Caterpillar Cat EP25K Forklift Lift Trucks Service Repair Manual SN：ETB8B-50001 and up

Service Manual Chassis, Mast & Options EP20K EP25K EP30K EP35K

ETB8B-00011-up ETB8B-50001-up ETB9B-00011-up ETB9B-50001-up

For use with EP20K-EP35K Controller Service Manual.

99759-6D100

FOREWORD

This service manual is a guide for servicing CatÂŽ lift trucks of 2.0 ton, 2.5 ton, 3.0 ton and 3.5 ton models. The instructions are grouped by systems to conveniently provide a ready reference.

A long productive life of your lift truck depends to a great extent on correct servicing — servicing consistent with what you will learn from this service manual. Read the respective sections of this manual carefully and familiarize yourself with all the components you will work on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are of the trucks with the serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right to change specifications or design without notice and without incurring obligation.

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

!

WARNING

!

CAUTION

NOTE

Indicates a specific potential hazard that could result in serious bodily injury or death.

Indicates a specific potential hazard that may result in bodily injury, or damage to, or destruction of, the machine.

Indicates a condition that can cause damage to, or shorten service life of, the machine.

Pub. No. 99759-6D100

!

WARNING

SAFETY

!

WARNING

The proper and safe lubrication and maintenance for this lift truck, recommended

by Cat lift truck, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance.

The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components.

Following is a list of basic precautions that should always be observed.

1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product.

2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loosefitting or torn clothing. Remove all rings from fingers when working on machinery.

3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.

!

WARNING

Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more.

Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.

8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely.

9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary.

12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck.

13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck.

Hang “Do not Operate� tag in the Operator’s Compartment.

14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures.

Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation.

Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly.

20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

22. When handling the parts containing asbestos, be careful not to inhale the asbestos. Doing so is hazardous to your health.

15. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Place wiring away from oil pipe.

If the shop dust may contain asbestos, follow the precautions described below.

16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

c.

17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.

18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

a.

Do not use compressed air for cleaning.

b. Do not brush or apply grinder on asbestos containing materials.

To clean asbestos containing materials, wipe with moistened cloth or use a vacuum cleaner with particle filter.

d. If you have to handle the parts containing asbestos for a long time, be sure to do it in a well-ventilated area. e.

If the asbestos in the air cannot be removed, wear a mask.

f.

Be sure to observe the working rules and regulations.

g. When disposing of materials with asbestos, be sure to observe the environmental protection regulations of your area. h. Avoid working in the atmosphere where asbestos particles may be suspended.

HOW TO USE THIS MANUAL (Removal, Installation, Assembly and Disassembly) Disassembly diagram (example)

2

1 Procedures are described in the text.

Disassembling sequence 209603

Sequence 1 2

Cover, Bolt, Washer (part name) Snap ring ................ (part name)

Suggestion for disassembling 1. Output shaft, Removing Remove output shaft using a special tool.

209604

Service Data

Gear Backlash A: Standard Value B: Repair or Service Limit

A

0.11 to 0.28 mm (0.0043 to 0.0110 in.)

B

0.5 mm (0.020 in.)

Symbols or abbreviation OP

Option

R1/4

Taper pipe thread (external) 1/4 inch (formerly PT1/4)

Rc1/8

Taper pipe thread (internal) 1/8 inch (formerly PT1/8)

G1/4A

Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)

Rp1/8

Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

Units 1. SI Units are used in this manual.

2. The following table shows the conversion of SI unit and customary unit.

Item Force

Pressure

Torque

SI unit

Customary unit

1N

0.1020 kgf

(1 lbf)

(0.4536 kgf)

1 kPa

0.0102 kgf/cm2

(1 psi)

(0.0703 kgf/cm2)

1 N路m

0.1020 kgf路m

(1 lbf路ft)

(0.1383 kgf路m)

GROUP INDEX GROUP INDEX

Items

GENERAL INFORMATION

Serial Number Locations, Chassis and Mast Model Identification, Dimensions, Technical Data

1

VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations, Console Box, Key Switch, Lamp Specification Chart, Electrical System of FC

2

POWER TRAIN

General Structure, Removal and Installation

3

TRANSFER AND DIFFERENTIAL

Structure and Functions, Procedures and Suggestions for Disassembly and Reassembly, Service Data

4

FRONT AXLE

Structure and Functions, Disassembly and Reassembly of Front Axle Assembly, Service Data

5

REAR AXLE

Rear Axle, Rear Wheels, Removal and Installation, Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data

6

BRAKE SYSTEM

Specifications, Structure and Functions, Procedures and Suggestions for Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data

7

STEERING SYSTEM

Specifications, Structure and Functions, Procedures and Suggestions for Removal and Installation, Steering Gear, Hydraulic Circuit, Troubleshooting, Service Data

8

HYDRAULIC SYSTEM

Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve

9

MAST AND FORK

Simplex Mast, Duplex Mast, Triplex Mast

10

SERVICE DATA

Inspection Standards, Periodic Replacement of Parts, Lubrication Standards, Main Component Weights, Tightening Torque for Standard Bolts and Nuts, Special Tools

11

OPTIONS

Rearview Mirror Kit, Backup Buzzer Kit, Working Lamp Kit, Tire Kit, Foot Direction Control Kit

12

GENERAL INFORMATION 1 Vehicle Exterior .......................................................................................

Models .......................................................................................................

Serial Number Locations ......................................................................

Chassis and Mast Model Identification ............................................

Dimensions ..............................................................................................

Technical Data .........................................................................................

1–1 1–1 1–2 1–3 1–4 1–5

GENERAL INFORMATION

Vehicle Exterior

Joystick box (FC models) Control lever (MC models)

103142

Models This manual applies to EP20K, EP25K, EP30K and EP35K.

Class

Truck Model

2 ton

EP20K

ETB8B-00011-up

2.5 ton

EP25K

ETB8B-50001-up

3 ton

EP30K

ETB9B-00011-up

3.5 ton

EP35K

ETB9B-50001-up

1-1

Serial Number

GENERAL INFORMATION

Serial Number Locations

Mast number

Chassis number

Nameplate

208204

1-2

GENERAL INFORMATION

Chassis and Mast Model Identification

[Chassis] EP

20

K

Generation designator

Maximum capacity 20: 2000 kg (4400 lb) 25: 2500 kg (5500 lb) 30: 3000 kg (6600 lb) 35: 3500 kg (7700 lb) Battery type

[Mast] 4

R

35

C

30

Maximum lifting height [“30” stands for 3000 mm (118 in.)]

Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 35: 3.5 ton class

Kind of mast R: simplex mast S: duplex mast Y: triplex mast Major change (“2” for the original, “3” for the first change, and so on up to “9”)

1-3

GENERAL INFORMATION

Dimensions

B

E

F

C

D A

211638

1-4

GENERAL INFORMATION

Technical Data Truck model

EP20K

EP25K

Class

2.0 ton

2.5 ton

19600 (2000)/500 [4400/20]

24500 (2500)/500 [5500/20]

2249 (88.5)

2274 (89.5)

1190 (46.9)

1190 (46.9)

Load capacity/load center

Truck size

N (kgf)/mm [lbf/in.]

Length to fork face

A

Width

B

mm (in.)

mm (in.)

Height of overhead guard C

2200 (86.6) mm (in.)

2200 (86.6)

mm (in.)

1520 (59.8)

1520 (59.8)

kg (lb)

2790 (6151)

2983 (6576)

990/898 (39.0/35.4)

990/898 (39.0/35.4)

Front

23 × 9 − 10

23 × 9 − 10

Rear

18 × 7 − 8

18 × 7 − 8

1950 (76.8)

1970 (77.6)

km/h (mph)

16.4/16.0 (10.2/9.9)

16.4/16.0 (10.2/9.9)

Lift speeds Unloaded/loaded

m (in.)/sec

0.60/0.40 (23.6/15.7)

0.60/0.38 (23.6/14.96)

Lowering speeds Unloaded/loaded

m (in.)/sec

0.50/0.50 (19.7/19.7)

0.50/0.50 (19.7/19.7)

V

80

80

Ah

600

600

mm (in.)

1025 × 708 × 769 (40.4 × 27.9 × 30.3)

1025 × 708 × 769 (40.4 × 27.9 × 30.3)

1385 (3053)

1385 (3053)

6° − 8°

6° − 8°

12.0

12.0

kW

15

15

W

550

550

Drive motor control method

IGBT chopper

IGBT chopper

Pump motor control method

IGBT chopper

IGBT chopper

D

Wheelbase Truck weight (w/o battery)

E/F

Tread Front/rear Tires size

Turning radius

mm (in.)

mm (in.)

