED
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
1. Disconnect the left hand side connector (35pins) of main harness at Main
controller.
2. Cut the white, the red, the green/yellow and the blue/red wire of the 35 pins
connector (not too close from the connector), which are located respectively
on the pin number 2, 17, 31 and 35. (view of the connector wire side)
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
5. From the fuse number 3 (10 amp) get a line to the flasher relay.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0802-01
Date : October 2009
7. Install the flasher relay on the relay tray under the fuse box.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-EL-0803-01
Date : December 2008 SERVICE
BULLETIN
Description:
Continued investigation has learned that the battery microswitch can be bypassed/ removed
without the risk of potential damage of MOSFET.
Advise:
In case of an error code 405 related to the battery microswitch, you can bypass / remove the
battery microswitch without any problem.
A new harness design will be implemented in 2009, allowing the factory to remove the
microswitch.
Until then trucks will be produced with a battery microswitch connected.
Battery
micro
switch
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
SERVICE
BULLETIN
Outline:
Although only a few incidental cases have been reported of a broken rear axle bolt and/or a
broken rear axle housing, the construction has been improved.
Investigation shows there is no reason to believe that the construction is not strong enough,
as the damage is related to high impact force on rear axle during driving over high obstacles
with relative high speed.
Modification:
The following modifications have been made to make the construction of the rear axle even
more resistant against high force of rear axle while driving over obstacles:
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
SERVICE
BULLETIN
Affected Parts:
Parts Number
Parts Name NEW FORMER Quantity
Steering axle (service kit) 49509-GA10B 49509-GA10A 1
Bolt (M16x1.5, 80mm) 40141-GA10C 40141-GA10B 3
Nut 08911-64610 3
Lock washer 08915-2461A 6
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
SERVICE
BULLETIN
Modification procedure:
For the modification the above mentioned new parts should be installed.
Disassemble:
- Remove the counterweight
- Remove the controller assy
- Disassemble the rear axle assy.
- Disassemble the 4 bolts connecting the steering mounting plate with the
steering axle bracket
Disassemble 4 bolts
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
SERVICE
BULLETIN
Check:
- check flatness of frame on steering axle mounting connections and make sure
it is 100% flat, otherwise tightening the rear axle to the frame will cause stress
in the construction.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
SERVICE
BULLETIN
Modification:
- Connect the steering axle service kit to the steering axle bracket.
- Tightening the 4 bolts with 250Nm.
- Drill 3 times Ǿ16.5-17mm holes in the rear axle mounting frame plate to
remove the thread in the frame and to allow the new bolts to fit.
Drill Ǿ16.5-17mm
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
SERVICE
BULLETIN
Installation:
- Install 3 new rear axle mounting bolts (M16x1.5 , 80mm) including washer via
the bottom of frame plate
- Install the rear axle assy on the frame
- Apply loctite 271 on the thread of the bolts
- Install washer and nut on top.
- Tightening the nut-bolt mounting with 240-320Nm
- Connect steering angle sensor and PS piping.
- Install controller
- Install counterweight
Tighten torque:
240-320Nm
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Service Bulletin
Issue : SB-TX-ST-1001
Date : June 2010 SERVICE
BULLETIN
Description:
It has been reported that in some cases the power steering would give a kickback.
After investigation it appears that this would occur 5 seconds after using the hydraulic
functions while steering.
When using the hydraulic function, the C1 solenoid is activated allowing oil to flow through
the control valve. When the joysticks return to neutral, it takes 5s before the C1 solenoid
opens. This provokes a kickback in the steering circuit.
Modification:
If you encounter this problem, the solution is to close the C1 solenoid mechanically; adding
a washer in the valve.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
Issue : SB-TX-ST-1001
Date : June 2010 SERVICE
BULLETIN
C1 Solenoid
Washer
Instruction:
C1 solenoid removal:
Removal of C1 solenoid:
a. Remove two screws and remove
solenoid body carefully.
b. There is an O-ring inside so that it is a
little tight to remove; therefore, it is
recommended to shake up and down.
c. After you get some clearance between
the valve and C/V, draw out the valve
turning it right and left a little.
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
Issue : SB-TX-ST-1001
Date : June 2010 SERVICE
BULLETIN
The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin