Caterpillar Cat EP25K PAC Forklift Lift Trucks Service Repair Manual SNETB8C-50001 and up

Service Manual Chassis, Mast & Options EP20K PAC EP25K PAC EP30K PAC EP35K PAC

ETB8C-00011-up ETB8C-50001-up ETB9C-00011-up ETB9C-50001-up

For use with EP20K PAC - EP35K PAC Controller Service Manual.

99759-6A100

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 trucks 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. 99759-6A100

!

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 PAC, EP25K PAC, EP30K PAC and EP35K PAC.

Class

Truck Model

2 ton

EP20K PAC

ETB8C-00011-up

2.5 ton

EP25K PAC

ETB8C-50001-up

3 ton

EP30K PAC

ETB9C-00011-up

3.5 ton

EP35K PAC

ETB9C-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

PAC AC motor 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 Class Load capacity/load center

Truck size

N (kgf)/mm [1bf/in.]

EP20K PAC

EP25K PAC

2.0 ton

2.5 ton

19600 (2000)/500 [4400/20]

24500 (2500)/500 [5500/20]

Length to fork face

A

mm (in.)

2249 (88.5)

2274 (89.5)

Width

B

mm (in.)

1190 (46.9)

1190 (46.9)

Height of overhead guard Cmm (in.)2200 (86.6) D

Wheelbase

2200 (86.6)

mm (in.)

1520 (59.8)

1520 (59.8)

kg (lb)

2775 (6118)

2995 (6603)

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)

20.0/20.0 (12.4/12.4)

20.0/20.0 (12.4/12.4)

Lift speeds Unloaded/loaded

m (in.)/sec

0.65/0.55 (25.6/21.7)

0.65/0.50 (25.6/19.7)

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°

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

14.5

14.5

Pump motor output

@ 15% duty factor

kW

20.0

20.0

Steering pump motor output (60 min. short duty) kW

1.2

1.2

Drive motor control method

MOS-FET

MOS-FET

Pump motor control method

MOS-FET

MOS-FET

1-5

GENERAL INFORMATION

Truck model Class Load capacity/load center

Truck size

N (kgf)/mm [1bf/in.]

EP30K PAC

EP35K PAC

3.0 ton

3.5 ton

29400 (3000)/500 [6600/20]

34300 (3500)/500 [7700/20]

Length to fork face

A

mm (in.)

2522 (99.3)

2577 (101.5)

Width

B

mm (in.)

1230 (48.4)

1230 (48.4)

Height of overhead guard Cmm (in.)2250 (88.6) D

Wheelbase

2259 (88.9)

mm (in.)

1690 (66.5)

1690 (66.5)

kg (lb)

3231 (7123)

3665 (8080)

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)

20.0/20.0 (12.4/12.4)

18.0/16.5 (11.2/10.3)

Lift speeds Unloaded/loaded

m (in.)/sec

0.60/0.45 (23.6/17.7)

0.55/0.40 (21.7/15.7)

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°

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

14.5

14.5

Pump motor output

@ 15% duty factor

kW

20.0

20.0

Steering pump motor output (60 min. short duty) kW

1.2

1.2

Drive motor control method

MOS-FET

MOS-FET

Pump motor control method

MOS-FET

MOS-FET

1-6

VEHICLE ELECTRICAL COMPONENTS Electrical Component Locations ........................................................ 2 – 1 Console Box ............................................................................................ 2 – 5 Functions of Central Vehicle Monitor System (CVMS) ............................... 2 – 5 Electrical Components in Console Box ..................................................... 2 – 8 Disassembly and Reassembly .................................................................. 2 – 9

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

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

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

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

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

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

Auto-light Systems ................................................................................

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

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

2 – 10 2 – 11 2 – 12 2 – 12 2 – 13 2 – 13 2 – 14 2 – 15 2 – 16

Nomenclature ........................................................................................... 2 – 16 Precautions to be taken when handling FC system .................................. 2 – 17 Description ................................................................................................ 2 – 17 Operating Principles ................................................................................. 2 – 18 How to Set Controller (Setup Option Setting) ............................................ 2 – 20 Troubleshooting ........................................................................................ 2 – 21

2

VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations

6 Detail "A"

7 1 A

2

3 4

5

9

8

Detail "B"

13 B

10

12

11

1 2 3 4 5 6 7

Central vehicle monitoring system (CVMS) Direction lever Lighting switch Key switch Auto-light switch Head lamp Auto-light sensor

8 9 10 11 12 13

2-1

Contactor Fuse holder DC/DC converter Horn Foot brake switch FC hydraulic control valve

211648

VEHICLE ELECTRICAL COMPONENTS

14

15

211649

14 Parking brake switch

15 Brake fluid level sensor

2-2

VEHICLE ELECTRICAL COMPONENTS

16

19

18

17 211650

16 Joystick box (FC only) 17 Controller cooling fan

18 Controller assembly 19 Contactor assembly

2-3

VEHICLE ELECTRICAL COMPONENTS

24

D

Detail "C" Detail "D"

22

21

C

23

20 211651

20 Drive motor 21 Drive motor thermal and speed sensor 22 Pump motor

23 Pump motor thermal and speed sensor 24 Steering pump motor

2-4

VEHICLE ELECTRICAL COMPONENTS

Console Box 1 2 3 4 5 6 7

1

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

6

2

5

4 3

7 206900

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

Functions of Central Vehicle Monitor System (CVMS)

209510

Operations

No. 1

2

Monitor name

When OFF

When ON or flashing

Service indicator

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

Controller/motor overheat indicator

Controller, drive motors and pump motor in normal temperature

Overheat

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

Remarks

Brake fluid level indicator Normal fluid level

Low fluid level 2-5

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

VEHICLE ELECTRICAL COMPONENTS

No.

Monitor name

When OFF

When ON or flashing

Remarks

5

Parking brake indicator Parking brake disengaged

Parking brake engaged

6

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 3 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 3 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.

7

8

9

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.

Button 2

2. Place the direction lever in NEUTRAL. 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

209600A

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.

2-6

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 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.

2-7

VEHICLE ELECTRICAL COMPONENTS

Electrical Components in Console Box

Monitor harness Direction lever harness

2 3 1

211652

1 2

Key switch Lighting switch

3

2-8

Auto light switch

VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly Disassembly

2

1 5

3 4 211653

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.

Steering tilt lock lever 211645

Reassembly Follow the disassembly procedure in reverse.

2-9

VEHICLE ELECTRICAL COMPONENTS

Direction Lever Structure

4

1

2 3

211646

1 2

Lever Harness

3 4

2-10

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.

2-11

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)

1st position (Circuit 1)

2nd (cir. 1 & 2)

2nd position (Circuit 1 & 2)

209515

2-12

VEHICLE ELECTRICAL COMPONENTS

Fuses Capacity (A)

Location

Main connecting device

500

Contactor assembly

Line contactor, Logic controller

10

Fuse holder

Controller fans, DC/DC converter

50

Steering motor

Steering pump motor

15

Horn switch, Lighting switch, Contactor 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

2-13

VEHICLE ELECTRICAL COMPONENTS

Auto-light System System Operation

With the auto-light switch turned on, the contactor automatically closes the head lamp and working lamp circuits when the darkness sensed by the auto-light sensor is enough to illuminate the lights.

Auto-light sensor assembly

A

Head lamp

B

Detail "A"

C

Auto-light sensor assembly harness Harness D Lighting switch

Red Yellow

Harness B

Key switch

Yellow

Red

White Blue Blue

Auto-light switch

White

Detail "C"

Detail "B"

2-14

211654

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

2-15

Replace.

Replace.

VEHICLE ELECTRICAL COMPONENTS

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

3

2

4

1

5

103542A

1 2 3

FC hydraulic control valve Seat switch Controller

4 5

2-16

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 the control system is within truck specifications.

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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 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).

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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 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.

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