Travel speeds Unloaded/loaded

Battery voltage Battery rated capacity (5 hrs.) MAX Battery compartment size Battery weight

kg (lb)

Tilt angle (forwards – backwards) Drive motor capacity

(60 min. short duty) kW

Pump motor output

@ 15% duty factor

Steering pump motor output

1-5

GENERAL INFORMATION

Truck model

EP30K

EP35K

Class

3.0 ton

3.5 ton

29400 (3000)/500 [6600/20]

34300 (3500)/500 [7700/20]

2522 (99.3)

2577 (101.5)

1230 (48.4)

1230 (48.4)

2250 (88.6)

2259 (88.9)

mm (in.)

1690 (66.5)

1690 (66.5)

kg (lb)3231 (7123)

3665 (8080)

Load capacity/load center N (kgf)/mm [lbf/in.]

Truck size

Length to fork face

A

Width

B

mm (in.)

mm (in.)

Height of overhead guard C mm (in.)

D

Wheelbase Truck weight (w/o battery)

E/F

Tread Front/rear

990/898 (39.0/35.4)

990/898 (39.0/35.4)

Front

28 × 9 − 15

250 − 15

Rear

18 × 7 − 8

18 × 7 − 8

2180 (85.8)

2230 (87.8)

km/h (mph)

16.4/16.0 (10.2/9.9)

16.4/16.0 (10.2/9.9)

Lift speeds Unloaded/loaded

m (in.)/sec

0.54/0.34 (21.3/13.4)

0.45/0.28 (17.7/11.0)

Lowering speeds Unloaded/loaded

m (in.)/sec

0.50/0.50 (19.7/19.7)

0.50/0.50 (19.7/19.7)

V

80

80

Ah

750

750

mm (in.)

1025 × 852 × 769 (40.4 × 33.5 × 30.3)

1025 × 852 × 769 (40.4 × 33.5 × 30.3)

1872 (4127)

1872 (4127)

6° − 8°

6° − 8°

Tires size

Turning radius

mm (in.)

mm (in.)

Travel speeds Unloaded/loaded

Battery voltage Battery rated capacity (5 hrs.) MAX Battery compartment size Battery weight

kg (lb)

Tilt angle (forwards – backwards) Drive motor capacity

(60 min. short duty) kW

12

12

Pump motor output

@ 15% duty factor

15

15

Drive motor control method

IGBT chopper

IGBT chopper

Pump motor control method

IGBT chopper

IGBT chopper

kW

1-6

VEHICLE ELECTRICAL COMPONENTS Electrical Component Locations ........................................................ 2 – 1 Console Box ............................................................................................ 2 – 4 Functions of Central Vehicle Monitor System (CVMS) ............................... 2 – 4 Electrical Components in Console Box ..................................................... 2 – 7 Disassembly and Reassembly .................................................................. 2 – 8

Direction Lever ........................................................................................

Accelerator Control ...............................................................................

Key Switch ...............................................................................................

Lighting Switch .......................................................................................

Fuses .........................................................................................................

Lamp Specification Chart ....................................................................

Troubleshooting of Lighting and Horn Systems ............................

Electrical System of FC (Finger-tip Control System) ....................

2– 9 2 – 10 2 – 11 2 – 11 2 – 12 2 – 12 2 – 13 2 – 14

Nomenclature ........................................................................................... 2 – 14 Precautions to be taken when handling FC system .................................. 2 – 15 Description ................................................................................................ 2 – 15 Operating Principles ................................................................................. 2 – 16 How to Set Controller (Setup Option Setting) ............................................ 2 – 18 Troubleshooting ........................................................................................ 2 – 19

2

VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations

5

5

2 1 3 4

View "A" 7

8

A

6

9

211639

1 2 3 4 5

Central vehicle monitoring system (CVMS) Direction lever Lighting switch Key switch Head lamp

6 7 8 9

2-1

Horn Brake fluid level sensor Accelerator sensor Speed sensor

VEHICLE ELECTRICAL COMPONENTS

10

12 11

13 211640

10 Joystick box (FC only) 11 Traction controller

12 Hydraulic controller 13 Contactor

2-2

VEHICLE ELECTRICAL COMPONENTS

18

17

14 15 16 211641

14 Fuse holder 15 FC hydraulic control valve 16 Drive motor

17 Pump motor 18 Steering motor (2 ton class and 2.5 ton class only)

2-3

VEHICLE ELECTRICAL COMPONENTS

Console Box 1 2 3 4 5 6

Central vehicle monitoring system (CVMS) Mode selector button Steering tilt lever Key switch Lighting switch Mode check button

NOTE For setting the clock and selection of KPH or MPH, refer to “Selection of KPH or MPH” and “Setting the clock”.

103148

Functions of Central Vehicle Monitor System (CVMS)

208077

Operations

No.

Monitor name

When OFF

When ON or flashing

Remarks

1

Service indicator

Starts flashing 20 hours before set time. Remains ON when set time is reached.

2

Worn motor brush indicator

Drive motor and pump motor Worn brushes brushes in operable condition

After brushes are replaced, indicator turns OFF.

Controller/motor overheat indicator

Controller, drive motors and pump motor in normal temperature

Overheat

Overheat causes significant output loss. When component temperature lowers to normal level, output power returns.

Remaining battery charge warning indicator

Normal battery condition

Flashing indicates battery needs to be recharged soon.

ON indicates battery needs to be recharged and lifting function inoperable.

3

4

5

Brake fluid level indicator Normal fluid level

Low fluid level 2-4

VEHICLE ELECTRICAL COMPONENTS

No.

Monitor name

When OFF

When ON or flashing

Remarks

6

Parking brake indicator Parking brake disengaged

Parking brake engaged

7

Fault detection indicator

Normal

Vehicle malfunction

Vehicle speed and error code display

Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction.

Battery discharge indicator (BDI)

The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning indicator 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 4 will be continuously lit and the vehicle enters power reduction mode.

Hourmeter, time display

It normally displays the time.

When the key switch is set to the I (ON) position, the drive motor, pump motor, and vehicle service hours are indicated sequentially.

8

9

10

Error codes appear on the error code display.

The vehicle speed display can be switched between KPH and MPH. Follow the steps in “Selection of KPH or MPH” below.

The time of clock can be adjusted. Follow the steps in “Setting the clock” below.

Selection of KPH or MPH

1. Apply the parking brake.

2. Place the direction lever in NEUTRAL.

Button 2

3. Turn the key switch to the I (ON) position.

Button 1

4. Push and hold button 1 for one to two seconds.

NOTICE: Display will show KPH and a 24-hour clock until it is changed. When MPH is selected, the clock will change to a 12-hour clock.

Setting the clock

211642

1. Apply the parking brake.

2. Place the direction lever in NEUTRAL. 3. Turn the key switch to the I (ON) position.

4. Push and hold button 1 until the minutes’ display flashes.

5. Release button 1.

6. Adjust the minutes with button 2.

7. Push button 1 and release when the hours’ display flashes.

8. Adjust the hour with button 2.

9. Push button 1 to lock in the time.

2-5

VEHICLE ELECTRICAL COMPONENTS Error code display

Indication

Condition

E

If the key switch is turned I (ON) while the direction lever is either in the forward or reverse position and/or if the accelerator pedal is depressed.

(E)

Faulty setting of seat switch

E 0

ON

Drive motor overheated

E 2

ON

Pump motor overheated

E 3

ON

Traction module overheated

E 4

ON

Worn drive motor brush

E 6

ON

Worn pump motor brush

E 7

ON

Hydraulic module overheated

H 1

ON

Faulty setting of lift lever

H 2

ON

Faulty setting of tilt lever

H 3

ON

Faulty setting of attachment lever 1

H 4

ON

Faulty setting of attachment lever 2

L O

ON

Battery consumption too much

(E) indicates flashing E.

2-6

VEHICLE ELECTRICAL COMPONENTS

Electrical Components in Console Box

Monitor harness Direction lever harness

2 1

211643

1

Key switch

2

2-7

Lighting switch

VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly Disassembly

2

1 5

3 4

211644

Sequence 1 2 3

Console box (front panel) Central vehicle monitor panel Direction lever

4 5

Steering tilt lock lever Console box (rear panel)

Disassembly procedure (1) Remove the front panel and monitor panel from the console box.

(2) Disconnect the harness connectors from the horn and direction lever.

(3) Remove the screw from the steering tilt lock lever, and remove the lever from the rear panel of the console box.

(4) Remove the rear panel.

Reassembly Steering tilt lock lever

Follow the disassembly procedure in reverse.

2-8

211645

VEHICLE ELECTRICAL COMPONENTS

Direction Lever Structure 4

1

2 3

211646

1 2

Lever Harness

3 4

2-9

Connector Screw, Spring washer

VEHICLE ELECTRICAL COMPONENTS

Accelerator Control

Accelerator pedal Accelerator pedal rod Stopper bolt

Initial position

Lock nut 1.5 to 2.5° For reference: H: 38 to 40 mm (1.50 to 1.57 in.)

