FB15RL-15 Shop Manual
FB15RL-15 Shop Manual
FB15RL-15 Shop Manual
FB15RL(F)/18RL(F) -15
FB10RW/13RW/15RW -15
SERIAL NUMBERS 150001 and up
SECTION INDEX
00. FOREWORD
70. TROUBLESHOOTING
Always pay attention to “Safety” before starting any work — this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag mark
inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.
The symbols described below are used in this manual for convenience and better understanding.
Tightening torque Fastening parts that require specified tightening force when assembling.
SPECIFICATION
1.Main specification
1.2 Model Manufacturer's Designation FB10RL-15, FB10RLF-15 FB13RL-15, FB13RLF-15
1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Electric Electric
Characteristics
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1000 1250
1.6 Load Center c Load Center mm 500 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 870 1080
1.8 Load Distance x Front Axle Center to Fork Face mm 175 175
1.9 Wheelbase y mm 1110 1250
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 1985 2000
2.4 Front kg 2555 2855
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 465 430
2.4.2 Extended Front kg 905 890
Weight
Unloaded
2.4.3 Rear kg 1115 1145
2.5 Front kg 1940 2020
Loaded
2.5.1 Axle Loading Mast/Forks Rear kg 1080 1265
2.5.2 Retracted Front kg 690 635
Unloaded
2.5.3 Rear kg 1330 1400
3.1 Tyre Type Solid Solid
3.2 Front 260 x 120 260 x 120
3.3 Tyre Size Rear 360 x 180 360 x 180
Tyre
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1500 1800
1.6 Load Center c Load Center mm 500 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 1300 1560
1.8 Load Distance x Front Axle Center to Fork Face mm 175 175
1.9 Wheelbase y mm 1350 1500
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 2175 2255
2.4 Front kg 3245 3620
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 475 480
2.4.2 Extended Front kg 955 970
Weight
Unloaded
2.4.3 Rear kg 1265 1330
2.5 Front kg 2360 2465
Loaded
2.5.1 Axle Loading Mast/Forks Rear kg 1360 1635
2.5.2 Retracted Front kg 715 690
Unloaded
2.5.3 Rear kg 1505 1610
3.1 Tyre Type Solid Solid
3.2 Front 254 x 114 254 x 120
3.3 Tyre Size Rear 360 x 180 360 x 180
Tyre
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1000 1250
1.6 Load Center c Load Center mm 500 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 870 1080
1.8 Load Distance x Front Axle Center to Fork Face mm 175 175
1.9 Wheelbase y mm 1110 1250
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 1985 2000
2.4 Front kg 2560 2860
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 460 425
2.4.2 Extended Front kg 910 895
Weight
Unloaded
2.4.3 Rear kg 1110 1140
2.5 Front kg 1945 2025
Loaded
2.5.1 Axle Loading Mast/Forks Rear kg 1075 1260
2.5.2 Retracted Front kg 695 640
Unloaded
2.5.3 Rear kg 1325 1395
3.1 Tyre Type Solid Solid
3.2 Front 260 x 120 260 x 120
3.3 Tyre Size Rear 330 x 145 330 x 145
Tyre
4.33 and 4.34 Values are not including a cliearance. See Aisle width section for detail
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1500
1.6 Load Center c Load Center mm 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 1300
1.8 Load Distance x Front Axle Center to Fork Face mm 175
1.9 Wheelbase y mm 1350
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 2185
2.4 Front kg 3250
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 470
2.4.2 Extended Front kg 955
Weight
Unloaded
2.4.3 Rear kg 1265
2.5 Front kg 2365
Loaded
2.5.1 Axle Loading Mast/Forks Rear kg 1355
2.5.2 Retracted Front kg 720
Unloaded
2.5.3 Rear kg 1500
3.1 Tyre Type Solid
3.2 Front 254 x 114
3.3 Tyre Size Rear 330 x 145
Tyre
4.33 and 4.34 Values are not including a cliearance. See Aisle width section for detail
Kg FB18RL Kg Kg
1800 FB15RL 1800 FB15RS 1800 FB15RW/RP
1500
FB14RL 1500
FB13RS 1500
FB13RW/RP
FB13RL FB10RS FB10RW/RP
1200 FB10RL 1200 FB09RS 1200
3. Dimension Diagram
B1
B3
W
a
L4
h4
h3
h5
h1
β
h2
m2
α
y
L1
B4Z16901
• Only persons authorized by the owner or operator of the equipment and having proper certification (local or national)
may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.
MAINTENANCE LOCATION
• When carrying out inspection and maintenance, use a level, dry, dust-free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
• Keep the maintenance work shop neat and implement the work safely.
• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how to use it.
• Before carrying out inspection, lower the forks to the ground and stop the machine.
• Before starting the inspection, turn OFF the key switch and pull it out.
• Keep turning OFF the key switch except when needed.
• Place the card showing ÅgUnder inspectionÅh on the operatorÅfs seat or the operation panel.
• Keep plugging out the battery plug except when needed.
• Place the directional lever, speed lever, and work equipment control levers in neutral.
• Place the chocks under the wheels to fix them.
• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
• If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the lift truck
before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
• Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and mast
from dropping.
• Before performing the inspection work in between the mast and the body, ensure to disconnect the battery plug.
Otherwise if the reach mechanism accidentally moves, you will be trapped, resulting in injury or death.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance with
instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully
corrected or that defective parts have not been removed.
• Always use tools that are suited for inspection and maintenance.
It is extremely dangerous to use broken tools or tools designed for another
purpose.
• Immediately after using the lift truck, the oil is at high temperature.
Do not drain the oil or replace the filter when the oil is hot. Hot oil
may spurt out and cause burns.
• When carrying out inspection and maintenance, wait for the oil
temperature to go down, and carry out the operation in the order
given in this manual.
• Do not forget that the work equipment circuits are always under
pressure. Do not add oil, drain oil, or carry out maintenance or
inspection before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is
dangerous if the jet of high-pressure oil hits your skin or eyes.
Always wear safety glasses and thick gloves, and use a piece of
cardboard or a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the accumulator
piping.
• If you are hit by a jet of high pressure oil, consult a doctor
immediately.
• Never put your hands or feet into the mast structure. There is danger
that you will get caught in moving parts and be seriously injured.
• Do not use the mast as a ladder. If you slip, there is danger that you will
fall.
• Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting
methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have ample
strength and are not damaged.
• Block the tires contacting the ground to prevent the lift truck from
moving.
• Insert blocks to prevent the truck from coming down.
• Do not go under the lift truck during the lifting operation.
• If the specified lifting point is the counterweight, check that the
counterweight mounting bolts are tightened to the specified torque
before carrying out the lifting operation. check also that there is no
damage to the lifting portion on the counterweight.
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill electrolyte
on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes, flush them
immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite or vegetable
oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or
goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly
EXPLOSIVE, and is easily ignited with a small spark or flame. Do
not smoke or create any spark near the battery.
• Before working with batteries, stop the engine and turn the starting
switch to the OFF position.
• When removing the battery, remove the cable from the negative
terminal first. When installing the battery, install the cable to the
positive terminal first.
• Avoid short-circuiting the battery terminals through accidental
contact with tools or other metal objects across the terminals.
• Tighten the battery terminals securely. Loose terminals can
generate sparks and lead to an explosion.
• When removing or installing the battery, confirm which is the
positive terminal and negative terminal. Be careful not to
connect the cables to the opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
• For drawing out or pushing in the battery, refer to “Chapter 30
Removal/Installation”.
• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and start a
fire.
• Before recharging, confirm that the electrolyte level is appropriate. If it is lacking, refill the distilled water or pure
water.
• Recharge the battery in a well-ventilated, rain-sheltered (humidity), dust-free and clean place.
• When starting the recharge, if the battery electrolyte temperature is higher than 35 °C, leave the battery in the
shadow and recharge the battery after the temperature drops.
• When the protection fuse in the battery charger blows out, ensure to use our companyÅfs genuine parts.
(For fuse replacement, refer to ÅgChapter 20 Inspection/AdjustmentÅh.
• As the high explosive hydrogen gas is produced from the battery, keep
away the battery from open fire while recharging or after charged.
• If the top surface of battery is dirty, the battery life will be shortened.
Before recharging, clean it with a moistened cloth. If cleaned with a dry
cloth or chemical fiber cloth or dusted with a duster, the static electricity
generated causes the explosion.
• If the incorrectly adjusted voltage tap of power supply is used for a long
period of time, the battery charger may be damaged. Adjust the power
supply tap periodically.
• Use the cable and the wall outlet of power supply at the facility side (building) of which capacity is greater than the
maximum input current of the charger. If the capacity is insufficient, it will cause fire.
• When plugging or unplugging the cord, hold the cable by the plug.
Do not pull the cord. If done so, the cord will be broken.
• The loose plugging the plug in the outlet, the damaged contact terminal or the damaged power cord may heat up,
causing fire. Check them. If damaged, repair it.
• As large current flows when recharging, plug the cord directly in the determined outlet. Do not extend the cord or do
not use the multiple tap.
• As large current flows when recharging, do not plug out the cord directly from the outlet. To stop the recharging, push
the automatic charging button or the uniform charging button of which the charge display lamp lights.
FUSE REPLACEMENT
WASTE MATERIALS
BATTERY REMOVAL/INSTALLATION
• In the state that the mast is completely retracted, press down the battery lock pedal to the lowest position.
• Ensure to perform the battery removal/installation in the unload state.
• Operate while confirming the hose movement.
CAUTION AT DISASSEMBLY/ASSEMBLY
• When disassembling, remember the locations of parts and the direction of shaft. Keep screws and shafts in the
empty box for re-use.
• Use the wooden hammer when removing the bracket or hit lightly evenly with the wooden hammer when installing.
Do not use the metal hammer. If you use the metal hammer, the parts may be cracked.
• Clean the disassembled parts. Check abnormalities. If any part is lacking or broken, replenish or replace it.
• After assembled, confirm that parts are not left and screws are firmly tightened.
• Handle with care not to damage the parts. Especially, do not stick water, dust or sand to the stator coil and pivot as
well as scar.
• Dust the coil with a dry cloth or soft brush. Do not rub with a hard material or wipe with gasoline, kerosene or solvent.
If used, it damages the insulation.
• Tighten securely the terminals. Insulate the connected parts with the insulation tape.
• For storage of the motor, select a place where it is dry and free from humidity, dust, alkali and other toxic gas.
• Apply the rust preventive to the shaft end and wrap the motor with an oil paper or vinyl cloth.
• Wipe out dust on motor installing portions (flange surface, shafts) with a clean cloth and apply the grease if
necessary. Connect it smoothly.
• When connecting, do not push it in forcibly.
• Do not rub or apply force to the wires leading from the motor. Do not carry the motor, holding the wires leading from
the motor. Do not assist when hanging it up. It leads to the serious trouble.
• When hanging up or down the motor, ensure to use the motor hanging bolt.
• After installing the motor, confirm that the shaft rotates when rotated by hand.
1. In the case of using impact wrenches or 2. In the case of using torque wrenches
spanners
Unit: kgm (Nm) [ft. lb] Unit: kgm (Nm) [ft. lb]
a This table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or
which requir to tighten to otherwise specified torque.
Width D mm 19 22 30
(inch) (0.748) (0.866) (1.181)
Tightening torque Nm {kgm} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
[ft.Ib] [21.7 – 28.9] [57.9 – 75.9] [86.8 – 119.3]
Port size
3/4-16UNF 13/16-12UNF 15/16-12UNF
(inch)
Tightening torque Nm {kgm} 68.6 – 73.6 {7 – 7.5} 117.7 – 161.8 {12 – 16.5} 107.9 – 147{11 – 15}
[ft.Ib] [50.6 – 54.2] [86.8 – 119.3] [79.5 – 108.4]
Bore A mm 14 18 22 24 30
(inch) (0.551) (0.709) (0.866) (0.945) (1.181)
Tightening torque Nm {kgm} 19.6 – 29.4 {2 – 3} 23.5 – 68.6 {3 – 7} 58.8 – 98.1 {6 – 10} 107.9 – 166.7 {11 – 17} 147– 206 {15–21}
[ft.Ib] [14.5 – 21.7] [21.7 – 50.6] [43.7 – 72.3] [79.6 – 122.9] [108.52 – 151.8]
Removal of parts
Leaving Applying
Assembly When screws and shafts are secured with LOC-
LOCTITE
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pullers,
etc. If LOCTITE is so strong that a part may be bro-
1. Degreasing and cleaning ken when it is removed, heat it (to 200 - 250°C) with
1) Clean the parts in trichloroethylene, acetone, a soldering iron, gas torch, etc., and you can
ether, alkaline solution, etc. which are highly remove it easily. It is generally difficult to dissolve
volatile. LOCTITE in chemical solutions.
2) Degrease the parts as perfectly as possible.
3) Since gasoline, light oil, kerosene, etc. are not When assembling again
highly volatile, they are not recommended. If it
1) If a LOCTITE film on threads is broken, it is left
is obliged to use them, dry them completely.
as white powder on the threads. In this case,
4) If the mating parts are made of thermosetting you can apply LOCTITE again to the threads
resin, treat them with LOQUICK PRIMER after without removing the white powder.
degreasing them.
2) If shafts or flanges secured with LOCTITE are
disconnected, LOCTITE remaining on them
2. Air drying may need to be removed to maintain dimen-
sional accuracy. You can remove the remain-
1) Wait until the cleaning fluid dries out.
ing LOCTITE easily, however, with a wire
2) If the parts are treated with LOQUICK brush, etc.
PRIMER, do not wipe them but dry them in air
3) If plates secured with LOCTITE need to be
for 5 - 10 minutes. (If LOCTITE is used before
assembled again after they are separated, be
LOQUICK PRIMER dries out, its effect is low-
sure to remove all the hardened LOCTITE and
ered.)
roughen the mating surfaces with sandpaper.
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads or
the shaft and hole to be fitted by amount to fill the
clearance between them by one of the following
methods.
• Applying directly from LOCTITE container nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
BATTERY....................................................................................20-4
TRANSFER CASE....................................................................20-10
SERVICE DATA
Lift 16.7{170}
Control valve relief MPa
pressure {kgf/m2}
Tilt 16.7{170}
BATTERY
2. Restricted fire
Do not make a short circuit or spark. Keep away tobacco and fire from the battery.
3. Avoidance of electric shock
Wear the gloves to prevent electric shock when performing the maintenance and inspection.
4. Ventilation
Ventilate well when the battery is used or not used.
1. Stopper
2. Cap
3. Float (red color)
Before the float (red color) indicates the lowest level of battery
2
electrolyte, refill water. (Refer to [How to refill water in the battery]
3 When the stopper (1) of float (3) touches the cap (2) (when the
gap a=0 is achieved in the left figure), the battery electrolyte
level is lowest.
A. Refilling water
B. Refilling is finished.
1. Open the lid of battery cap and refill water in the battery.
Indication on the
model plate
1
A BCD
A
B
C
D
2
RL type
B4Z16280
2. According to the table below, select the wire suitable for the
measured voltage from the wire (1) of charger transformer.
a Depending on the power source frequency, the wire to be
connected differs.
Range of Voltage
Tap
50 Hz 60 Hz
A 195 V: 190 – 199 V
B 195 V: 190 – 199 V 205 V: 200 – 209 V
C 205 V: 200 – 209 V 215 V: 210 – 219 V
D 215 V: 210 – 219 V
3. Connect the selected wire to the wire (2) leading from the elec-
tro magnetic switch.
1. Charging Transformer
2. Electro-magnetic Switch
2. Remove the drain plug (1) and drain the hydraulic oil. After
drained, tighten the drain plug.
2
3
9. Operate the cylinder (lift, tilt and reach) to the stroke end 5 to 6
times to let air out.
TRANSFER CASE
B4Z16903
OIL REPLACEMENT
1. Remove the drain plug (2) and drain the oil.
FUSE REPLACEMENT
REPLACEMENT PROCEDURE
1. Sit on the operatorÅfs seat and operate the reach lever to
extend the mast. (Reach-out)
2. Turn the key switch to [O] (OFF) and disconnect the battery
plug.
4. Lower the front panel downward (1). Open the upper side of
the front panel toward you (2) and remove it, lifting upward (3).
2
5. If the fuse shown below blows out, replace it with the one
4 having the identical capacity.
Capacity
Name of circuit protected Color
(For truck)
3 Light lamp, accessory circuit (1) 10A Red
Controller control circuit (2) 10A Red
EPS (3) 40A —
1
Never use the wire or a fuse other than the one with
specified capacity. Otherwise, it exceeds the standard
value.
6. Open the cap of fuse holder and remove the fuse in it. Confirm
visually the blown-out fuse.
a The sample marked with X in figure at the left hand side
shows the blown-out fuse.
7. Hook the front panel to the bar (1) at the frame side, turn it
toward the truck (2) and lift it upward (3).
2 Then, tighten the fixing knobs.
1
3
DISC BRAKE
2. Assemble the brake rod and set the brake pedal height to 60 to
e 70 mm.
a d
h 3. Loosen the adjuster bolt c beforehand and adjust the turn-
buckle e so that the brake bar a becomes perpendicular (90 ±
2°).
c
b
25 ~ 30 mm
1. Outer roller
㪭 1) Roller selection
䌢 Select a roller so that the dimension V in the figure at the
left hand side becomes 9.9 ± 10.6 mm and values at right
and left are identical. The target is 9.9 mm.
䌢㪈
㫊㫋㪸㫅㪻㪸㫉㪻㩷㫊㪿㫀㫄㩷㪊㪅㪇
2) Shim adjustment
㪫㪿㫀㪺㫂㫅㪼㫊㫊㩷㫆㪽㩷
At the maximum height of high lifting, adjust using the
shims of same thickness at the right and left sides so that
the clearance b1 between the rail and the roller becomes
0 to 0.5 mm when contacting closely the roller to the rail.
2. Inner roller
1) Roller selection
Select a roller so that the dimension a in the figure at the
䌢㪉
2) Screw adjustment
In the state of reach-out, adjust by screwing same amount
㪹㪊
at right and left sides so that the roller touches lightly the
rail (b3 is 0.1 to 0.3 mm) when contacting closely the roller
㪻 to the rail.
2) Shim adjustment
In the state of reach-out, adjust using the shims of same
㫊㫋㪸㫅㪻㪸㫉㪻㩷㫊㪿㫀㫄㩷㪌㪅㪉
㪹㪋
1) Bolt adjustment
In the state of the uppermost height of support, tighten
bolts same amount at back and forth sides simultaneously
so that the clearance f4 between the rail and the roller
becomes 0 to 0.2 mm and the set height becomes
identical at the right and left sides.
䌦4
LIFT CHAIN
1. Adjust the chain stopper so that the lowest surface of fork
matches with the floor.
㪠㫅㫅㪼㫉㩷㫄㪸㫊㫋
㪽 2. At the maximum height of high lifting, confirm that the inner
mast does not lean to the right and left sides.
3. If leaned, loosen the chain by a mount of f when the fork
descends at the lower rail side a as shown in the figure at the
㪸 㪹 light hand.
㪹㩷㫊㫀㪻㪼㩷㪺㪿㪸㫀㫅
㪝㫆㫉㫂
㪝㫃㫆㫆㫉
VOLTAGE CHECK
When the EPS operation trouble occurs, set the starter switch to OFF and perform the following check.
1. 8V stable current 4. At the left turn (When turning the steering wheel right)
Connect as shown above and turn the volume knob After adjusted in the neutral position, when turning the
so that the voltage between terminals and steering wheel left, if the voltage between terminals
becomes 8 V. and varies smoothly to 1 V, it is normal.
4 ± 0.3 V 1 V
Normal Value
(The voltage changes smoothly.)
2. In the neutral (When the steering wheel is not turned) 5. Right turn Neutral
When the steering wheel is in the neutral position, if After turning the steering wheel right and releasing
the voltage between terminals and is 4.3 V ± the hand off, when retuned to the neutral position, if
0.3 V, it is normal. If not, adjust using the shim (A) the voltage between terminals and becomes
so that the voltage becomes normal. 4 V ± 0.3 V. (Measure several times)
(The 0.1 mm thick shim changes 0.07 V.)
Normal Value 7 V 4 ± 0.3 V
Normal Value 4 ± 0.3 V
3. At the right turn (When turning the steering wheel right) 6. Left turn Neutral
After adjusted in the neutral position, when turning the After turning the steering wheel left and releasing
steering wheel right, if the voltage between terminals the hand off, when retuned to the neutral, if the
and varies smoothly to 7 V, it is normal. voltage between terminals and becomes 4 V
± 0.3 V. (Measure several times)
4 ± 0.3 V 7 V
Normal Value
(The voltage changes smoothly.) Normal Value 1 V 4 ± 0.3 V
GREASING
Use the MOLY SPEED GREASE No.0 (SUMICO LUBRICANT CO., LED) for torque sensor and actuator.
In the maintenance, check that the grease is applied to parts in the sensor. If necessary, grease them.
METER PANEL
By operating switches (1), (2), (3), and (4) on the meter panel, per-
form the settings and adjustments of speed limit / traveling power /
lift speed, select the display of date-time / hour meter and adjust it.
SETTING OF DATE-TIME
1. Keep pressing the mode / set select switch (4) for more than 2
seconds. (To enter the vehicle speed limit mode)
2. Press the mode / set select switch (4) once more to enter the
date-time adjusting mode.
The calendar year (lowermost two digits) - month date - time is
displayed and the calendar year blinks.
3. To change the calendar year, press the power select switch
(up-switch) (3) or vehicle speed limit select switch (down-
switch) (2).
4 3 2
3 2 1
When setting to the enable (ON) by pressing the switch, the vehicle
speed limit indicator (5) (turtle icon) is displayed and the value of
vehicle speed limit at this moment blinks for two seconds at the
same time.
a L o M o H o Go off o L…
4 3
2. When the mode / set select switch (4) is pressed in either state
of L, M or H, setting is completed and blinking stops.
L M H Go off Power Mode Content
Even at low speed, the cargo
L Low Power operation - traveling is possible and
the energy can be saved.
The cargo operation - traveling
M Middle Power suitable for normal work can be
performed.
The vehicle can travel strongly at
high speed and the high performance
H High Power of cargo operation can be achieved.
The battery consumption increases.
Characteristics desired by a user can
Go-off User Mode be obtained by setting with the
service tool.
1. Press the power select switch (UP switch) (3) and then press
the mode/select switch (4) after the display of travel power
indicator goes off. (The user mode is set.)
2. Keep pressing the mode / set select switch (4) for 2 seconds.
(The mode becomes the vehicle speed limit mode.)
4 3 2 1 3. Press the shift switch (1) several times.
(The display changes to the lift speed setting mode.)
The display below appears on the date-time display area and
the numeral part blinks.
a Example of display: LIFT-SPd-95
4. Place the wooden block (3) under the frame at the right and left
sides to float the drive wheel from the ground.
(Only when measuring the travel limit current)
5. Turn the tilt lever to the forward and lower the fork to the
ground.
6. Disconnect the wiring of brake switch and short it to 0 V.
1 (Only when measuring the travel limit current)
Or remove the center plate and push in the brake switch lever
(Electrically the brake is open.)
7. Set the current meter (clamp tester) to the cable of motor to be
3
2 measured and measure the limit current under the measuring
condition shown on the table below.
1 8. After finishing the check, connect the wiring of brake switch
B4Z16904 again.
(Only when measuring the travel limit current)
Motor Measuring condition Measuring cable Clamp setting Judging limit current
Set the power mode to H and turn fully the forward/
DC 1000 A
backward lever to the forward without stepping
peak range 317 to 351 A (peak)
Travel down the brake pedal. DU, DV, DW
(AC 1000 A (224 to 247 A (rms))
(The drive wheel does not rotate.)
peak range)
At this moment, measure the current.
Set the power mode to H and turn fully the tilt lever
DC 1000 A
to the forward to tilt the mast forward. At this
Cargo- peak range 319 to 390 A (peak)
moment, measure the current. PU, PV, PW
handling (AC 1000 A (226 to 276 A (rms))
(Set the tilt parameter to the factory setting (=100%)
peak range)
when implementing.)
Measure the current when turning the steering Cables of
EPS As usual 30 A ± 1.5 A
wheel right or left fully. EPS motor
2 1
4
5
P
B4Z16285
NEUTRAL POSITION
1. Neutral position of the horizon of the fork is determined when
Back tilt Front tilt all of two horizontal switches (limit switches) are ON at the
ON same time.
Horizontal SW 1
NO
OFF
ON
Horizontal SW 2
NC OFF
Neutral position
B4P16290
B4P162901
Red tape
B4P162902
OIL
• As the work equipment is used under severe conditions (high temperature, high pressure), the oil deteriorates as it is
used. Use the oil suitable for the grade and operating temperature described in the Shop Manual.
Even if the oil is not contaminated, ensure to replace the oil at the specified time.
• As the oil is equivalent to the blood to the human being, handle the oil with care to prevent the entry of impurity (water,
metal debris and dust). Most of mechanical troubles arise from the entry of impurity.
Especially, when storing or refilling, handle the oil with care to prevent the entry of impurity.
• Do not mix the oil of different grade or different makes.
• Refill the specified amount of oil.
Too much oil or too little oil causes trouble.
• If the oil in the work equipment becomes unclear, the entry of water or air in the circuit is suspected.
Consult with our sales dealer.
• Whenever replacing the oil, ensure to replace the related filter at the same time.
The oil and grease are available at KOMATSU Sales and Service dealers.
Ambient temperature
Cold-strage
Lubrication point Type of fluid model Lift Truck Standard spec. Lift Truck Capacity
C
SAE5W-CD
Hydraulic tank Hydraulic oil* 16
SAE10W-CD
SAE5W-CD
SAE10W-CD
Each lubricating
Engine oil*
point
SAE30W-CD
SAE10-30SD
WARNING
• The display of load weight varies during traveling. Be sure to stop the reach truck on a flat location and confirm the
load weight.
• The over-load alarm load weight is set heavier than the maximum load weight in the initial setting.
When the alarm buzzer beeps, reduce the load immediately to avoid the overturn of reach truck.
INTRODUNCTION
The weight gauge is set to meet the specification of reach truck when shipped.
If a customer request of the load weight change of over-load alarm or the set value change after the replacement of mast
or attachment, re-set referring to this manual.
• Load Weight Display Function: It displays the load weight on the meter panel.
• Over-load Alarm Function: When the load weight exceeds the preset alarm load weight, the alarm buzzer beeps,
telling the over-load to the operator.
ITEM TO BE PREPARED
• PC service tool
1. Cylinder pressure receiving area (per one piece) cm2 15.9 19.63 33.18 38.48
2. Zero point set hydraulic pressure kgf/cm2 13.43 12.68 11.93 10.44
MAST ..........................................................................................30-5
TRANSFER.................................................................................30-7
LIFT CYLINDER
REMOVAL
The procedure for removal of the lift cylinder on one side is
explained below as an example.
1. Place chocks (1) under the load wheels and drive wheel.
1
2 1
B4Z16905
4 B4Z16906
B4Z16907
INSTALLATION
For installation, reverse the removal procedure.
FORK CARRIAGE
REMOVAL
1. Place chocks (1) under the load wheels and drive wheel.
1 – 1.5 t 160 kg
1.8 t 180 kg
1
B4Z16908
4. Remove the cotter pin (2) and pull out the pin (3). Then, sepa-
rate the chain and remove the chain from the chain roller.
5. Operate the lift operating lever to raise the inner mast so that
the fork carriage can be removed.
6. Operate the crane to pull the fork carriage out of the vehicle in
the forward direction.
B4Z16909
INSTALLATION
For installation, reverse the removal procedure.
MAST
REMOVAL
1. Park the machine in a flat place.
2
1
1
B4Z16910
6. Hoist the roller support, using the crane. After loosening the lift
chain, place the wooden block (4) in between the mast and the
chain.
7. Lower down the roller support, using the crane. Then, pinch the
wooden block with the mast and the lift chain to fix it.
8. Operate the operating lever to reliev any pressure remaining in
4 the piping.
9. Remove the drain plug on the hydraulic tank to drain the
hydraulic oil. After draining, replace the plug.
10. Remove the piping.
a After removing the pipings, attach a blank plug to the
piping to prevent loss of hydraulic oil and entry of dust.
B4Z16911
11. Remove the sling. Attach a hook to the outer mast, hoist it
using the crane and keep it suspended.
12. Remove the stopper bolt (5) at the tip of reach leg at right and
left sides.
13. Operate the crane to pull the mast out of the vehicle in the for-
ward direction.
B4Z16912
INSTALLATION
Install in reverse steps and note the following points.
㪼 1. Reach leg roller (Rear side)
1) Selection of roller
Select a roller so that the clearance e between rail and
roller is 0.1 to 0.5 mm.
2) Shim adjustment
Adjust using the shims of same thickness for right and left
㪹㪋
sides so that the roller touches the rail lightly (b4 is 0.1 to
0.3 mm) when contacting closely the roller to the rail in the
reach-out state.
㪌㪅㪉
2) Screw adjustment
Set in the reach-out state so that the clearance f between
㪹㪊
mast and leg rail becomes identical at right and left sides.
Adjust by turning the screws at right and left sides by the
㪻 same amount so that the roller touches lightly to the rail
(b3 is 01 to 0.3 mm.) when contacting closely the roller to
the rail.
TRANSFER
3. Remove the fixing bolts (2) and then the steering (3).
2
3
B4Z16913
4. Hoist the rear inspection door (4) with the crane to remove it.
25 kg
B4Z16914
8. Remove two EPS fixing bolts and then the EPS assembly (10)
while lifting upward and pulling out backward.
20 kg
10
11
10. Remove the wiring (12) of pump motor at three locations and
the speed sensor connector (13) at two locations.
12
13
11. Remove three pump motor fixing nuts and hoist the pump
15 motor (16) with bracket (14) and main pump (15) installed
using the crane to remove the pump motor.
46 kg
16
14
13. Remove the cotter pin (17) and then the brake linkage.
17
14. Remove four drive motor fixing bolts. Hoist the drive motor (18)
with brake installed using the crane and pull it out backward.
50 kg
18
15. Hook the head guard and hoist it with the crane. While hoisting
the head guard, remove four transfer fixing bolts (19).
19
19
17. Hoist the frame with the crane and remove the transfer from
the lower side of frame.
3. Remove the fixing bolts (2) and then the steering (3).
2
3
B4Z16915
4. Hoist the rear inspection door (4) with the crane to remove it.
B4Z16916
B4Z16917
B4Z16918
7
8
9. Remove two EPS fixing bolts and then the EPS assembly (10).
10
B4Z16919
11
11. Remove the wiring (12) of pump motor at three locations and
the speed sensor connector (13) at two locations.
12
13
12. Remove three pump motor fixing nuts and hoist the pump
15 motor (16) with bracket (14) and main pump (15) installed,
using the crane to remove the pump motor.
46 kg
16
14
14. Remove the cotter pin (17) and separate the brake linkage.
17
15. Remove four drive motor fixing bolts. Hoist the drive motor (18)
with brake installed with the crane and pull it out backward.
50 kg
18
16. Remove the fixing bolt and then the side panel (19).
19
17. Hook the head guard and hoist it with the crane. While hoisting
the head guard, remove eight transfer fixing bolts (20).
20
19. Hoist the frame with the crane and remove the transfer from
the lower side of frame.
INSTALLATION
Install in reverse steps and note the following points.
245 – 309 Nm
2 Suspension fixing bolt
{25 – 31.5 kgm}
50 kg
RS Type
6. EPS actuator
Apply the MOLI DRY SPRAY 5510 to the spline portion.
(RL type)
REMOVAL
When performing the battery draw operation, ensure to
1 set the fork lift truck in the unload state.
4. In the state that the mast is completely retracted, step down the
battery lock pedal (2) to the lowest position.
Ensure to step down the battery lock pedal to the lowest
2
position. Otherwise, it leads to damage to the battery.
5. While stepping down the lock release pedal, turn the reach
lever forward to push out the mast.
The battery case (3) is drawn out together with the mast. (The
figure at the left hand side shows the drawn-out battery case
(3).)
8. Hoisting four holes of battery case (3) with the lifting sling,
replace the battery.
a For battery mass, refer to the table below.
B4Z16920
INSTALLATION
1. Park the fork lift truck on a flat place.
REMOVAL
When performing the battery draw operation, ensure to
1 set the fork lift truck in the unload state.
4. In the state that the mast is completely retracted, step down the
battery lock pedal (2) to the lowest position.
Ensure to step down the battery lock pedal to the lowest
2
position. Otherwise, it leads to damage to the battery.
5. While stepping down the lock release pedal, turn down the
reach lever forward to push out the mast.
The battery case (3) is drawn out together with the mast. (The
figure at the left hand side shows the drawn-out battery case
(3).)
6. Separate the battery plug (12) using the battery plug release
lever (4).
10. Aligning the positioning pole (8) at the battery stand (or carrier)
with the positioning pole (9) at the tray side, insert the hook at
the tip of battery (or carrier) in the groove at the tray side.
11. Release the stopper (10) at the tray side and the stopper (11)
at the stand (or carrier) side.
INSTALLATION
1. Park the fork lift truck on a flat place.
6. Lock the stopper (10) at the tray side and the stopper (11) at
the stand (or carrier) side.
8. Turn the tray door stopper (7) to release it from the tray.
12. Confirm that the hydraulic hose sits on the hose guide (4) of
battery case.
a If the hydraulic hose is dislocated from the hose guide,
13 place it on the hose guide.
14
14. Pull slowly the reach lever (1) toward you. Then, the battery is
1 pulled in together with the mast.
15. Operate the reach lever (1) until the mast is completely pulled
in and stops.
The battery case is locked and fixed to the fork lift truck.
When operating the reach, be positioned properly in the
operator's compartment.
REMOVAL
1. Park the machine in a flat place and place car stops under the
front and backside of the load wheel.
Jack up the frame so that the drive wheel should be 120 mm
above the ground. (Use the frame lifting fitting.)
After the jack-up, apply a square timber to the bottom of the
frame for safety.
2. Turn the drive wheel 90° so that it can face sideways, and then
remove the mounting bolts.
INSTALLATION
1. Raise the wheel and assemble it to the transfer by pushing
bottom of the tire with your knee.
CONTROL VALVE.....................................................................40-39
TILT CYLINDER........................................................................40-43
MAST ........................................................................................40-45
DRIVE MOTOR.........................................................................40-46
EPS MOTOR.............................................................................40-48
TRANSFER
STRUCTURE
RW type
Turning bearing
Support L-support
Turning bearing
Turning gear
Motorshaft gear
Intermediate gear
Pinion shaft
Drive shaft
Drain plug
Side cover
Bevel gear
DISASSEMBLY
1. Support
1
1) Remove the joint (1).
2
2) Remove the screw (2), nut (3) and plate (4).
3
5 3) Remove the support (5).
4
2. Side cover
1) Remove six bolts (6) and then the side cover (7).
a Remove the drain plug (8) to drain oil beforehand.
3. Turning gear
1) Remove four bolts (9).
9
2) Remove the Turning gear (10) and the oil seal (11).
10
11
4. Upper cover
1) Remove eight bolts (12) and then the upper cover (13).
12
13
16
ASSEMBLY
1. Bearing, outer-lace, oil seal
3 Drive the outer-laces (1) and (2) of bearing and the oil seal (3)
2 in the case.
7
147 – 196 Nm {15 – 20 kgm}
Lock nut (8)
(After tightening the lock nut, caulk it.)
11 1) Assemble the pinion shaft assembly (9) and the shim (10)
in the case.
a For amount of shim, refer to step 3 in “Note when
assembling”.
10
9 2) Adjust the backlash and tooth contact.
a Refer to steps 4 and 5 in “Note when assembling”.
6. Side cover
Install the side cover (15) to the case with the bolt (16).
15
17
7. Upper cover
18 Install the O ring (19) to the upper cover (18). Then, install the
20
upper cover to the case with eight bolts (20).
9. Support
31 27
1) Drive the bearing outer-laces (27) and (28) in the support
(26).
26 2) Assemble the steering shaft (29) and the bearing (30) in
30 the support (26) and fix them with the snap ring (31).
3) Assemble the support (26) in the upper cover (18).
28
29 18
STARTUP TORQUE
1. Turning bearing block
As the startup torque can be changed by the degree of nut
tightening, adjust by tightening the nut so that the startup
torque becomes 14.7 to 17.6 Nm {1.5 to 1.8 kgm} (81.3 to
97.0 N {8.3 to 9.9 kgf}) in the center of steering pinion gear.
b = (B – 152.15) × 100
6) Mount the shim of S1 on the pinion shaft and put it into the
housing (the thickness of the shim must be the same for
the right and left of pinion shaft).
g = (33.7 – G) × 100
5) Insert the values of the (e), (f) and (g) calculated above
into the following expression and calculate the shim
thickness S2 for the back of the bevel gear (round the
calculated value off to one decimal place)
e+f+g
S2 = 0.29 +
100
6) Mount the shim of S2 on the bevel gear and put it into the
housing.
3. Checking backlash
1) After assembling the bevel gear and pinion shaft, measure
the backlash.
2) The backlash must be in the range between 0.06 and
0.25.
3) If the backlash is not in the correct range, adjust the
thickness of the shim (S2) used for the bevel gear.
2) Cross contact
Since these conditions cannot rallly be corrected, use
gear without an adjustment unless the small or big end.
3) Miss contact
EPS ACTUATOR
STRUCTURE
E.P.S. Motor
Slider case
Sensor
Piston roller
shaft
Plug
Spring
Slider roller shaft
Spacer
Slider roller Shaft A
Intermediate gear
E䊥䊮䉫
Gear
Gear case
DISASSEMBLY
Note on assembling
(1) The actuator is a precision instrument. When disassembling the actuator, never force the parts by a screwdriver on a
machined area because it must not be gouged or scratched Place a soft plastic sheet on the work bench.
(2) Take care to prevent grease flowing out of the actuator when it is assembled.
(3) Work should be performed on a work bench (Special Tool No. 11).
Fig. 4-1
Fig. 4-2
3) Hit with the plastic hammer the output shaft (8) that is
marked with arrow in the figure at the left hand side and
disengage the shaft from the bearing.
4) Remove the gear case cover (6) from the gear case (7).
6
7
8
10
12
8. Output shaft
Remove the snap ring (14) first and then the output shaft (8)
from the gear case cover by hitting with the plastic hammer as
shown in the figure at the left hand side.
14
A (16)
C (15)
D
E
B (8)
ASSEMBLY
Note on assembling
(1) Assemble on the work bench (special tool No.11).
Special tool
No.11
2. Output gear
4 1) Grease in the gear case (3).
2) Assemble the output gear (4) in the gear case.
3
MOLY
SPEED
GREASE
No. 0
3. Intermediate gear
5
6 1) Drive the bearing (6) in the intermadiate gear (5) and
assemble them in the gear case.
MOLY SPEED 2) Grease again as shown in the figure at the left hand side.
GREASE No. 0
12
7. Dowel pin
Drive the dowel pin, using the special tool No. 7.
8. EPS motor
1) Apply the sealing agent (THREEBOND #1215) to the EPS
Motor bracket and assemble it.
EPS motor
Motor
4 2
A: 4.1 +0.02
–0 (Drive with the special tool No.2)
B: 4.5 +0.02
–0 (Drive with the special tool No.1)
15
13. Spring
Set the spring (19) in the slider (15) as shown in the figure at
the left hand side.
a Assemble the input shaft (20) so that the pin at the lower
side enters in the cut portion of spring and the pin at the
upper side enters in the cut portion of slider.
a Thickness of shim
Insert the shim so that the clearance between the
shim and the snap ring becomes 0.2mm.
20 kg
2) Drive the piston roller shaft (25) in the piston roller (24),
using the special tool No. 5.
3) Place the piston in the piston case and confirm that the
piston moves lightly.
4) Apply LOCTITE #271 to the screwed portion of piston
roller shaft (25) and screw it in the piston.
2) Tighten tentatively the fixing screw (28) and drive the pin
(27), using the special tool No.3. Then, tighten the fixing
screw (28).
28
27
1) Attach the sensor to the piston case using the 8) When the measured voltage is outside of the
mounting screw. range, increase or decrease the shim quantity
2) Set the EPS voltage checker as shown in the so that the voltage falls into the range.
drawing above.
When the voltage is Decrease the shim
3) Turn the EPS voltage checker volume so that the above the range amount
voltage on terminals and becomes 8 V.
When the voltage is Increase the shim
4) Measure the voltage between terminals below the range amount
and . This voltage is regarded as V1.
[Varying quantity of shim by 0.1 mm results in 0.07 V change in the voltage.]
5) Insert the value of V1 to the following
expression and calculate the shim quantity (T) 9) Insert the bar to the input shaft and, while
of shim A. turning the input shaft with hand, measure the
voltage between terminals and again.
T = (4 – V1) / 0.7 (mm)
4 ± 0.3 V
Voltage value
6) Remove the sensor. (at rotation of the input shaft)
Place the shim corresponding to quantity T,
a In case the voltage at certain position is
and then attach the sensor to the piston case
out of the range, adjust the shim so that
again.
all measured voltages are within the
7) Measure the voltage between terminals range at any given position.
and again, and make sure the voltage is
within the range given below.
10) Secure the output shaft so that it will not rotate. 11) Secure the output shaft again as done in step
Turn the input shaft to right or left, then move 10 above. Rotate the input shaft to its right and
your hand off the input shaft to let it move left extreme positions. Then, measure the
freely. After the input shaft is returned to its voltages between terminals and at 6 to
original position by the spring force (it is 8 positions along the circumference and make
neutral then), measure the voltage between sure that they are all within the range.
terminals and several times.
Make sure measured voltages are within the Voltage Full clockwise rotation: 7 ± 0.4 V
range given below. value Full Counter clockwise rotation: 1 ± 0.4 V
Decrease shim
1.4
Left extreme
0.6
Increase shim
SST1 – 5
SST2 4.0 +0.01 7 0 ± 0.1 15 20 4.1 +0.02 10.0 +0.05 80.0 10.0
–0 –0 –0
SST3 4.0 +0.01 9.0 ± 0 1 15 20 3.5 +0.02 20.0 +0.05 70.0 10.0
–0 –0 –0
SST6
SST7
SST8
SST9
SST10
Weld A on the back of the B with a 1 mm spigot joint, so that the height of the A is 21 mm.
SST12
BRAKE SYSTEM
STRUCTURE
Adjusting screw
Brake spring
Pad
Brake spring
Disc brake
Pad
Adjusting screw
Cam
Support
Pin
DISASSEMBLY
1. Loosen the Brake spring Lock nut (1) on the brake springs to
1 make the brake inoperative.; Then remove the brake spring
Lock nut and the brake spring (2).
3. Remove the pin (5), the adjusting screw (6), and the cam (7).
6
a Do not grip the cam with pliers.
5 7
ASSEMBLY
Assembly of the disk brake is the reverse of the disassembly
procedure.
Pay attention to the following:
a Take care not to smear oil on the pad friction face or the
disk.
Grease the perimeter of the cam 3. Referring to “Chapter 20 Inspection/Adjustment”, adjust the
disc brake, brake pedal and linkage.
CONTROL VALVE
D
E
B
A
2. Repair scratches on the spool and body interiors by 4. Wash metallic parts in kerosene, gas oil, or
polishing them with a fine grindstone or an abrasive trichlene Coat them with hydraulic oil by spraying
cloth. with air.
3. Wash rubber parts in hydraulic oil. Grease them 5. Keep away from fire.
before mounting. Assemble them by taking care not
to damage them.
LIFT CYLINDER
STRUCTURE
(More than 4 m)
(Less than 4 m)
Item Unit High Lifting Height 3 to 3.5m High Lifting Height Higher than 4.7m
a Numbers in the figure correspond to numbers in the exploded view in the previous page.
a The lift cylinder of RW and RL (3 to less than 4m) fork lift trucks differs in shape from that in the above figure.
Judging standard
Judging Standard
Sym
Check Item Basic dimension Allowable limit Treatment
bol
(mm) (mm)
Clearance between High lifting height: 3 – 4.5 m 0.06 – 0.235 0.4 Replace a
A
piston rod and bushing High lifting height: higher than 4.7m 0.04 – 0.023 0.35 bushing.
Clearance between High lifting height: 3 – 4.5 m 0.05 – 0.30 0.5 Replace a
B
piston ring and cylinder High lifting height: higher than 4.7m 0.05 – 0.035 0.5 piston ring.
TILT CYLINDER
Stroke 43 mm
REACH CYLINDER
MAST
STRUCTURE
ADJUSTMENT AT ASSEMBLY
Referring to “Chapter 20 Inspection/Maintenance”, adjust.
DRIVE MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
PUMP MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
EPS MOTOR
STRUCTURE
DISASSEMBLY
1. Remove the brush band.
2. Remove the M4 screw and raise the brush spring to take out
the brush.
3. Remove the through bolt and remove the rear and front
brackets.
a Gently lift and remove the brackets without wrenching
them off
4. Hold the front part of the armature and firmly pull the armature
straight out.
a Take care not to damage the armature and magnet. Make
sure that dust or metal powder has not accumulated on
the magnet.
ASSEMBLY
Carry out assembly in the reverse order to removal, paying attention
to the following points.
1. Direction of yoke
Note the front and rear sides of the yoke.
3. Movement of brushes
Place the brushes in the brush holder. With the brush springs
set, confirm that the brushes move smoothly in the holder.
4. Positioning notches
Align the notches provided on the yoke and rear bracket for
assembly.
2. Insulation resistance
As illustrated, set the (–) ground probe of the megohmmeter to
the through-bolt and the (+) line to the connector pin. Make
sure the insulation resistance measurement reads the
specified value.
3. No-load operation
With power supplied at 12 V, perform no-load operation to
check the points below.
CASTER WHEEL........................................................................50-5
BRAKE......................................................................................50-12
TILT CYLINDER........................................................................50-19
MAST ........................................................................................50-19
DRIVE MOTOR.........................................................................50-20
CONTROLLER .........................................................................50-26
TRANSFER
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
Adjust using
Backlash between pinion shaft and
C – 0.1–0.25 shim (S2) for
drive gear
drive gear
DRIVE WHEEL
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
LOAD WHEEL
G.L
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
RS, RW TYPE
㩿㪪㪼㫋㩷㫃㪼㫅㪾㫋㪿㩷㫆㪽㩷㫊㫋㫆㫇㫇㪼㫉㩷㪹㫆㫃㫋㪀
245 – 309 Nm {25 – 31.5 kgm}
㪉㪌㪅㪌
Z
X-X
Y
X
24.5
(Set length of stopper bolt)
Z
Y
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
CASTER WHEEL
RL TYPE
Bracket
Damper (E)
Rubber
B C
Support
Upper shim
Rod head A
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
• When the tires are worn, you must adjust the shims of the left caster wheel and right caster bracket.
• When the drive wheel slips or the braking distance is increased, you can also increase the drive wheel load by this
adjustment.
• As the drive wheel load is increased, the turning stability lowers. Accordingly, be sure to check the travel after adjust-
ment and confirm that the adjustment level is proper.
1. Adjustment standard
Measure the wear of the drive wheel and the right and left caster wheels, and then perform the following adjustment.
(See the table below)
• If the wear of the drive wheel is 10 mm or Çåarger than that of the caster wheel, "Adjustment A" or "Adjustment B" is
required. For "Adjustment A" and "Adjustment B", see "3. Shim adjustment procedure (8)".
Example 1) Wear of drive wheel: 16 mm Example 2) Wear of drive wheel: 32 mm
Wear of caster wheel: 5 mm Wear of caster wheel: 10 mm
16 mm – 5 mm = 11mm o Adjustment A 32 mm – 10 mm = 22 mm o Adjustment B
• If the wear of the caster wheel is 10.8 mm or larger than that of the drive wheel, replace the caster wheel.
If the wear of the drive wheel is 35 mm or larger than that of the caster wheel, replace the drive wheel.
8
7
6 Range of adjustment A
5
4 Range of adjustment B
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Wear of drive wheel
2. Measurement of wear
Allowable wear
Measure the outside diameter of the tire or thickness of the
remaining rubber of the tire, and then calculate the wear of the tire.
Upper shim
Lower shim
㻰㼐㻌
㻰㼏㻌
㼀㼏㻌
㻰㼏㻌㻔㻻㼡㼠㼟㼕㼐㼑㻌
㼀㼏㻌
B4Z16923
6) Raise the frame with a jack so that the drive wheels are at
20 mm above the ground.
a Use the fitting for lifting the frame.
7) After jacking up, place wooden blocks under the frame for
safety.
B4Z16924
8) Loosen bolts (1) and (2) (M10) at the top of the left caster
㻞 wheel by approximately 5 mm.
䠍㻌
a Loosen bolt (1) at the deeper position first for the
structural reason.
a If the bolts are loosened too much, the caster
wheel will drop. Take extreme care not to loosen
too much.
9) Remove shim (3) according to the classification of
adjustment determined by measuring the wear of the
tires.
B4Z16925
a When shipped, two shims are inserted.
Adjustment A:
㻟㻌 Remove one shim and leave one shim.
Adjustment B:
Remove two shims and leave no shim.
a Store the removed shim(s) carefully, since it is
(they are) reused when the tire is replaced.
10) Tighten bolts (1) and (2) (M10) at the top of the left caster
wheel.
a Tighten bolt (2) at the nearer position first for the
structural reason.
3 Tightening torque: 34 to 74 Nm {3.5 to 7.5 kgm}
B4Z16926
Frame
Mounting face
B4Z16928
adjustment bolt b
adjustment bolt a
G2-LI
X
ADJUSTMENT
1. Adjustment of play of tray at front and rear
1) Push the tray in the depth of frame rear block and link it with the pedal link.
2) Draw out the tray and touch the head of bolt (a) to the rear block, eliminating the play of pedal.
3) Rotate counterclockwise the bolt two turns (turn back) and fix it with the lock nut.
2. Adjustment of tray push-in bolt (Portion P)
1) Reach in and rotate the bolt until the head of bolt touches the rubber (stopper).
2) Reach out and rotate the bolt two turns and fix it with the lock nut.
3. Adjustment of play of tray at right and left.
1) Push the tray to the right side.
2) Loosen the nylon nut fixing the adjustment plate and screw in the adjustment bolt (b) until it touches the edge of
guide leg.
3) Turn back the adjustment bolt (b) (counterclockwise) 1.5 turns and fix it with the lock nut.
RL type
ADJUSTMENT
1. Adjust so that the limit switch turns on when the dimension A1, which is the difference between point E and point F,
is 9 mm (Faces A and B are in parallel.).
2. Adjust the length of stopper D so that the limit switch C turns off when the dimension A2, which is the difference
between point E and point F, is 23.5 mm.
RW type
ADJUSTMENT
1. Adjust so that the limit switch turns on when the dimension A1, which is the difference between point E and point F,
is 1 mm (Faces A and B are in parallel.).
2. Adjust the length of stopper D so that the limit switch C turns off when the dimension A2, which is the difference
between point E and point F, is 13 mm.
Switch
5 mm
(at both right and left)
㪈 㪉 㪊
㪭㫀㪼㫎㪼㪻㩷㪽㫉㫆㫄
㪼㫅㪾㪸㪾㪼㫄㪼㫅㫋
ADJUSTMENT
1. Adjust the plate C so that the roller B turns on when the roller comes to the position A and the roller B turns off when
depressing the roller 10 mm. At this moment, the switch B should not be forcibly pressed.
2. After installing the floor plate, check the conduction between above connector pins.
Pins 2 and 3 only are conducted. Pins 1 and 3 only are conducted.
BRAKE
Pad
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
Replace 2
A Thickness of brake pad 11 4
sheets as a pair.
B Surface of cam to contact to adjusting screw • It is not worn to the extent of metal
exposure.
C Surface of adjusting screw to contact to cam • No scar is found.
EPS ACTUATOR
'
$
&
'
O
<
O <
<
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
B Gear case cover machining surface Shall be free from flaws or bruising
Replacement
C Piston sliding surface Shall be free from flaws
Replace
together
E Bush sliding surface Shall be free from flaws or abnormal wear
with piston
case
LOCKTITE #271
ADJUSTMENT
1. Adjust the lift potentio meter so that the output becomes 2.5V ± 0.1V when the lever is in the neutral position.
Then, turn the lever backward and confirm that the output is 1.2V ± 0.1V.
Return the lever in the neutral position again and confirm that output is 2.5 ± 0.1V
2. Adjust the micro-switches of tilt, reach and attachment so that they turn on within the stroke of 15 to 25 from the lever
neutral position.
CONTROL VALVE
C
B
Judgment criteria
Symbol Check item Treatment
Standard size Allowable limit
(mm) (mm)
LIFT CYLINDER
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
Replace the
A Clearance between piston rod and bushing 0.06 – 0.235 Less than 0.4
bushing
Replace the
B Clearance between cylinder and piston ring 0.05 – 0.30 Less than 0.5
piston ring
Judgment criteria
Check item Treatment
Standard size (mm) Allowable limit (mm)
Replace the
Clearance between piston rod and bushing 0.04 – 0.023 0.35
bushing
Replace the
Clearance between piston ring and cylinder 0.05 – 0.035 0.5
piston ring
REACH CYLINDER
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
A Clearance between cylinder head and piston rod 0.19 max. 0.35 max.
TILT CYLINDER
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
MAST
Judgment criteria
Check item Treatment
Standard size (mm) Repair limit (mm)
0.5–1.0
To side 2.0 (0.08) Shim adjustment
(0.02–0.04)
Clearance between outer
and inner masts
0.1–0.3 Replace with the
To front/rear 2.0 (0.08)
(0.004–0.012) oversize roller
0.5–2.0
To side 2.0 (0.08) Shim adjustment
(0.02–0.08)
Clearance between inner mast and
roller support
0.1–0.3 Replace with the
To front/rear 2.0 (0.08)
(0.04–0.012) oversize roller
DRIVE MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
MAINTENANCE
1. Routine Maintenance
1) Maintenance at operation
Dust Motor frame operation. Normal temperature rise. accumulated, stop and
Visual check. clean it.
2) Maintenance at stop
Dust sticking.
Iron core Clean.
Visual check.
Stator and rotor
assembly Coil and Clean.
Insulating resistance is more than 1 M.
insulation of Dry by heating.
(Measure at 500 V mega.)
connected part Vanish work.
Reference value
Temperature Measure the At 20°C: 11.7 – 14.3 k
sensor resistance. At 25°C: 9.7 – 11.8 k
Dust, discolor, peeling and rust should not exist. Rust prevention.
Paint Damage Visual check. Re-paint.
Clean.
Dirt, dust Dirt, sticking of dust and rust should not exist.
Cleaning Rust prevention.
accumulation Visual check. Re-paint.
PUMP MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
MAINTENANCE
1. Routine Maintenance
1) Maintenance at operation
Dust Motor frame operation. Normal temperature rise. accumulated, stop and
Visual check. clean it.
2) Maintenance at stop
Dust sticking.
Iron core Clean.
Visual check.
Stator and rotor
assembly Coil and Clean.
Insulating resistance is more than 1 M.
insulation of Dry by heating.
(Measure at 500 V mega.)
connected part Vanish work.
Reference value
Temperature Measure the At 20°C: 11.7 – 14.3 k
sensor resistance. At 25°C: 9.7 – 11.8 k
Dust, discolor, peeling and rust should not exist. Rust prevention.
Paint Damage Visual check. Re-paint.
Clean.
Dirt, dust Dirt, sticking of dust and rust should not exist.
Cleaning Rust prevention.
accumulation Visual check. Re-paint.
B: Depth of mica
D: Insulation of armature
0.5 M
D Insulation of armature –
or more
Megohmmeter
E Insulation of field coil
(DC 500 V)
Replace
0.5 M
F Insulation of holder ring –
or more
2.5 N
G Pressing force of brush spring Spring balance 3.9 N {0.4 kgf}
{0.25 kgf}
CONTROLLER
Item Specification
Input Voltage 48 V
EPS 30 ± 1.5 A
Rated Voltage 48 V
CASTER WHEEL........................................................................60-6
SUSPENSION ............................................................................60-7
BRAKE........................................................................................60-8
FV MAST (STD)........................................................................60-16
VT MAST ..................................................................................60-18
CONTROLLERS .......................................................................60-21
FR ACCELERATOR..................................................................60-26
TRANSFER
RL type
A-A
GO75 (3.4 )
LG-5
A A
LOCTITE #271
Z Y
In the center of steering pinion gear
81.3 – 97.0 N {8.3 – 9.9 kgf }
14.7 – 17.6 Nm
Startup torque
{1.5 – 1.8 kgm}
NLGI NO.2
(SAE J 310a) LOCTITE #271
G2-LI
147 – 196 Nm {15 – 20 kgm}
NLGI NO.2
(SAE J 310a)
LG-5
Measurement b
Case stamp a
Shaft stamp d
Shaft stamp c
RW type
LG-5
GO75 (3.4 )
LOCTITE #271
1+..'8'.
5.9 – 11.8 Nm
{0.6 – 1.2 kgm}
Z Y
In the center of steering pinion gear
81.3 – 97.0 N {8.3 – 9.9 kgf }
Startup 14.7 – 17.6 Nm
LOCTITE #271
torque {1.5 – 1.8 kgm}
G2-LI
NLGI NO.2
(SAE J 310a) NLGI NO.2
(SAE J 310a)
LG-5
Measurement b
Case stamp a
Shaft stamp d
Shaft stamp c
Gear
Startup 7.8 – 9.8 Nm stamp h Bearing measurement g
torque {0.8 – 1.0 kgm} G2-LI
Case stamp d
CASTER WHEEL
RL type
Bracket
5
8
Cap
Damper* Pin
G2-LI
G2-LI
Nut
Washer
Rubber
Stud Bearing
Damper
Support Bracket
Link
Bearing
Dust seal
Bracket Seal
Plate
Bracket
Plate 39 – 49 Nm
{4 – 5 kgm}
Washer
Bracket
Spring
Link
Bracket
Bushing
G2-LI
Bearing
Bracket
SUSPENSION
RW type
㩿㪪㪼㫋㩷㫃㪼㫅㪾㫋㪿㩷㫆㪽㩷㫊㫋㫆㫇㫇㪼㫉㩷㪹㫆㫃㫋㪀
245 – 309 Nm {25 – 31.5 kgm}
㪉㪌㪅㪌
Z
X-X
Y
X
24.5
(Set length of stopper bolt)
Z
Y
BRAKE
G2-LI
3. The controller drives the EPS motor by using the energy from
the battery to rotate the output shaft in the direction in which
Output Actuator
the input shaft rotates (to eliminate the torsion of the shafts).
shaft
Battery Joint
Steering gear 4. The rotation of the output shaft is transmitted to the tire through
the steering gears.
3. The pin fitted on the input and output shafts widens the
opening of the spring. This produces a reaction force, which
becomes the steering wheel operating force.
3. The slider (B) rotates and moves up and down along the roller
(C) fitted on the output shaft.
5. The vertical motion of the piston (D) varies the resistance value
of sensor (E) and the electric signal sent to the controller
changes.
CONTROL VALVE
Poppet
Y㪄Y
Housing
A B
Spool
Y Y Spool
L
H
Lift
C H C
L
Cap
Tilt
Reach
Relief valve
Emergency
let-down valve
A3
Tilt cylinder
B2
A2
B1
A1
Reach cylinder
Relief valve
16.7 Mpa
{170 kgf/cm2 }
Lift cylinder
P T
Down control
valve
More than FV 4.0m
Down safety valve Lift turn
FV MAST (STD)
VT MAST
FORK CARRIAGE
CONTROLLERS
OUTLINE
The main control equipment, which consists of the following equipment, controls the travel motor, hydraulic motor and
speed control of electric power steering (EPS) motor.
1. Main controller ...................... It is divided into the inverter control block, contact block and command/signal
communication control block.
It controls the travel motor, hydraulic motor, meter panel display and performs the
diagnosis.
Inverter is a power converter to change direct current to alternating current of any voltage and frequency. It converts
battery power (direct current) to three phase alternating current, by changing the three switches, and controls the motor
efficiency by changing the shape (frequency and the height of the wave) of sine waves of the three phase alternating
current.
DC (*1) AC
PWM
Machine
Inverter 0
Battery (reverse conversion) Induced
DC Motor
0
Single phase and three phase
alternating current of variable
voltage and variable frequency
(ex: 6 Hz - 120 Hz)
*1. The unit to convert alternating current to direct current. Loaded on AC controller.
MOTOR POWER CIRCUIT CONNECTION (DRIVING, OIL PRESSURE, EPS MOTOR CIRCUITS)
The illustration below is simply showing machine style point of contact for the points of contact of power module and power
transistor, without fuse, electric current sensor or condenser.
Main contactor (MD) and PS contactor (MPS) are usually closed, when they are opened and the key-switch is ON.
*1
DU (ON/OFF) signal
F R
Drive DV
motor IM *1
DW
F/R signal
Print
(ON/OFF) signal
card
*1 Accelerator signal
(ON/OFF) signal
*1
PU (ON/OFF) signal
Pump PV
motor IM *1
PW Lift signal
Print
(ON/OFF) signal
card
Tilt
SW
*1 Reach
signal
ATT
(ON/OFF) signal
FUSE
(ON/OFF) signal
L. H. R. H.
*1. Switching over the switch (FET) creates alternating current, and rotates alternating current motor. (Signal)
lu lu
lv lv
lw lw
HJZ04907
2 Acceleration and Change the Accelerator Motor speed Regulating speed Motor power cycle
deceleration of frequency of voltage
motor RPM three phase
(increase and electricity to CPU sends ON
decrease of vehicle flow to stator signal to Fast
speed) power OFF
module
based on
the voltage,
to change
the ON
frequency of
three phase Slow OFF
electricity.
HJZ04908
3. Temperature Protection
Monitoring the temperature by temperature detect element, equipped near the power module. When the temperature
exceeds 105 °C/160 °C (travel, hydraulic), drop the flow rate and prevent damage from overheat.
Note) Not for battery protection. To detect excessive electric discharge of battery, check with “Battery Capacity
Meter”.
Torque control : It controls the torque corresponding to the EPS torque sensor signal.
Note) The EPS chopper extends the life of EPS motor brush and saves effectively the energy.
FR ACCELERATOR
6 1
1 Black - Yellow
Blue - Red SW1 SW2
7
2
Connection Grey 3 White Red - White
Red - Black
8
2 3
UL wire 1.5 sq
Backward Forward
AVS wire 0.5 sq
5
3.7
4
Toward SW1 Toward SW2 43 40 30 20 10
(backward) (forward) 10 20 30 4043
3
0.25
0
Output characteristics
MICRO-COMPUTER CHARGER
Since the automatic equal charging method is adopted, if the AUTO
button is pressed everyday, the micro-computer judges and
performs the equal charging whenever necessary.
POWER PLUG
The input cables are connected with screws. Therefore, no plug is
provided.
a The ground wire is marked with [E]. Three other wires (power
cables) have no polarity.
ELECTRO-MAGNETIC BREAKER
The thermal relay is provided to the electro-magnetic breaker as an
over-current protector.
When the over-current flows in the input side of charger for any
reason, the thermal relay activates and the electro-magnetic relay
breaks.
[Thermal Relay]
When asked from a customer what action he or she should take in case of “The check lamps are ON”, you can advice
them quickly. Because the trouble can be suspected, judging from the state of lamps.
Display Degree of
Suspected cause
L1 to L6 lamps State of lit lamps trouble
L1 to L3 are ON Light
The cause will be one of No1 to No.5 listed in the table
L1 to L4 are ON Blink
below. Light
L1 to L5 are ON Blink
1 Poor maintenance of power tap Switch the power supply tap to meet the input voltage.
Check that the connector of charger is not loose. Plug out and in the connector
2 Poor contact of connector
twice and clean the connector with the terminal cleaner to restore the contact.
Do not over-discharge.
3 Deterioration of battery
Check the deterioration and damage of battery.
CONFIRMATION AT TROUBLE
When a user informs of abnormality, confirm the following, suspect the cause and treat it.
5. Check the specific gravity of electrolyte in each cell and the temperature of electrolyte.
APPEAL MODE
This mode is convenient to guide the concrete charge operation and teach how to use the micro-computer charger.
How to operate
Plug the power plug in and push the [AUTO] and [EQUAL] buttons simultaneously for 2 seconds.
• The lamps, which indicates the start of charging to the finish, light in 10 seconds.
a Since the micro-computer checks the amount of charge, the battery is not over-charged.
ABNORMAL DISPLAY
• When the voltage does not reach the inflection point within 10 hours since the start of charging, the
lamp lights.
Light
• Charging continues further. And, in case of normal charge, charging stops in 13 hours. In case of equal
charge, charging stops in 15 hours.
• When the voltage does not reach the inflection point within 10 hours since the start of charging, the
lamp lights.
• Charging continues further. When the voltage reaches the inflection point within 13 hours in the normal
Blink charge or within 15 hours in the equal charge, the abnormal lamp blinks.
• In case of normal charge, charging stops in 13 hours. In case of equal charge, charging stops in 15
hours. The lamp is blinking.
amount of charge
About 62 V
58 V
of current flow
Charging voltage
Inflection point
Time
When the auto charge button is operated, the auto charge lamp lights yellow, indicating that the charger charges in the
equal charge.
(In case of normal charge, the lamp lights green.)
(Note 1) In the following cases, the time to perform the equal charge is automatically adjusted.
• When charging the battery discharged below 60%.
• When stopping the charge during charging.
• When implementing the equal charge.
(Note 2) When connecting or disconnecting the battery connector, the automatic equal adjustment function, that
memorizes the charger controller, is cleared. The memory of automatic equal adjustment function starts when
connected disconnected.
• When the equal charge is specially required (After re-filling pure water, electrolyte temperature below 10°C), push the
EQUAL button. When pressing the EQUAL button, the EQUAL display lamp changes from “lighting” to “blinking” and
the L1 lamp lights, telling the start of equal charge.
2. Cord connection
2
1) Turn the key switch off and press the power supply
release button to disconnect the power plug from the
body.
2) Insert the supply cord to the plant power supply and the
output plug cord to battery plug (the plug connected to the
cord from battery).
a When the plug connection is completed, the display panel
normal and equal lamps will flash.
• Before pulling out the cord, press the "Stop" button and
make sure the "Normal" and "Equal" buttons are turned on
indicating the initial state has been recovered.
5. Abnormality display
• If the charging time is abnormally long, the micro computer
judges it as an abnormal charge, thus stopping the charging
and bringing up the abnormality display.
• Abnormality display: The operation panel “CHECK” lamp
goes on.
a When the “CHECK” lamp went on, stop the charging
and contact a Komatsu dealer.
• The “CHECK” lamp goes off when the battery plug is pulled
out.
6. At power failure
• If a power failure occurred during the charge, the charge will
be stopped temporarily. Upon recovery from the failure, the
charging will be resumed from the point it had left before the
failure.
• However, if the failure duration exceeds an hour, pre-charg-
ing state is brought out, thus disabling the charging upon
recovery from the failure. Press the charging button again
when such state is present.
B4Z16283
㻷㻱㼅㻌㻿㼃 㻾㻱㻸㻭㼅㻌㻭
㼅㻾
㼅㻾
㼅㻾
㼅㻾
㻟 㻞 㻝 㻠 㻞 㻟 㻝
㻟 㻞 㻝 㻠 㻞 㻟 㻝
㼅㻾
㼃㻾
㼃㼅
㻮
㼃
㻷㻱㼅㻌㻿㼃
㼃㻾
㻜㻚㻤㻡㻌㻾 㼃㼅 㻮㻭㼀㼀㻱㻾㼅
㻟 㻟
CHASSIS 㻢㼂㻌EXTRACTION
HARNESS 㼅
㻞 㻞
㻮
㻮
㻠㻤㼂
㻝 㻝 㻞 㻞
㻲㼁㻿㻱
㼃
㻝 㻝
㻞㻭 㻢㼂
㻾 㻗㼂㼕㼚 㻰㻯㻙㻰㻯
㻝 㻝
㻔㻠㻚㻡䡚㻥㼂㻕 CONVERTER
㻮 㻮
㻞 㻞 㻙㼂㼕㼚
㻮㼞 㻗㼂㼛㼡㼠
㼃㻾
㻟 㻟
㼃 㻔㻟㻚㻟㼂㻌㻝㻚㻞㻭㻕
㻸
㻠 㻠 㻙㼂㼛㼡㼠㻔㻳㻺㻰
㼃㻾
㻻㻼㻱㻾㻭㼀㻵㻻㻺
㻸㼁㻹㻼
㼃㻾
㻮㼞
㼃
㼃
㼅
㻝 㻝 㻟 㻝 㻞 㻝 㻞
㻝 㻝 㻟 㻝 㻞 㻝 㻞
㻾
㼅
㻮
㼃
㻝㻚㻞㻡㼟㼝
㼃
㻳
㻮
㻮
㻾
㼃㻵㻾㻱
㻟 㻝 㻞 㻟 㻝 㻞 㻝 㻞
㻟 㻝 㻞 㻟 㻝 㻞 㻝 㻞
㻾
㻾
㻮
㻮
㼃
㻸㻭㻿㻱㻾
DIAGNOSTIC PROCEDURE BY
ABNORMAL CODE (ALA CODE) .............................................70-20
DIAGNOSTIC PROCEDURE BY
ABNORMAL CODE (ERR CODE) ............................................70-23
DIAGNOSTIC PROCEDURE BY
METER DISPLAY TROUBLE CODE ........................................70-60
METER PANEL.........................................................................70-92
DIAGNOSIS TOOL
a Prepare the tools needed for abnormal diagnosis.
4
1
2 3
5 6
B4Z16931
HARNESS LIST
B4Z16941
31 22
21 10
9 1 1
2
2
1
24 17
8 2 1
16 1
7 2 12 1
13
7
17
1
12
6 1 3
2
2 1
1 9
10 21
1 22 31
7 6
13 12
17 1
7
8
16
17
24
12 1
24 11
2
4
1 3
2
1
3
87 86
85
90
B4Z16942
2 1 3
1
3
4 1
2
2
1
3
31 22
21 10 1
9 1
3
17
24 8
16 1
13 7 1
7
17 1
12 2
6
2
1
2
2
1 9 1 1
10 21
1 22 31 2
7 6
13
12
17 1 7
8 2
16
2 17
4 24
1
1
1
3 2
1
2 1
1 2
The CPU board controls the controller and the gate drive.
Check visually the harmful scars and damages, serious discoloration and corrosion on the connector block.
Pay attention to the items below when checking.
• Do not touch components on the printed circuit board by hand to avoid damage from static electricity.
• Hold the edge of printed circuit board when handling.
• When carrying or storing the printed circuit board, be sure to pack it in the electrostatic prevention bag.
2. DSW SETTING
The DSW1 is the switch for selecting the travel and cargo handling.
ON KSD04 (The DSW2 is not used.)
DSW-ON position Note: The switch-over of cargo handling and travel cannot be
DSW-OFF position set.
1 2 3 4
DSW1
Setting of travel inverter unit
ON KSD04
DSW-ON position
DSW-OFF position
1 2 3 4
DSW1
Setting of cargo handling inverter unit
ABNORMAL DETECTION
When the abnormality occurs on the truck, the detection of
abnormality is announced by lighting the travel system abnormal
indicator (tire icon) and abnormal occurrence indicator (spanner
icon).
For first 10 seconds, the indicators blink and the alarm beeps.
4. Place the wooden blocks (3) under the frame at the right and
left sides to float the wheels from the ground.
5. Remove the front panel (4).
1
3
2
1 B4Z16934
B4Z16935
When measuring in the state that the fork lift truck is electric-
powered, float the drive wheels and fix them firmly not to rotate
when the motor suddenly starts to rotate.
In this state, lock the drive wheels, measure the maximum current
and perform the switch-back operation and hydraulic operation.
FUSE CHECK
Confirm that the fuses is not blown out.
4
2
1
13 14 15 16 17 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
13 14 15 16 17 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
3. EPS CONTROLLER
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
The key switch is turned on when the lift lever is Return the lift lever in the neutral
ALA-5006 position, turn off the key switch and < 70 – 20 >
in the position other than neutral position. turn it on again.
The key switch is turned on when the tilt lever is Return the tilt lever in the neutral
ALA-5007 position, turn off the key switch and < 70 – 20 >
in the position other than neutral position. turn it on again.
The key switch is turned on when the reach Return the reach lever in the neutral
ALA-5008 lever is in the position other than neutral position, turn off the key switch and < 70 – 21 >
position. turn it on again.
The key switch is turned on when the ATT 1 Return the ATT 1 lever in the neutral
ALA-5009 lever is in the position other than neutral position, turn off the key switch and < 70 – 21 >
position. turn it on again.
The key switch is turned on when the ATT 2 Return the ATT 2 lever in the neutral
ALA-500A lever is in the position other than neutral position, turn off the key switch and < 70 – 22 >
position. turn it on again.
Diagnostic
Code No. Content of Abnormality Procedure Page
ERR40-8110 The CAN communication process of meter panel is abnormal. < 70 – 36 >
ERR40-8120 The CAN transmission/reception process of meter panel is abnormal. < 70 – 41 >
ERR40-8140 The CAN transmission of meter panel is abnormal. < 70 – 49 >
ERR40-8314 The CAN communication between travel controller and meter panel is abnormal. < 70 –51 >
ERR40-8320 The CAN communication between EPS controller and meter panel is abnormal. < 70 – 53 >
The CAN communication between cargo handling controller and meter panel is
ERR40-8330 < 70 – 56 >
abnormal.
ERR40-8510 After key ON, the CAN communication of meter panel is abnormal. < 70 – 57 >
• The harness of ATT 2 lever sensor circuit is • The micro-switch of battery drawing lever is
defective. defective.
• The harness of battery drawing lever micro-switch is
defective.
Repair Procedure
Repair Procedure
1. Confirm that the battery drawing lever micro-switch
1. Confirm that the ATT 2 lever micro-switch signal is
signal is inputted.
inputted.
Measure the voltage between terminals No.16 and
Measure the voltage between terminals No.12 and
No.15 of connector CN1D.
No.17 of connector CN2P.
Normal Value: 0V (The battery is stored.)
Normal Value: 4.6V
4.6V (The battery is drawn out.)
(The ATT 2 lever is in the neutral position.)
2. If the voltage is normal in step 1, replace the travel
2. If the voltage is normal in step 1, replace the cargo
controller board.
handling controller board.
3. If the voltage is abnormal in step 1, check the
3. If the voltage is abnormal in step 1, check the
harness between micro-switch and travel controller
harness between lever micro-switch and cargo
and repair it.
handling controller and repair it.
4. If the voltage is abnormal in step 1 and the harness
4. If the voltage is abnormal in step 1 and the harness
is normal in step 3, repair the micro-switch.
is normal in step 3, repair the lever micro-switch.
Before implementing the diagnosis, ensure to pull out the battery plug.
Otherwise, the controller and the panel will be damaged. Because even if the key switch is turned off, the
CAN communication is powered.
1 2 3 4 5 6 7 8 9 10 11
CN1E 12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
1 2 3 4 5 6 7 8 9 10 11
12 11 10 9 8 7
12 13 14 15 16 17 18 19 20 21 22 25 24
6 5 4 3 2 1
How to reset
Turn OFF the key switch.
Remark
When ERR-5083 occurs simultaneously, the EPS
controller board is abnormal.
How to reset
Turn OFF the key switch.
Remark
OK: Go to step 2.
When ERR-4084 occurs simultaneously, the
NG: After cleaning the connector with the contact harness between travel controller and cargo
refreshing agent, re-connect the connector. handling controller is broken or the cargo handling
controller board is defective.
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
CN3D
Viewed from the engagement side of connector
OK: Go to step 3.
NG: Repair or replace the harness.
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3P
Viewed from the engagement side of connector
OK: Go to step 3.
NG: Repair or replace the harness.
Remark
When ERR-3084 occurs simultaneously, the
harness between travel controller and cargo
handling controller is broken or the cargo handling
controller board is defective.
When ERR-4081 occurs simultaneously, the
harness between travel controller and EPS
controller is broken.
OK: Go to step 3.
NG: Repair or replace the harness.
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3P
Viewed from the engagement side of connector
OK: Go to step 3.
NG: Replace or repair the harness.
How to reset
Turn OFF the key switch.
Remark
1) When ERR-3083 occurs simultaneously, the EPS
controller is defective.
2) When the harness between EPS controller and
cargo handling controller is defective, ERR-4084
takes the priority over other codes for display.
Content of Trouble
• Poor contact or short-circuit of CAN communication harness
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line at the meter
travel controller are not disconnected or not panel side.
loosened. Judging: Between meter panel terminal No.11 (green)
Judging: No disconnection of connector and no and meter pane terminal No.9 (blue):
looseness of terminal 20 k – 100 k
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
NG: Clean the connector with the contact refreshing NG: Repair or replace the equipment.
agent and re-connect the connector.
4. Disconnect the harness and measure the
resistance of CAN communication line at the travel
2. Measure the resistance at the terminals of CAN
controller side.
service connector in the state that connectors of all
equipment are connected. Judging: Between CN3D terminal No.9 and CN3D
terminal No.3 (blue): 20 k – 100 k
Judging: Between service tool terminal No.2 (green)
and service tool terminal No.3 (blue):
40 – 70 Travel Controller
CN3D
13 14 15 16 17
Service Tool
7 8 9 10 11 12
1 2 3 4 5 6
2 1
4 3
OK: Go to step 5.
Viewed from the engagement side of connector
NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short-circuit
test of CAN communication line of harness.
NG: Repair or replace the harness.
CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.
NG: Repair or replace the equipment.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
Content of Trouble
• Poor contact or short-circuit of CAN communication harness
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line at the meter
EPS controller are not disconnected or not panel side.
loosened. Judging: Between meter panel terminal No.11 and
Judging: No disconnection of connector and no meter pane terminal No.9: 20 k – 100 k
looseness of terminal
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
OK: Go to step 4.
OK: Go to step 2. NG: Repair or replace the equipment.
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. 4. Disconnect the harness and measure the
resistance of CAN communication line at the travel
controller side.
2. Measure the resistance at the terminals of service
tool. Judging: Between CN3D terminal No.9 and
CN3D terminal No.3: 20 k – 100 k
Judging: Between service tool terminal No.2 (green)
and service tool terminal No.3 (blue):
40 – 70 Travel Controller
CN3D
13 14 15 16 17
Service Tool
7 8 9 10 11 12
1 2 3 4 5 6
2 1
4 3
OK: Go to step 5.
Viewed from the engagement side of connector
NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short-circuit
test of CAN communication line harness.
NG: Repair or replace the equipment.
CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.
NG: Repair or replace the equipment.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
Content of Trouble
• Poor contact or short-circuit of CAN communication harness
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line at the meter
cargo handling controller are not disconnected or panel side.
not loosened. Judging: Between meter panel terminal No.11 and
Judging: No disconnection of connector No looseness meter pane terminal No.9: 20 k – 100 k
of terminal
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
OK: Go to step 4.
OK: Go to step 2. NG: Repair or replace the equipment.
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. 4. Disconnect the harness and measure the
resistance of CAN communication line at the travel
controller side.
2. Measure the resistance at the terminals of service
tool. Judging: Between CN3D terminal No.9 and
CN3D terminal No.3: 20 k – 100 k
Judging: Between service tool terminal No.2 (green)
and service tool terminal No.3 (blue):
40 – 70 Travel Controller
CN3D
13 14 15 16 17
Service Tool
7 8 9 10 11 12
1 2 3 4 5 6
2 1
4 3
OK: Go to step 5.
Viewed from the engagement side of connector
NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short-circuit
test of CAN communication line harness.
NG: Repair or replace the harness.
CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.
NG: Repair or replace the equipment.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
Content of Trouble
• Poor contact or short-circuit of CAN communication harness
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line at the meter
meter panel are not disconnected or not loosened. panel side.
Judging: No disconnection of connector and no Judging: Between meter panel terminal No.11 and
looseness of terminal meter panel terminal No.9: 20 k – 100 k
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
NG: Clean the connector with the contact refreshing NG: Repair or replace the equipment.
agent and re-connect the connector.
4. Disconnect the harness and measure the
resistance of CAN communication line at the travel
2. Measure the resistance at the terminals of service
controller side.
tool.
Judging: Between CN3D terminal No.9 and
Judging: Between service tool terminal No.2 (green)
CN3D terminal No.3: 20 k – 100 k
and service tool terminal No.3 (blue):
40 – 70
Travel Controller
CN3D
Service Tool
13 14 15 16 17
7 8 9 10 11 12
2 1
1 2 3 4 5 6
4 3
OK: Perform step 3 and later. Perform the short-circuit NG: Repair or replace the equipment.
test of CAN communication line harness.
NG: Repair or replace the harness.
CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.
NG: Repair or replace the equipment.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
Content of Trouble
• Poor contact or short-circuit of harness connector of travel controller
• Abnormal travel controller
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
travel controller are not disconnected or not travel controller and EPS controller.
loosened. Judging: Between CN3D terminal No.9 (green)
Judging: No disconnection of connector and no and CN1E terminal No.3 (green): 0
looseness of terminal Between CN3D terminal No.3 (blue) and
CN1E terminal No.14 (blue): 0
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3D
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. OK: Replace the travel controller.
NG: Repair or replace the harness.
2. Measure the resistance at the terminals of service
tool.
4. Measure the resistance of CAN communication line
Judging: Between service tool terminal No.2 (green) between travel controller and cargo handling
and service tool terminal No.3 (blue): controller.
40 – 70
Judging: Between CN3D terminal No.8 (green) and
CN3P terminal No.8 (green): 0
Between CN3D terminal No.2 (blue) and
CN3P terminal No.2 (blue): 0
Service Tool
2 1
4 3 CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector
Content of Trouble
• Poor contact or short-circuit of harness connector of EPS controller
• Abnormal EPS controller
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
EPS controller are not disconnected or not EPS controller and meter panel.
loosened. Judging: Between CN1E terminal No.4 (green) and
Judging: No disconnection of connector and no meter panel terminal No.11 (green): 0
looseness of terminal Between CN1E terminal No.15 (blue) and
meter panel terminal No.9 (blue): 0
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter Panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
OK: Go to step 4.
agent and re-connect the connector.
NG: Repair or replace the harness.
2 1 CN1E
4 3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
Viewed from the engagement side of connector 6 5 4 3 2 1
Content of Trouble
• Poor contact or short-circuit of harness connector of cargo handling controller
• Abnormal cargo handling controller
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
cargo handling controller are not disconnected or cargo handling controller and travel controller.
not loosened. Judging: Between CN3P terminal No.8 (green) and
Judging: No disconnection of connector and no CN3D terminal No.8 (green): 0
looseness of terminal Between CN3P terminal No.2 (blue) and
CN3D terminal No.2 (blue): 0
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Service Tool
2 1
4 3
OK: Go to step 3.
NG: Repair or replace the harness.
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter Panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. OK: Go to step 4.
NG: Repair or replace the harness.
2 1 Meter Panel
4 3
6 5 4 3 2 1
12 11 10 9 8 7
5. Disconnect the harness and measure the 7. Disconnect the harness and measure the resis-
resistance between CAN communication line at the tance between CAN communication line at the
travel control side and GND. cargo handling controller side and GND.
Judging: Between CN3D terminal No.15 and Judging: Between CN3P terminal No.15 and
CN3D terminal No.9: More than 1 M CN3P terminal No.9: More than 1 M
Between CN3D terminal No.15 and Between CN3P terminal No.15 and
CN3D terminal No.3: More than 1 M CN3P terminal No.3: More than 1 M
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector Viewed from the engagement side of connector
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 7.
NG: Replace the EPS controller.
Content of Trouble
• Poor contact or short-circuit of harness connector between travel controller and meter panel
• Abnormal meter panel
Repair Procedure 2. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
travel controller, EPS controller and meter panel are travel controller and meter panel.
not disconnected or not loosened. (Measure while keeping the connector of EPS
controller connected.)
Judging: No disconnection of connector and no
looseness of terminal Judging: Between CN3D terminal No.9 (green)
and meter panel terminal No.11 (green): 0
Between CN3D terminal No.3 (blue) and
meter panel terminal No.9 (blue): 0
CN3D
Meter Panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
agent and re-connect the connector.
OK: Replace the meter panel.
NG: Repair or replace the harness.
Content of Trouble
• Poor contact or short-circuit of harness connector between EPS controller and meter panel
• Abnormal meter panel
Repair Procedure 2. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
travel controller, EPS controller and meter panel are EPS controller and meter panel.
not disconnected or not loosened. Judging: Between CN1E terminal No.4 (green) and
Judging: No disconnection of connector and no meter panel terminal No.11 (green): 0
looseness of terminal Between CN1E terminal No.15 (blue) and
meter panel terminal No.9 (blue): 0
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter Panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. OK: Replace the meter panel.
NG: Repair or replace the harness.
Content of Trouble
• Poor contact or short-circuit of harness connector between cargo handling controller and meter panel
• Abnormal meter panel
Repair Procedure 2. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
cargo handling controller, EPS controller and meter cargo handling controller and meter panel.
panel are not disconnected or not loosened. (Measure while keeping the connector of EPS
controller connected.)
Judging: No disconnection of connector and no
looseness of terminal Judging: Between CN3P terminal No.8 (green) and
meter panel terminal No.11 (green): 0
Between CN3P terminal No.2 (blue) and
meter panel terminal No.9 (blue): 0
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
agent and re-connect the connector.
OK: Replace the meter panel.
NG: Repair or replace the harness.
Content of Trouble
• Poor contact or short-circuit of harness connector of travel controller
• Abnormal travel controller
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
travel controller are not disconnected or not travel controller and EPS controller.
loosened. Judging: Between CN3D terminal No.9 (green) and
Judging: No disconnection of connector and no CN1E terminal No.3 (green): 0
looseness of terminal Between CN3D terminal No.3 (blue) and
CN1E terminal No.14 (blue): 0
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3D
OK: Go to step 2. Viewed from the engagement side of connector
2 1 CN3D CN3P
4 3
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 3.
Viewed from the engagement side of connector
NG: Repair or replace the harness.
OK: Replace the travel controller.
NG: Repair or replace the harness.
Content of Trouble
• Poor contact or short-circuit of harness connector of EPS controller
• Abnormal EPS controller
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
EPS controller are not disconnected or not EPS controller and meter panel.
loosened. Judging: Between CN1E terminal No.4 (green) and
Judging: No disconnection of connector and no meter panel terminal No.11 (green): 0
looseness of terminal Between CN1E terminal No.15 (blue) and
meter panel terminal No.9 (blue): 0
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7
2 1
1 2 3 4 5 6 7 8 9 10 11
4 3 12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
Content of Trouble
• Poor contact or short-circuit of harness connector of cargo handling controller
• Abnormal cargo handling controller
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
cargo handling controller are not disconnected or cargo handling controller and travel controller.
not loosened. Judging: Between CN3P terminal No.8 (green) and
Judging: No disconnection of connector and no CN3D terminal No.8 (green): 0
looseness of terminal Between CN3P terminal No.2 (blue) and
CN3D terminal No.2 (blue): 0
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Service Tool
2 1
4 3
OK: Go to step 3.
NG: Repair or replace the harness.
Content of Trouble
• Poor contact or short-circuit of harness connector of meter panel
• Abnormal meter panel
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line between
meter panel are not disconnected or not loosened. EPS controller and meter panel.
Judging: No disconnection of connector and no Judging: Between meter panel terminal No.11 (green)
looseness of terminal and CN1E terminal No.4 (green): 0
Between meter panel terminal No.9 (blue) and
CN1E terminal No.15 (blue): 0
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
Viewed from the engagement side of connector
NG: Clean the connector with the contact refreshing
OK: Go to step 4.
agent and re-connect the connector.
NG: Repair or replace the harness.
2 1 Meter Panel
4 3 6 5 4 3 2 1
12 11 10 9 8 7
5. Disconnect the harness and measure the 7. Disconnect the harness and measure the
resistance between CAN communication line at the resistance between CAN communication line at the
travel control side and GND. cargo handling controller side and GND.
Judging: Between CN3D terminal No.15 and Judging: Between CN3P terminal No.15 and
CN3D terminal No.9: More than 1 M CN3P terminal No.9: More than 1 M
Between CN3D terminal No.15 and Between CN3P terminal No.15 and
CN3D terminal No.3: More than 1 M CN3P terminal No.3: More than 1 M
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector Viewed from the engagement side of connector
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 7.
NG: Replace the EPS controller.
Content of Trouble
• Poor contact or short-circuit of CAN communication line (Harness and communication parts in each controller)
• Abnormal travel controller
Repair Procedure 4. Connect the harness connector to the travel
1. Turn off the key switch and disconnect the battery controller and measure the resistance of CAN
connector. communication line harness between cargo
handling controller and meter panel.
2. Check visually that the connectors and terminals of
travel controller and meter panel are not Judging: Between CN3P terminal No.8 (green)
disconnected or not loosened. and meter panel terminal No.11 (green): 0
Judging: No disconnection of connector and no Between CN3P terminal No.2 (blue) and
looseness of terminal meter panel terminal No.9 (blue): 0
CN3P
Meter panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 5
OK: Go to step 3.
NG: Repair or replace the harness.
NG: Clean the connector with the contact refreshing
agent and re-connect the connector.
5. Connect the harness connectors except meter
panel (Only the meter panel connector is removed.)
3. Connect the harness connector to the EPS and measure the resistance between CAN_H and
controller and measure the resistance of CAN CAN_L at the CAN service connector terminals.
communication line harness between travel Judging: Between service tool terminal No.2 (green)
controller and meter panel. and service tool terminal No.3 (blue):
Judging: Between CN3D terminal No.9 (green) and 100 – 140
meter panel terminal No.11 (green): 0
Between CN3D terminal No.3 (blue) and
meter panel terminal No.9 (blue): 0
Service Tool
CN3D
Meter Panel 2 1
17 16 15 14 13 4 3
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 6
Viewed from the engagement side of connector
NG: Replace the cargo handling controller.
OK: Go to step 4.
NG: Repair or replace the harness.
Service Tool
2 1
4 3
Remark
When ERR40-8320 is displayed simultaneously,
check its abnormal code first.
For repair procedure, refer to the abnormal code
item of ERR40-8320.
Content of Trouble
• Poor contact or short-circuit of CAN communication line (Harness and communication parts in each controller)
• Abnormal EPS controller
Repair Procedure 4. Disconnect the harness and measure the
1. Turn off the key switch and disconnect the battery resistance between connector terminals at the EPS
connector. controller side.
2. Check visually that the connectors and terminals of Judging: Between CN1E terminal No.2 and
EPS controller and meter panel are not CN1Eterminal No.4: 1 M
disconnected or not loosened. Between CN1E terminal No.2 and
Judging: No disconnection of connector and no CN1E terminal No.15: 1 M
looseness of terminal
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 5.
OK: Go to step 3. NG: Replace the EPS controller.
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. 5. Disconnect the harness and measure the
resistance between connector terminals at the
3. Disconnect the harness and measure the travel controller side.
resistance of CAN communication line harness Judging: Between CN3D terminal No.15 and
between EPS controller and meter panel. CN3D terminal No.9: 1 M
Judging: Between CN1E terminal No.4 (green) and Between CN3D terminal No.15 and CN3D
meter panel terminal No.11 (green): 0 terminal No.3: 1 M
Between CN1E terminal No.15 (blue) and
meter panel terminal No.9 (blue): 0
CN3D
CN1E 17 16 15 14 13
12 11 10 9 8 7
1 2 3 4 5 6 7 8 9 10 11 6 5 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7
Viewed from the engagement side of connector
OK: Go to step 6.
Viewed from the engagement side of connector
NG: Replace the travel controller.
OK: Go to step 4.
NG: Repair or replace the harness.
6. Disconnect the harness and measure the 8. Connect the harness connector to the EPS
resistance between connector terminals at the controller and measure the resistance of CAN
cargo handling controller. communication line harness between travel
Judging: Between CN3P terminal No.15 and controller and meter panel.
CN3P terminal No.9: 1 M Judging: Between CN3D terminal No.9 (green) and
Between CN3P terminal No.15 and meter panel terminal No.11(green): 0
CN3P terminal No.3: 1 M Between CN3D terminal No.3 (blue) and
meter panel terminal No.9 (blue): 0
CN3P
CN3D
Meter Panel
17 16 15 14 13 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7 12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector Viewed from the engagement side of connector
7. Disconnect the harness and measure the 9. Connect the harness connector to the travel
resistance between connector terminals at the controller and measure the resistance of CAN
meter panel controller side. communication line harness between cargo
Judging: Between meter panel terminal No.6 and handling controller and meter panel.
meter panel terminal No.11: 1 M Judging: Between CN3P terminal No.8 (green) and
Between meter panel terminal No.6 and meter panel terminal No.11(green): 0
meter panel terminal No.9: 1 M Between CN3P terminal No.2 (blue) and
meter panel terminal No.9 (blue): 0
Meter Panel
CN3P
6 5 4 3 2 1 Meter panel
12 11 10 9 8 7 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 8.
Viewed from the engagement side of connector
NG: Replace the meter panel.
OK: Go to step 10.
NG: Repair or replace the harness.
Service Tool
2 1
4 3
Service Tool
2 1
4 3
Content of Trouble
• Poor contact or short-circuit of CAN communication line (Harness and communication parts in each controller)
• Abnormal cargo handling controller
Repair Procedure 4. Connect the harness connectors except the meter
1. Turn off the key switch and disconnect the battery panel again (Only the meter panel connector is
connector. disconnected.) and measure the resistance
between CAN_H and CAN_L at the service
2. Check visually that the connectors and terminals of
connector terminals.
cargo handling controller and meter panel are not
disconnected or not loosened. Judging: Between service tool terminal No.2 (green) and
service tool terminal No.3 (blue): 100 – 140
Judging: No disconnection of connector and no
looseness of terminal
Service Tool
2 1
4 3
OK: Go to step 5.
NG: Replace the cargo handing controller.
OK: Go to step 3.
NG: Clean the connector with the contact refreshing 5. Connect the harness connector of meter panel
agent and re-connect the connector. again and measure the resistance between CAN_H
and CAN_L at the CAN service connector
terminals.
3. Connect the harness connector to the travel
Judging: Between service tool terminal No.2 (green) and
controller and EPS controller, and measure the
service tool terminal No.3 (blue): 40 – 80
resistance of CAN communication line harness
between cargo handling controller and meter panel.
Judging: Between CN3P terminal No.8 (green) and Service Tool
meter panel terminal No.11 (green): 0
Between CN3P terminal No.2 (blue) and 2 1
meter panel terminal No.9 (blue): 0 4 3
CN3P
Meter panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7 Viewed from the engagement side of connector
12 11 10 9 8 7
6 5 4 3 2 1
OK: Replace the cargo handling controller.
NG: Replace the meter panel.
Remark
Viewed from the engagement side of connector When ERR40-8314 and ERR40-8320 are displayed
simultaneously, check their abnormal codes first.
OK: Go to step 4. For repair procedure, refer to each abnormal code
NG: Repair or replace the harness. item.
Content of Trouble
• Abnormal communication immediately after turning on the key switch
• Poor contact or short-circuit of CAN communication line (Harness and communication parts in each controller)
• Abnormal meter panel
Repair Procedure 4. Disconnect the harness and measure the resistance
1. Turn off the key switch and disconnect the battery between terminals at the EPS controller side.
connector. Judging: Between CN1E terminal No.2 and
2. Check visually that the connectors and terminals of CN1E terminal No.4: 1 M
meter panel are not disconnected or not loosened. Between CN1E terminal No.2 and
Judging: No disconnection of connector and no CN1E terminal No.15: 1 M
looseness of terminal
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 5.
OK: Go to step 3. NG: Replace the EPS controller.
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. 5. Disconnect the harness and measure the
resistance between connector terminals at the
3. Disconnect the harness and measure the travel controller side.
resistance of CAN communication line harness Judging: Between CN3D terminal No.15 and
between EPS controller and meter panel. CN3D terminal No.9: 1 M
Judging: Between CN1E terminal No.4 (green) and Between CN3D terminal No.15 and
meter panel terminal No.11 (green): 0 CN3D terminal No.3: 1 M
Between CN1E terminal No.15 (blue) and
meter panel terminal No.9 (blue): 0
CN3D
CN1E 17 16 15 14 13
12 11 10 9 8 7
1 2 3 4 5 6 7 8 9 10 11
6 5 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7
Viewed from the engagement side of connector
6. Disconnect the harness and measure the 8. Connect the harness connector to the EPS
resistance between connector terminals at the controller and measure the resistance of CAN
cargo handling controller side. communication line harness between travel
Judging: Between CN3P terminal No.15 and controller and meter panel.
CN3P terminal No.9: 1 M Judging: Between CN3D terminal No.9 (green) and
Between CN3P terminal No.15 and meter panel terminal No.11(green): 0
CN3P terminal No.3: 1 M Between CN3D terminal No.3 (blue) and
meter panel terminal No.9 (blue): 0
CN3P
CN3D
Meter Panel
17 16 15 14 13 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7 12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector Viewed from the engagement side of connector
7. Disconnect the harness and measure the 9. Connect the harness connector to the travel
resistance between connector terminals at the controller and measure the resistance of CAN
meter panel controller side. communication line harness between cargo
Judging: Between meter panel terminal No.6 and handling controller and meter panel.
meter panel terminal No.11: 1 M Judging: Between CN3P terminal No.8 (green) and
Between meter panel terminal No.6 and meter panel terminal No.11(green): 0
meter panel terminal No.9: 1 M Between CN3P terminal No.2 (blue) and
meter panel terminal No.9 (blue): 0
Meter Panel
CN3P
6 5 4 3 2 1 Meter panel
12 11 10 9 8 7 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 8.
Viewed from the engagement side of connector
NG: Replace the meter panel.
OK: Go to step 10.
NG: Repair or replace the harness.
Service Tool
2 1
4 3
Meter Display Trouble Code: ERR-3001 (Travel) Meter Display Trouble Code: ERR-3002 (Travel)
Content of Trouble Content of Trouble
Breaking of main contactor Shorted main contactor
Blown-out fuse
Symptom of truck
Symptom of truck Inoperable travel/cargo handling/EPS
Inoperable travel/cargo handling/ EPS (The main contactor does not open.)
Retry of contactor turning-on process
Troubled set after retry of 5 times Repair Procedure
(The retry is continued after set.) 1. Check the connection of battery cable. (Check the
leaking of + potential to secondary voltage side of
contactor.)
Repair Procedure
2. Check the main contactor (foreign matters in the
1. Check the main contactor (foreign matters in the
contact, mechanical interference). Repair or replace
contact, mechanical interference). Repair or replace
it.
it.
3. Disconnect the harness and check the harness
2. Check and replace the fuse.
between travel controller and contactor coil. Repair
3. Disconnect the harness and check the harness or replace it.
between travel controller and contactor coil. Repair
Judging: Between CN1D terminal No.3 (green/red) and
or replace it.
contactor coil terminal No.2: 0
Judging: Between CN1D terminal No.3 (green/red) and
Between CN1D terminal No.4 (green/yellow)
contactor coil terminal No.2: 0
and contactor coil terminal No.1: 0
Between CN1D terminal No.4 (green/yellow)
and contactor coil terminal No.1: 0
Main Contactor
CN1D
Main Contactor
CN1D 22 23 24 25 26 27 28 29 30 31
10 11 12 13 14 15 16 17 18 19 20 21 1 2
22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 1 2
1 2 3 4 5 6 7 8 9 Viewed from the engagement side of connector
Viewed from the engagement side of connector 4. If normal in the above check, replace the travel con-
troller.
4. If normal in the above check, replace the travel con-
troller.
How to reset
Turn OFF the key switch.
How to reset
Turn OFF the key switch.
Remark
None
Remark
In case of broken contactor wire, if succeeded in the
try, the error is reset.
Symptom of truck
Inoperable travel/cargo handling/ EPS
(The main contactor is open.)
Repair Procedure
1. Measure the battery voltage. If necessary,
re-charge the battery.
2. Check visually that the connectors and terminals of
travel controller are not disconnected or not
loosened.
3. Check the harness between the connector CN1D
terminal No.7 of travel controller and the battery.
Repair or replace it.
How to reset
Turn OFF the key switch.
Remark
VB = lower than 28.2V / 800 rms
Lower than 15V / 30 ms detection
Symptom of truck
Inoperable travel/cargo handling (The main contactor
does not close.)
CN1D
Repair Procedure 31 30 29 28 27 26 25 24 23 22
1. Disconnect the battery connector and leave the 21 20 19 18 17 16 15 14 13 12 11 10
truck for 10 minutes. 9 8 7 6 5 4 3 2 1
OK: Go to step 6.
NG: Repair or replace the harness.
Meter Display Trouble Code: ERR-3011 (Travel) Meter Display Trouble Code: ERR-3013 (Travel)
ERR-3012 (Travel) ERR-3014 (Travel)
ERR-3015 (Travel)
Content of Trouble Content of Trouble
Travel Controller (The upper side is shorted.)(3011) Travel controller (Broken U phase wire) (3013)
Travel Controller (The lower side is shorted.)(3012) Travel controller (Broken V phase wire) (3014)
Travel controller (Broken W phase wire) (3015)
Symptom of truck
Unable to travel Symptom of truck
Unable to travel
Repair Procedure
1. Disconnect the battery connector and leave the Repair Procedure
truck for 10 minutes. 1. Disconnect the battery connector and leave the
2. Disconnect the motor cable from the U, V and W truck for 10 minutes.
terminals and check the motor cable between P 2. Check the loosened cable tightened at the motor
terminal and N terminal respectively, using the terminal and the breaking of cable.
tester. If leaked, remove or repair. 3. Disconnect the cable from the motor terminal and
3. Confirm that no foreign matters exist on the P and N check the breaking of wire between phases.
terminals and around the U, V and W terminals. (Between U and V phases, Between V and W
(Check visually foreign matters on the printed circuit phases, Between W and U phases)
board.) (The resistance between phases of motor is
4. If normal in the above check, replace the travel normally several tens m.)
controller. • Broken wire: Replace the motor.
Meter Display Trouble Code: ERR-3016 (Travel) Meter Display Trouble Code: ALA-3021 (Travel)
Content of Trouble Content of Trouble
Defect of quick charging (Defect of charging capacitor Travel Controller (Temperature Rise)
between P and N)
Symptom of truck
Symptom of truck Unable to travel
Inoperable travel/cargo handling/EPS (The main The warning is detected over 108°C.
contactor does not close.)
The warning is released below 105°C.
The current cut-off works over 105°C.
Repair Procedure
1. Check the repair procedure of abnormal codes
Repair Procedure
3010.
1. When heavily loaded or operated continuously, stop
2. Check the repair procedure of abnormal code 5010.
the truck to cool down the controller.
3. If normal in the above checks, replace the travel
2. When normally traveling, if the alarm occurs in a
controller.
short period of time, check ERR-3021.
How to reset
How to reset
Turn OFF the key switch.
Can be recovered below 105°C.
Remark
Remark
The trouble codes 3010, 4010 and 5010 also appear.
Resistance / voltage of temperature sensor in the
(About 15 seconds later, they are displayed as the
normal condition
capacitor between P and N cannot be charged.)
25°C: 100 k / 3.2V (± 10 %)
50°C: 36 k / 2.0V (± 10 %)
75°C: 15 k / 1.0V (± 10 %)
100°C: 6.5 k / 0.5V (± 10 %)
Check the insufficient cooling caused by
malfunctioning fan.
Meter Display Trouble Code: ERR-3021 (Travel) Meter Display Trouble Code: ALA-3031 (Travel)
Content of Trouble Content of Trouble
Travel Controller (Abnormal Temperature) Travel Controller (Temperature Rise)
Symptom of truck
Unable to travel Remark
The error is detected over 175°C. Resistance / voltage of travel motor temperature
sensor in normal condition
The error is released below 175°C.
25°C: 10.7 k / 3.5V (± 10 %)
50°C: 4.4 k / 2.4V (± 10 %)
Repair Procedure 100°C: 1.0 k / 1.9V (± 10 %)
1. Stop the truck to cool down the travel motor. 150°C: 0.3 k / 0.3V (± 10 %)
2. Measure the resistance of harness between travel
controller and travel motor temperature sensor.
Judging: Between CND1 terminal No.20 (yellow/green)
and travel motor temperature sensor terminal
No.1 (yellow/green): 0
Between CND1 terminal No.29 (yellow/black)
and travel motor temperature sensor terminal
No.2 (yellow/black): 0
Travel Motor
CN1D temperature Sensor
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
Meter Display Trouble Code: ERR-3030 (Travel) Meter Display Trouble Code: ERR-3041 (Travel)
Content of Trouble Content of Trouble
Short-circuit between phases of travel motor (The load Short-circuit of relay DS1
is shorted.)
Symptom of truck
Backup lamp and sound pressure adjustment-type
Symptom of truck
backup buzzer (both equipments are optional) do not
Unable to travel operate.
How to reset
Turn the key switch to the OFF position.
Remark
Voltage of backup lamp relay and backup buzzer in the
normal state
• Release the accelerator: 0 V
• Fully operate forward: 0 V
• Fully operate backward: Approx. 12 V
Meter Display Trouble Code: ERR-3050 (Travel) Meter Display Trouble Code: ERR-3051 (Travel)
Content of Trouble Content of Trouble
Defective travel controller temperature sensor Defective travel motor temperature sensor
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
How to reset
When recovered to the normal condition, the error
code is reset.
Remark
When the abnormality is detected, the voltage of travel
motor temperature sensor is lower than 0.15 V or
higher than 4.95 V.
Meter Display Trouble Code: ERR-3052 (Travel) Meter Display Trouble Code: ERR-3053 (Travel)
Content of Trouble Content of Trouble
The output of travel current sensor (U phase, W Defective travel accelerator
phase) is defective.
Symptom of truck
Symptom of truck Unable to travel (Free-run state)
Unable to travel
Repair Procedure
Repair Procedure 1. Confirm that connectors and terminals at the
1. Confirm that foreign matters do not exist around the accelerator side are not disconnected and not
current sensor on the CPU board. loosened.
2. If normal in the above check, replace the travel 2. Measure the resistance of harness between travel
controller. controller and accelerator.
Judging: Between CND1 terminal No.21 (red) and
How to reset accelerator terminal No.8 (red): 0
Turn ON the key switch. Between CND1 terminal No.30 (black) and
accelerator terminal No.6 (black): 0
Between CND1 terminal No.31 (white) and
Remark
accelerator terminal No.7 (white): 0
Check visually the current sensor. If it is abnormal,
replace the travel controller.
CN1D Accelerator
31 30 29 28 27 26 25 24 23 22 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 8 7 6 5
9 8 7 6 5 4 3 2 1
How to reset
Turn OFF the key switch.
Remark
Accelerator voltage in the normal state
• Release the accelerator: 2.5 V
• Fully operate forward: About 4.48 V
• Fully operate backward: About 0.52 V
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
Travel Motor
CN1-D1 Speed Sensor B
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
Meter Display Trouble Code: ERR-3061 (Travel) Meter Display Trouble Code: ERR-3062 (Travel)
Content of Trouble Content of Trouble
Defective FR direction switch Defective logic of floor switch _a and floor switch _b
Symptom of truck
Inoperable travel/cargo handling/ EPS
(The main contactor is open.)
Repair Procedure
1. Measure the battery voltage. If necessary,
re-charge the battery.
2. Check visually that the connectors and terminals of
cargo handling controller are not disconnected or
not loosened.
3. Check the harness between the battery and the
connector CN1-P terminal No.7 of cargo handling
controller. Repair or replace it.
How to reset
Turn OFF the key switch.
Remark
VB = lower than 28.2 V / 800 rms: 48 V specification
Lower than 15V / 30 ms detection
Emergency Power
cut-off Button
CN1P
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10 3 4
9 8 7 6 5 4 3 2 1
Meter Display Trouble Code: ERR-5011 (Cargo Handling) Meter Display Trouble Code: ERR-5013 (Cargo Handling)
ERR-5012 (Cargo Handling) ERR-5014 (Cargo Handling)
ERR-5015 (Cargo Handling)
Content of Trouble
Cargo Handling Controller (The upper side is shorted.) Content of Trouble
Cargo Handling Controller (The lower side is shorted.) Cargo handling controller (Broken U phase wire)
(ERR-5013)
Meter Display Trouble Code: ALA-5021 (Cargo Handling) Meter Display Trouble Code: ERR-5021 (Cargo Handling)
Content of Trouble Content of Trouble
Cargo Handling Controller (Temperature Rise) Cargo Handling Controller (Abnormal Temperature)
Meter Display Trouble Code: ERR-5030 (Cargo Handling) Meter Display Trouble Code: ALA-5031 (Cargo Handling)
Content of Trouble Content of Trouble
Short-circuit between phases of pump motor Pump Motor (Temperature Rise)
(The load is shorted.)
Symptom of truck
Symptom of truck Unable to handle the cargo
Unable to handle the cargo The warning is detected over 163°C.
The warning is released below 160°C.
Repair Procedure The current cut-off works over 160°C.
1. Disconnect the battery connector and leave the
truck for 10 minutes.
Repair Procedure
2. Check visually that foreign matters do not exist
1. When heavily loaded or used continuously, stop the
around the U, V and W terminals of cargo handling
truck to cool down the pump motor.
controller.
2. If the alarm appears in a short period of time in the
3. Check short-circuiting between motor cables
normal operation, check, referring to ERR-5031.
(broken cladding, entry of foreign matters).
4. Remove the cargo handling motor cable from the
cargo handling controller. Insulate the terminals of How to reset
cargo handling cable with the insulation tape to Can be recovered below 160°C.
prevent them from touching to other controller, “ + “
polarity and “ - “ polarity.
Remark
5. After connecting the battery connector, be seated
Resistance / voltage of pump motor temperature
on the seat and turn ON the key switch.
sensor in normal condition
Confirm that the error code 5030 disappears.
25°C: 10.7 k / 3.5V (± 10 %)
• It disappears. : Replace the cargo handling
50°C: 4.4 k / 2.4V (± 10 %)
motor.
100°C: 1.0 k / 0.9V (± 10 %)
• It does not disappear. : Replace the cargo
150°C: 0.3 k / 0.3V (± 10 %)
handling controller.
How to reset
Turn ON the key switch.
Remark
As a resistor of several 10 m is connected between
phases of motor, it cannot be checked with the tester.
Symptom of truck
Unable to handle the cargo Remark
The error is detected over 175°C. Resistance / voltage of travel motor temperature
sensor in normal condition
The error is released below 175°C.
25°C: 10.7 k / 3.5V (± 10 %)
50°C: 4.4 k / 2.4V (± 10 %)
Repair Procedure 100°C: 1.0 k / 0.9V (± 10 %)
1. Stop the truck to cool down the pump motor. 150°C: 0.3 k / 0.3V (± 10 %)
2. Measure the resistance of harness between the
cargo handling controller and the pump motor
temperature sensor.
Judging: Between CN1P terminal No.20 (yellow/green)
and pump motor temperature sensor terminal
No.1 (yellow/green): 0
Between CN1P terminal No.29 (yellow/black)
and pump motor temperature sensor terminal
No.2 (yellow/black): 0
Pump Motor
CN1P Temperature Sensor
31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
Meter Display Trouble Code: ERR-5041 (Cargo Handling) Meter Display Trouble Code: ERR-5050 (Cargo Handling)
Content of Trouble Content of Trouble
Short-circuit of relay DS3 Defective cargo handling controller temperature
sensor
Symptom of truck
Forward travel buzzer (optional) does not operate
Symptom of truck
Repair Procedure The normal cargo handling is operative.
1. Check that the connector on the forward travel • Operated in the normal temperature
buzzer side is not disconnected and the terminals • Fan drive
are not loosened.
2. Measure the resistance of the wiring harness
between each controller and connector of each Repair Procedure
optional equipment. 1. As the error arises from the controller, replace the
cargo handling controller.
Judging: Between CN1P terminal No. 5 (red) and
forward travel buzzer terminal No. 1 (red): 0
How to reset
Between CN1P terminal No. 15 (black) and
forward travel buzzer terminal No. 2 (black): 0 When returned to the normal state, the error code is
reset.
CN1D Remark
When the abnormality is detected, the temperature
sensor voltage is lower than 0.2 V or higher than
4.95 V.
31 30 29 28 27 26 25 24 23 22 1
21 20 19 18 17 16 15 14 13 12 11 10 2
9 8 7 6 5 4 3 2 1
㻲㼛㼞㼣㼍㼞㼐㻌㼠㼞㼍㼢㼑㼘㻌㼎㼡㼦㼦㼑㼞
㼂㼕㼑㼣㻌㼒㼞㼛㼙㻌㼏㼛㼚㼚㼑㼏㼠㼛㼞㻌㼒㼕㼠㼠㼕㼚㼓㻌㼒㼍㼏㼑
B4Z16937
OK: Go to step 3.
NG: Repair or replace the wiring harness.
How to reset
Turn the key switch to the OFF position.
Remark
Accelerator voltage in the normal state
• Release the accelerator: 0 V
• Fully operate forward: About 0 V
• Fully operate backward: Approx. 12 V
Meter Display Trouble Code: ERR-5051 (Cargo Handling) Meter Display Trouble Code: ERR-5052 (Cargo Handling)
Content of Trouble Content of Trouble
Abnormal pump motor temperature sensor Defective output of cargo handling current sensor (U
phase, W phase)
Symptom of truck
The normal cargo handling is operative. Symptom of truck
Repair Procedure
Repair Procedure
1. Check that no foreign matters exist around the
1. Confirm that the pump motor temperature sensor
current sensor on the CPU board.
connector is firmly connected.
2. If normal in the above check, replace the cargo
2. Check the harness between CN1-P terminals No.
handling controller.
20 / No.29 of cargo handling controller and the
pump motor temperature sensor. Repair or replace
it. How to reset
Judging: Between CN1P terminal No. 20 (yellow/green) Turn OFF the key switch.
and pump motor temperature sensor terminal
No.1 (yellow/green): 0
Remark
Between CN1P terminal No. 29 (yellow/black)
Check visually the current sensor. If abnormal, replace
and pump motor temperature sensor terminal
the cargo handling controller.
No.2 (yellow/black): 0
Pump Motor
CN1P Temperature Sensor
31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2
9 8 7 6 5 4 3 2 1
Meter Display Trouble Code: ERR-5053 (Cargo Handling) Meter Display Trouble Code: ERR-5057 (Cargo Handling)
Content of Trouble Content of Trouble
Defective lift lever POT Defective pump motor speed sensor
(POT: POT denotes the potentio meter. It is a fine Symptom of truck
volume control.)
Unable to handle the cargo
Repair Procedure
1. Confirm that the connectors and terminals of pump
Symptom of truck
motor speed sensor are not disconnected and not
The truck is driven by the lift switch 1 setting value. loosened.
2. Measure the resistance of harness between the
Repair Procedure cargo handling controller and the pump motor
speed sensor.
1. Confirm that the connectors and terminals of lift
Judging: Between CN1P terminal No.27 (white) and
lever POT are not disconnected and not loosened.
pump motor speed sensor terminal No.1
2. Measure the resistance of harness between the (white): 0
cargo handling controller and the lift lever POT. Between CN1P terminal No.28 (black) and
Judging: Between CN2P terminal No.22 (black) and pump motor speed sensor terminal No.2
lift lever VR switch terminal No.1 (black): 0 (black): 0
Between CN2P terminal No.23 (white) and
lift lever VR switch terminal No.2 (white): 0 Pump motor
CN1P speed sensor
Between CN2P terminal No.24 (red) and
lift lever VR switch terminal No.3 (red): 0
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
CN2P Lift Lever
9 8 7 6 5 4 3 2 1
VR Switch
24 23 22 21 20 19 18 17 3 2 1 OK: Go to step 3.
16 15 14 13 12 11 10 9 8 NG: Repair or replace the harness.
7 6 5 4 3 2 1
Viewed from the engagement side of connector 3. Check the pump motor speed sensor. Repair or
replace it.
OK: Go to step 3.
4. Check the gear of motor pump (poor mesh of gear
NG: Repair or replace the harness. with the sensor, entry of magnetic substance).
Repair or replace the motor.
3. Check the lift lever POT. Repair or replace it. 5. If normal in the above check, replace the cargo
handling controller.
4. If normal in the above check, replace the cargo
handling controller.
How to reset
Meter Display Trouble Code: ERR-5058 (Cargo Handling) Meter Display Trouble Code: ERR-4001 (EPS)
Content of Trouble Content of Trouble
Defective load meter pressure sensor Blown-out fuse (Open fuse)
Symptom of truck
Normal operation Symptom of truck
Repair Procedure Inoperable EPS
1. Confirm that the connectors and terminals of
pressure sensor are not disconnected and not Repair Procedure
loosened.
1. Check and confirm that the internal connection
2. Measure the resistance of harness between the
harness is not disconnected and not loosened.
cargo handling controller and the pressure sensor.
Judging: Between CN2P terminal No.14 (black) and 2. Check and replace the fuse.
pressure sensor terminal No.3 (black): 0 3. If normal in the above check, replace the EPS
Between CN2P terminal No.15 (white) and controller.
pressure sensor terminal No.2 (white): 0
Between CN2P terminal No.16 (red) and How to reset
pressure sensor terminal No.1 (red): 0
Turn OFF the key switch.
Load meter
CN2P pressure sensor
Remark
None
24 23 22 21 20 19 18 17 3 2 1
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness.
How to reset
Turn off the key switch.
Remark
Voltage at terminal in the normal state
Terminal No.14: 0 V
Terminal No.15: 0.5 – 4.5 V
Terminal No.16: 5 V
Meter Display Trouble Code: ERR-4004 (EPS) Meter Display Trouble Code: ERR-4010 (EPS)
Content of Trouble Content of Trouble
The low voltage is detected. (Dropped battery voltage) EPS controller (Upper and lower FETs are shorted.)
Remark
Check the leakage of rain-water.
Check foreign matters on the printed circuit board.
Meter Display Trouble Code: ERR-4013 (EPS) Meter Display Trouble Code: ALA-4021 (EPS)
Content of Trouble Content of Trouble
The transistor (FET) is open The FET temperature rises.
The motor is open.
Symptom of truck
Symptom of truck Inoperable EPS
Inoperable EPS The abnormality is detected over 100°C.
The error is released below 95°C.
Repair Procedure
1. Disconnect the battery connector and leave the Repair Procedure
truck for 10 minutes. 1. Stop the truck to cool down the controller block.
2. Check that the motor cable connectors are not 2. Check the mounting of EPS controller. (Looseness)
disconnected and not loosened. Check that the Repair or replace it.
cables are not broken. 3. Check the screws (FET fixing screw) on the side of
3. Disconnect the connectors from the motor terminals controller. Repair or replace it.
and check the wires between motor terminals are 4. Check the fan. Repair or replace it.
not broken.
5. If normal in the above check, replace the EPS
• Broken wire: Replace the motor. controller.
• Normal: Replace the EPS controller.
How to reset
How to reset Can be recovered below 95°C.
Turn OFF the key switch.
Remark
Remark As the thermistor is mounted on the circuit board, it
None cannot be checked.
Meter Display Trouble Code: ERR-4021 (EPS) Meter Display Trouble Code: ERR-4050 (EPS)
Content of Trouble Content of Trouble
The FET temperature is abnormal. Defective FET temperature sensor
Repair Procedure
Repair Procedure
As the error arises from controller, replace the EPS
1. Stop the truck to cool down the controller block. controller.
2. Check the mounting of EPS controller. (Looseness)
Repair or replace it.
How to reset
3. Check the screws (FET fixing screw on the side of
When returned to the normal, the error is reset.
controller. Repair or replace it.
4. Check the fan. Repair or replace it.
Remark
5. If normal in the above check, replace the EPS
controller. None
How to reset
Can be recovered below 100°C.
Remark
As the thermistor is mounted on the circuit board, it
cannot be checked.
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
EPS
1 2 3 torque
sensor
OK: Go to step 3.
NG: Repair or replace the harness.
How to reset
Turn OFF the key switch.
Remark
Voltage at terminal in the normal state
Terminal No.7: 1.50 – 3.50 V
Terminal No.20: 0.45 V
Terminal No. 21: 4.55 V
Remark
None
CN1D Key switch
31 30 29 28 27 26 25 24 23 22 1
21 20 19 18 17 16 15 14 13 12 11 10 2 3
9 8 7 6 5 4 3 2 1
How to reset
Normal recovery
Remark
None
CN1D Accelerator
Travel motor
CN1D speed sensor A/B
31 30 29 28 27 26 25 24 23 22 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 8 7 6 5
31 30 29 28 27 26 25 24 23 22 1 2 9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
Viewed from the engagement side of connector
Viewed from the engagement side of connector
How to reset
How to reset
Normal recovery
Normal recovery
Remark
Remark
No leak from the signal line
When replacing the motor, confirm the connection to When the wire of accelerator VR is broken, the error is
prevent misconnection. detected.
31 30 29 28 27 26 25 24 23 22 4 3 2 1
How to reset 21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
8 7 6 5
Normal recovery
Control valve SW
Remark CN2P
None 24 23 22 21 20 19 18 17 4 3 2 1
16 15 14 13 12 11 10 9 8 8 7 6 5
7 6 5 4 3 2 1
Viewed from the engagement
side of connector
OK: Replace the control valve.
NG: Repair or replace the harness.
How to reset
Normal recovery
Remark
No leak from the signal line.
When the wire of accelerator lever is broken, the error
is detected.
Repair Procedure
1. Confirm that the cargo handling motor wires are
correctly connected to the cargo handling controller.
If not, correct it.
How to reset
Normal recovery
Remark
When replacing the motor, confirm the connection.
Repair Procedure
1. Connect the harness connector correctly.
How to reset
Normal recovery
Remark
Check screws in the EPS unit, fixing locations and
motor relay connector.
METER PANEL
When the CAN termination resistor in the meter panel is used, pin 7 is connected to pin 10 by the harness
at the vehicle side. If the abnormality of CAN communication is suspected on the vehicle in which the ter-
mination resistor in the meter panel is used, before checking the items below, confirm that the connection
mentioned above is implemented on the harness at the vehicle side.
1. When turning ON the key switch, the meter panel does not work at all.
(The LCD is not displayed. The LCD backlight and warning lamps do not light at all.)
Cause Remedy
NO NO
Check
Abnormal battery
Re-charge
2. When the battery is connected, the entire meter panel keeps lighting.
Cause Remedy
3. When the battery is connected, all lamps light. But, some segments and some warning lamps do not light.
Cause Remedy
4. After turning ON the key switch, the LCD backlight does not light.
(The LCD display and warning lamps work normally.)
Cause Remedy
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
8. When turning OFF the key switch, the display of meter panel does not go off.
Cause Remedy
9. All of LCD and warning lamps light (AE) and go off repeatedly. The meter panel d o not function normally.
Cause Remedy
Is the voltage between pins (12) NO
and (5) of connector lower than Defective meter panel Replace
26 V?
YES Over-discharge of battery
Re-charge
(Voltage drop of power supply)
10. The neutral safety warning lamp does not light or goes off.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the state of vehicle?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
11. The parking warning light does not light or does not go off.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the state of vehicle?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
13. The warning lamp of travel system trouble does not light (blinks).
Cause Remedy
YES
Defective meter panel Replace
14. The warning lamp of cargo handling system trouble lights (blinks).
Cause Remedy
15. The warning lamp of cargo handling system trouble does not light (blink).
Cause Remedy
YES
Defective meter panel Replace
YES
Defective meter panel Replace
* [Err??---????] is displayed.
18. The display of battery remaining goes off or is obviously different from the actual remaining.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the state of battery?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
19. The display of power is obviously different from the actual power.
Cause Remedy
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
20. The display of forward-run/backward-run goes off or is different from the actual state of traveling.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the actual traveling?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
21. The display of travel speed goes off or is different from the actual travel speed.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the actual travel speed?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
22. The display of travel speed limit (turtle icon) is different from the actual state.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the actual set speed limit?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
23. The display cannot be switched to the clock or time cannot be set.
Cause Remedy
24. When turning ON the key switch, the display of clock is obviously incorrect.
Cause Remedy
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
30. The display of cargo handling time is not accumulated or remains [0.0h].
Cause Remedy
Is the communication data Does the controller normally
inputted to pins (11) [(10)] YES accumulate the cargo handling time YES Defective meter panel Replace
and (9) [(8)] of connector? and output the communication data?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
NO Breaking of harness
Check
Poor contact of connector
32. When displaying the load meter, the value obviously different from the actual state of vehicle is displayed.
Cause Remedy
Is the communication data Does the controller normally
inputted to pins (11) [(10)] YES output the communication data YES
Defective meter panel Replace
and (9) [(8)] of connector? related to the load meter?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
35. Even if the button is pressed, the display cannot be switched to the code of trouble history and hour time at the occurrence.
Cause Remedy
36. Even if the button is pressed, the travel speed limit setting (user adjustment mode) cannot be displayed.
Cause Remedy
38. Even if the MODE button is pressed after changing the value,
the travel speed limit setting (user adjustment mode) cannot be reflected.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the travel speed limit setting?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
39. Even is the button is pressed, the lift speed setting (user adjustment mode) cannot be displayed.
Cause Remedy
41. Even if the MODE button is pressed after changing the value,
the lift speed limit setting (user adjustment mode) cannot be reflected.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the lift speed limit setting?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
42. Even if the LMH button (UP button) is pressed, the lift power setting (user adjustment mode) cannot be switched.
Cause Remedy
43. Even if the MODE button is pressed after changing the value, the power setting (user adjustment mode) cannot be reflected.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the power speed limit setting?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
44. Even if the turtle icon button (DOWN button) is pressed, the ON/OFF of travel speed limit cannot be changed.
Cause Remedy
Is the communication data Does the controller normally output
inputted to pins (11) [(10)] YES the communication data related to YES Defective meter panel Replace
and (9) [(8)] of connector? the travel speed limit setting?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
45. The meter panel communication error is displayed. ([Err---????] is displayed on the LCD.)
Cause Remedy
NO
Abnormal controller Check
46. The controller communication error is displayed. ([Err??---????] is displayed on the LCD.)
Cause Remedy
The controller
communication Replace
error is detected
BATTERY ...................................................................................80-7
TRAVEL EQUIPMENT................................................................80-9
HYDRAULIC EQUIPMENT.......................................................80-17
TOTAL TEST.............................................................................80-19
a The check item No. corresponds to No. of specific voluntary check record table.
Equip-
Check Item Check Content
ment
Check
Check Item Judging Standard Treatment
Location
No looseness, no stacked dust, no Tightening,
Tightening Tightened
rust cleaning and
part screws
Visual and hitting check painting
Correct connection
Tightening,
No loose connection
Connection insulation
Insulation treatment
check
Terminal Visual check
Joint of termi-
No damage to the cladding Repair in a
nal and har-
Visual check special factory
ness
No stuck dust
Iron Core Cleaning
Visual check
Stator and Cleaning,
rotor assembly Coil and Insulating resistance of more than
heating dry,
insulation of 1M (Measured in 500V mega
varnish
connection range)
treatment
Gap Removal of
Sped sensor No sticking of foreign matter
confirmation foreign matters
Reference Value
Temperature Measurement
sensor of resistance 20C°: 11.7 – 14.3 k
25C°: 9.7 – 11.8 k
No damage, no discolor, no
Anti-corrosion
Motor
Equip-
Check Item Check Content
ment
pins 1 and 3.
Equip-
Check Item Check Content
ment
4) Place the wooden block under both right and left frames to float the truck
from the ground. (Only when measuring the cut-off current at traveling)
5) Tilt the mast forward and lower down the fork on the ground.
6) Disconnect the wiring from the brake switch. (Only when measuring the
cut-off current at traveling)
Or remove the center plate and keep the brake switch lever pushed in
(Electrically, the brake is open.)
7) Set the ammeter (clamp tester) to the cable to be measured and measure
the cut-off current under the condition listed on the table below.
8) After finishing the check, re-connect the wiring to the brake switch.
(Only when measuring the cut-off current at traveling)
Cable to be
Motor Measuring Condition Clamp Setting Cut-off Current
measured
Set the power mode to H
Control Equipment
Equip-
Check Item Check Content
ment
4 EPS fuse 40 A –
counter.
3) Loosen the nut and replace the fuse.
4) After replacement, tighten the nut
securely.
5
Mark Voltage Battery Capacity (Ah) Capacity
14. Wiring Examine the items below by visual check and touching by finger.
(Including the 1. Damage to the wire harness, loose clamp
charger cord) 2. Loose terminal connection block, state of taping
3. Contact of battery connector, loose bolts
4. Damage to the wire harness sheath (cladding)
Equip-
Check Item Check Content
ment
Check of conduction
Switch Judging
between (Pin No.)
Equip-
Check Item Check Content
ment
3
• Before the float (red) (3)
indicates the lowest level of battery electrolyte, refill water
• When the stopper (1) of float (3) touches the cap (2) (Gap a = 0 in the above
figure), the battery electrolyte level is the minimum.
a Depending on battery manufacturer, the cap (2) differs in shape.
1) Open the cap of battery cap and refill the battery with water (pure water).
2) When the white line appears, stop refilling immediately.
Equip-
Check Item Check Content
ment
a Normal value:
S20 = 1.27 – 1.29
Battery
Equip-
Check Item Check Content
ment
Equip-
Check Item Check Content
ment
RW type
50.5
24.5
(Set length of stopper bolt)
RL type
Travel Equipment
More than 67 mm
Equip-
Check Item Check Content
ment
Play 10 – 20 mm
㪈㪇䌾㪉㪇㩷㫄㫄
2. Looseness check of
installation block
3. Rattle
Move the steering wheel in the
shaft direction and diameter
direction and check whether the
steering wheel rattles or not.
4. Steering Condition
Travel and steer. And check that any abnormality exists.
Turn right
4 ± 0.3 V 7 V (It varies smoothly.)
(When turning the steering wheel right)
Turn left
4 ± 0.3 V 1 V (It varies smoothly.)
(When turning the steering wheel left)
Equip-
Check Item Check Content
ment
36 – 37. 3. Wear and contact of brush, spring force, dirt, wear and burn of commutator
EPS equipment 1) Limit of brush wear (Height: H measurement)
(Continued)
EPS motor More than 13 mm
Equip-
Check Item Check Content
ment
When in free 60 – 70 mm
Pedal Height (h)
When stepping on Same height as the floor plate
4. Brake Switch
Adjust the installation of switch so that the brake switch turns on when the pedal
height becomes as shown below.
The switch should have the margin stroke of 1.5mm when stepping down the
brake pedal fully.
Equip-
Check Item Check Content
ment
2. Spring installation height (L), clearance (H) between cam and adjuster
screw
L = 120 mm
H=0
Horizontal
H=0
H
Cam Adjuster screw
The cam should be horizontal as shown in the figure. (When the pedal is not
stepped down)
3. Contacting surfaces of cam and adjuster screw
The surfaces should not worn to the extent of exposed metal. No scars on the
Braking Equipment
Equip-
Check Item Check Content
ment
53 – 54. Fork 1. Damage and wear of fork and fork stopper pin
Check them visually.
2. Deformation of fork
Align the fork in the center of truck and
measure the height difference C and the
open distance.
3. Wear of fork
Measure the thickness A at the root of fork and check it to meet the specification.
4. Crack of fork
Especially, as the force will be concentrated on the location below, check in the
crack search method.
Cargo Handling Equipment
• Root of fork F
• Hook of fork D, E
Equip-
Check Item Check Content
ment
Equip-
Check Item Check Content
ment
Equip-
Check Item Check Content
ment
59 – 74 Nm {6 – 7.5 kgm}
Adjustment :If the amount exceeds the specification, replace the packing of
control valve and cylinder.
Specific
16.7 MPa {170 kgf/cm2}
pressure
A
B4Z16939
Equip-
Check Item Check Content
ment
2. State of installation
Body, Safety Equipment, etc.
3. Operation of meters
2. Mirrored image
KGM TO FT IB ............................................................................90-8
TEMPERATURE .........................................................................90-9
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
0 1 2 3 4 5 6 7 8 9
10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85
20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93
30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01
40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09
50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17
60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25
70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33
80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41
90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49
10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53
20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17
30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82
40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47
50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11
60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76
70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40
80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05
90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70
0 1 2 3 4 5 6 7 8 9
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
0 1 2 3 4 5 6 7 8 9
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06
0 1 2 3 4 5 6 7 8 9
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0 1 2 3 4 5 6 7 8 9
10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154
30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690
40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226
50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762
60 27.216 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
0 1 2 3 4 5 6 7 8 9
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0 1 2 3 4 5 6 7 8 9
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.41 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
Temperature
Fahrenheit–Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
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Printed in Japan 05-18 (01)