H

Switching position of idle switch E2

Lever

IDL

Adjusting screw Position meter

209531

Adjustment Procedures 1. Disconnect the battery plug.

2. Install the position meter by loosely mounting the adjusting screws.

3. Connect the accelerator pedal rod to the lever.

4. Check that there is no continuity between the E2 and IDL terminals.

5. Move the lever 1.5 to 2.5° from the initial position.

6. Check that there is continuity between the E2 and IDL terminals (the idle switch in the position meter is ON), then finally tighten the adjusting screws of the position meter.

7. Make sure the stopper bolt height H is approximately 38 to 40 mm (1.50 to 1.57 in.). Depress the accelerator pedal until it comes in contact with the stopper bolt.

Adjust the height H of the stopper bolt until letter “15” flashes on the I/O diagnosis display.

2-10

VEHICLE ELECTRICAL COMPONENTS

Key Switch Terminal

B

M1, M2

Connection destination

Main fuse Battery

Logic card

(OFF)

I (ON)

206806A

Lighting Switch Terminal

2, 5

3

6

Connection destination

Battery

Head lamps

Working lamps

Push

OFF BAT

2

1

5

3 Cir. 1 4 Cir. 2 6

1st (cir. 1) 2nd (cir. 1 & 2)

1st position (Circuit 1) 2nd position (Circuit 1 & 2)

209515

2-11

VEHICLE ELECTRICAL COMPONENTS

Fuses Capacity (A)

Location

Main connecting device

325 325

Traction motor Contactor assembly

50

Pump motor Steering pump motor

15

Horn switch, Lighting switch Fuse holder

10

Key switch, Contactor

NOTE Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart Item

Bulb Quantity Bulb color

Lamp

Remarks 80 V

Head lamps

2

Clear

55 W

Working lamp

1

Clear

55 W

External diagram

205833

2-12

VEHICLE ELECTRICAL COMPONENTS

Troubleshooting of Lighting and Horn Systems Complaint Lampsgeneral

Possible cause

Remedy

Will not light

1.

2.

3.

4.

Dead or weak battery Fuses blown out Open or short in circuit Bulbs burnt out

Recharge or replace.

Check and replace.

Repair or replace.

Replace.

Will light dimly

1.

2.

3.

4.

5.

6.

Dead or weak battery Burned contact points in switches Loose terminals Dirty lenses Water drops inside lenses Bulbs service life expired

Check and recharge.

Repair or replace.

Retighten.

Clean.

Dry and replace packings.

Replace.

Head lamps

Will not light

1. Lighting switch defective 2. Bulbs burnt out

Replace.

Replace.

Other lamps

Backup lamps will not light

1. Backup lamp switch defective 2. Bulbs burnt out

Correct if improperly installed: replace if internally defective.

Replace.

Will not sound

1.

2.

3.

4.

5.

Check and replace.

Repair or replace.

Replace.

Replace.

Repair or replace.

Will give an offensive sound

1. Horn switch defective 2. Horn defective

Horn

Fuse blown Open or short in circuit Horn switch defective Horn defective Horn button defective

2-13

Replace.

Replace.

VEHICLE ELECTRICAL COMPONENTS

Electrical System of FC (Finger-tip Control System) Nomenclature

5

6

103144

1 2 3

FC hydraulic control valve Flow regulator valve Seat switch

4 5 6

2-14

Controller Emergency switch FC control levers (finger-tip control system)

VEHICLE ELECTRICAL COMPONENTS

Precautions to be taken when handling FC system The FC system is controlled by a microcomputer in the controller. As the microcomputer is a delicate electronic component, take the following precautions when handling and inspecting the FC system.

(1) When removing the controller cover, take proper precautions to keep out all moisture such as rain and splashing water.

(2) After using the controller setting function, check to make sure control system is within truck specifications.

208084A

NOTE Improper setting of the system will result in the inability to lower the forks in an incremental manner.

(3) Before performing repairs which require welding, be sure to disconnect the battery plug and the controller from the system at its connectors.

(4) When handling the controller by hand, never touch its electrical terminals, or the static charge from your body will rupture some of the electronic elements in the internal controller circuits.

Description The FC system, unlike the conventional mechanical control, is electronically actuated to reduce the effort required of the operator in moving the control levers for lift, tilt and attachment functions.

101466A

• This system provides the following safety functions: (a) The lift, tilt and attachment functions are not performed even if the control levers are moved when the emergency switch is in ON (pushed) position.

(c) The system indicator light in the LED section alerts the operator to problems occurring in the electrical system and, at the same time, stops function. (If any problem occurs in the lift system, for example, the system becomes inoperative.)

(b) The lift, tilt and attachment functions are not performed even if the control levers are moved when the seat switch is not ON (the operator is not seated).

2-15

VEHICLE ELECTRICAL COMPONENTS

Operating Principles (1) The system is activated by turning OFF (pulled, not pushed) the emergency switch when the key switch and the seat switch are ON (when the operator is seated).

(2) As the control levers (joysticks) are moved to operate the equipment (mast and forks), the amount of lever movement will be translated into an electrical signal; this signal goes into the controller where it is converted to an output signal. At this point the controller issues an ON signal to increase the pump motor speed, thereby hydraulic pressure will be introduced into the control valve. The system is now ready to actuate the equipment. The output signal is applied to the proportioning solenoid, selected by the direction of the joystick movement. Inside the control valve of the solenoid, the spool valve is forced to slide, altering the internal oil passage that directs the oil to the corresponding cylinders. The spool keeps on sliding until it comes to the position where the pressure of its pilot chamber becomes equal to the force of its centering spring. In the meantime, the cylinder extends or retracts against its load. As the joystick is moved back to its neutral position, the signal to the proportioning solenoid decreases in order to lower the pilot chamber pressure and allow the centering spring to push the spool to its neutral position, whereby the line to the cylinder shuts off. The pressure in the line is now trapped, holding the cylinder in place. At the same time, the motor speeds lowers and the part of the system actuating the equipment goes into a no-load state.

(3) Supply power to the controller is initiated from the Power Relay through a 10-Amp fuse. Pressing the emergency switch shuts down the output to solenoids.

2-16

VEHICLE ELECTRICAL COMPONENTS

How to Set Controller (Setup Option Setting)

Failures resulting from incorrect setting

Set the controller on any of the following occasions:

(1) Incorrect setting for truck size (2.5 ton, 3 ton) or incorrect model setting

Occasions:

(a) An incorrect setting will result in abnormal lowering speed and inching feel. If a setting for a 2.5 ton model is made on a 3 ton model, for example, the lowering speed will be abnormally low. If a setting for a 3 ton model is made on a 2.5 ton model, the lowering speed will be abnormally high.

• After the mast has been changed, or an optional equipment added.

• After the controller assembly has been replaced.

How to set: See the “Setup Option Setting” section in the “Controller Service Manual GROUP 1 CONTROLLER”.

(2) Incorrect setting for number of control valve spools

General Precautions:

(a) If the setting made for the number of spools is greater than the actual (FAULT lamp lights and error code is displayed), the equipment does not operate.

(1) Use low air pressure to clean electrical equipment (controller, motor, battery, cable, etc.). If using steam, do not blow it directly on the equipment.

(2) When the counterweight back door is removed, make proper measures to keep out rain.

(Regarded as open-circuit in control valve solenoid or joystick.)

(3) After using DRS (Diagnosis Run Set) switch, recheck the switch setting.

(b) If the setting made for the number of spools is less than the actual, only the devices equal to the number of set spools will be actuated.

(4) The controller containing the microcomputer should never come into contact with water. When the cover is removed, take proper precautions to keep out all moisture such as rain and splashing water.

(3) Incorrect setting for mast (a) A setting for a dual-stage full free mast or triple-stage full free mast on a truck with dualstage panoramic mast will not affect the lowering speed.

(5) In case of some welding work on the frame or body, disconnect the battery from the power supply line.

And disconnect the controller from the system by undoing all connectors. If the welding job has to be performed near the controller position, remove the controller from the truck.

(b) If the setting is made for dual-stage panoramic mast on a truck with dual-stage full free or triple-stage full free mast, the lowering speed of the 1st lift cylinder will be abnormally low.

This setting will not affect the lowering speed of the 2nd lift cylinders.

(6) Your body could pick up a large static charge.

Keep this in mind when you handle the controller by hand: never touch its electrical terminals, or the static charge from your body will rupture some of the electronic elements in the controller's internal circuit.

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VEHICLE ELECTRICAL COMPONENTS

Troubleshooting 1. Preparatory steps

(1) The system receives supply power when the battery connector is connected, the key switch is turned to the ON position, and the emergency switch is turned OFF (pulled, not pushed). The finger-tip control becomes operable after the seat switch closes (when operator is seated).

(2) Before deciding to replace a blown fuse, make sure the harness connectors in the power line are all in good condition.

(3) The use of the test-use connector (special tool) is recommended for checking the connector-to-connector lines for continuity and for reading the voltage across two terminals and the ohmic resistance of a line.

(4) When coupling or uncoupling a connector, make sure that the key switch is turned OFF and the battery connector is disconnected. Never try to forcibly insert or pull off the connector, or its pins will be damaged.

When coupling a connector, be sure that the inserted half snaps into its self-locking position.

(5) Before starting troubleshooting work, check to be sure that the conditions indicated in the following table are met on the machine side.

2-19

205038

VEHICLE ELECTRICAL COMPONENTS Inspection of machine side components

Shown in the following table are the machine side basic components that must be inspected first when a problem occurs in the FC system and the conditions and points for performing their checking.

Conditions in the machine

Key switch OFF Emergency switch ON

Check item

What to check

Remedy

Hydraulic line

Hoses, pipes and connectors for damage and sign of leak.

Hydraulic devices

Check control valve and hydraulic cylinders Repair damaged or for damage and oil leaks. leaking parts, if any.

Electrical connectors and wires

Check connectors for tightness, burns and breakage; check wires for insulator stripping and signs of rubbing.

Repair.

System check lamp

Check to be sure the lamp goes ON and OFF properly; if not, check the bulb.

Replace lamp bulb if blown.

Hydraulic devices

With your hands off the control levers, see if the solenoid valves and hydraulic pump are making any abnormal sounds.

Refer to the sections dealing with control valve and hydraulic pump, respectively.

Operate the control levers to see if any abnormal sounds, indicative of flow throttling, comes from control solenoid valve or from any other solenoid valve.

(Proper function of solenoid valves is essential to troubleshooting.)

Check each work attachment for the following: (a) Does it work properly? (b) Does it “inch” properly? (c) Does mast go down with proper speed?

See “4. Troubleshooting guide for solenoid control valves” on page 2-24.

Key switch ON Emergency switch OFF

Work attachments

2-20

Repair leaking or damaged parts.

VEHICLE ELECTRICAL COMPONENTS 2. How to move the mast in an emergency

If the truck fails during operation, and you have to drive it (if the engine is OK) or tow it to some distant place like the repair shop, follow the instruction below.

!

CAUTION

Before doing these steps, be sure that there is no one standing under the mast.

(1) Mast lowering (a) Loosen lock nut 1 on the lift section of the control valve. (b) Using an Allen wrench, slowly loosen screw 2.

This causes the mast to go down by gravity: tighten screw 2 and the mast will stop. (c) Tighten lock nut 1.

!

CAUTION

Leaving nut 1 loose is dangerous: the mast might suddenly start descending by gravity.

2-21

208076A

VEHICLE ELECTRICAL COMPONENTS

(2) How to cope with a failed (open-circuit) seat switch.

Your troubleshooting investigation might reveal that the seat switch is an open-circuit or otherwise faulted and will not function.

In such a case, you can create a temporary circuit through the seat switch wiring. The method is explained in this illustration. The seat switch is a safety part. Be sure to replace it with a new one as soon as possible.

Two connectors are in the seat switch line at the indicated location; Open these connectors, and couple up the male and female connector halves to form a circuit bypassing the seat switch.

205012B

!

CAUTION

Illustrated above is a band-aid method permissible only in an emergency situation. Be sure to restore the seat switch line to the normal hookup after replacing the failed switch.

2-22

VEHICLE ELECTRICAL COMPONENTS 3. How to clean harness connectors and system components

(1) Open-circuit troubles are often due to dirty harness connectors and components. Dust, together with greasy matter forms grime, which in time penetrates electrical connections resulting in loose metal-to-metal contact or electrical separation of contact surfaces. For this reason, it is essential that the connectors and components be cleaned at each periodic inspection and at the time of servicing the truck. Instead of a commonly used solvent, use the electronic parts cleaner (in the manner illustrated on the right).

Electronic parts cleaner

205046A

Three Bond 29D or Pow-R-Wash CZ*

NOTE The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grime. No need to wipe off the sprayed liquid.

(2) After checking the connector for continuity, wash it as shown. Then, uncouple the connector and spray the contact surface activator onto contact surfaces. Now, install and remove the connector several times to wet the surfaces thoroughly with the activator liquid. After coupling up the connector, check to be sure that it is correctly locked.

Contact surface activator

Three Bond 2501S (aerosol) or Nyogel 760G*

NOTE Do not spray too much: bear in mind that this spray liquid reacts with some resins (plastic materials). * : Products contained in Terminal Maintenance Kit (SE000003).

205047

2-23

VEHICLE ELECTRICAL COMPONENTS 4. Troubleshooting guide for solenoid control valves

Trouble symptom

Possible cause

Remedy

The pump discharge pressure will not build up

1. Sticky plunger in proportioning solenoid of reducing valve, or sticky shuttle in reducing valve 2. Open in lead wire or in solenoid coil 3. Input current to solenoid too small

Disassemble and clean by washing.

If the plunger is sticky, replace the solenoid.

Repair or replace.

4. Unload valve stuck open 5. Spool stuck in flow-divider valve Sticky spool

Sticky plunger in proportioning solenoid of reducing valve, or sticky shuttle in reducing valve.

2-24

Check to make sure that solenoid is drawing specified maximum input current. • Check unload solenoid for action. • Check unload valve for action.

Disassemble and clean by washing.

Disassemble and clean by washing.

If plunger is sticky, replace solenoid.

POWER TRAIN General Structure ...................................................................................

Common Removal and Installation Procedures ............................

3–2

Front Wheel Removal and Installation .......................................................

3–2

Battery Removal and Installation ...............................................................

3–4

Power Train Assembly Removal .........................................................

Power Train Assembly Installation ....................................................

3–5

3–1

3–8

3

POWER TRAIN

General Structure

Power flow 208364

Location of Power Train Component 1 2 3 4 5

Drive motor Transfer gear Differential gear assembly Right axle shaft Right wheel hub

6 7 8 9

The power train mainly consists of the following three units.

Right wheel brake Left axle shaft Left wheel hub Left wheel brake

differential gear system is a device that makes it possible; it detects the difference in turning resistance between inside and outside wheels being turned and automatically differentiates the number of revolutions between them accordingly.

1) Drive motor 2) Transfer and differential assembly 3) Front axle assembly

The power transmitted to the output gear is then sent to the differential gear assembly 3. When the vehicle is turning, the right axle shaft 4 and left axle shaft 7 rotate at different speeds. The power distributed to the right axle shaft 4 is transmitted to the right front wheel by way of the right wheel hub 5.

These units are connected to each other internally through splines and gears to transmit driving power and externally through cases joined together with bolts to form a power train assembly.

The power train assembly is secured to the vehicle frame with bolts at the front axle supports.

The power distributed to the left axle shaft 7 is transmitted to the left front wheel via the left wheel hub 8. When the vehicle is running in a straight direction, its left and right wheels are equal in turning resistance and therefore no speed difference occurs between them.

The output of the drive motor 1 is first transmitted to the input gear shaft of the transfer gear 2. The transfer gear 2 is a 3-stage reduction gear. At each reduction stage, the motor output is decreased in the gear speed and increased in the turning torque in inverse proportion before transmitted to the output gear (bolted to the differential gear) of the final reduction stage.

Each of the left and right wheel hubs 5, 8 is provided with a wheel brake drum. In the brake drum is housed the internal expansion duo-servo type wheel brake 6, 9.

The gears used are noise-free helical gears for quiet vehicle operation.

For further information about the structures of individual components and system operation, refer to the relevant sections.

To allow the vehicle to make a curve smoothly, outside wheels must turn faster than inside wheels. The 3-1

POWER TRAIN

Common Removal and Installation Procedures Front Wheel Removal and Installation Removal 1. Park the truck on level floor with the parking brake applied, the direction lever in neutral, the forks lowered, and the key switch in the OFF position.

2. Prepare tools, jacks, and wheel blocks.

101206A

To Raise Front Wheel

3. Block the rear wheels.

4. Loosen the wheel nuts about two turns.

NOTE Loosen, but do not remove, the wheel nuts.

5. Raise the front end of the truck. Use one of the appropriate methods illustrated at right.

!

100828A

Position the jack under the frame and raise the front wheel.

WARNING

To prevent possible injury, do not replace the front wheel when the truck is loaded.

Alternative Method

Dismount the truck before raising the front wheel.

To prevent possible personal injury, raise the truck only until the front wheel just clears the ground.

Do not put any portion of your body under the truck. Securely support the truck on blocks after raising it.

6. Remove the wheel nuts (loosened in Step 4.).

NOTE

100913

Be careful not to damage the bolt threads when removing the wheel.

Tilt the mast all the way back, place blocks under the mast, and tilt the mast forward.

7. Remove the wheel.

Inspection of Tires for Wear Replace the tire if the depth of its tread groove is less than 5 mm (0.2 in.).

100680

3-2

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