Toyota 5FBE18 Forklift Service Repair Manual

FOREWORD This manual covers the service procedures of the TOYOTA BATTERY FORKLIFT 5FBE10-20 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of September 1998. Please understand that disagreement can take place between the descriptions i n the manual and actual vehicles due t o change i n design and specifications. Any change or modifications thereafter will be informed b y Toyota Industrial Vehicles' Parts & Service News.

TOYOTA Material Handling Company A Division of TOYOTA INWSRIES CORPORATION

SECTION INDEX SECTION

NAME

GENERAL BATTERY OTHER THAN U.S.A.] (1993.1 - 1998.8) CONTROL ClRCU IT [FOR IFOR u.s.A.1 (1993.1 -1999.1 OTHER THAN U.S.A.] (1998.9 CONTROL CIRCUIT [FOR [FOR UL. U.S.A.. CANADA] (1999.2 MULTI-DISPLAY FUNCTIONS )

-

-) -)

A

[FOR OTHER THAN U.S.A.] (1993.1 1998.8) [Fouu.s.A.j (1993.1 - )

ELECTRICAL SYSTEM TROUBLESHOOTING ELECTRICAL SYSTEM TROUBLESHOOTING

/

-

[FOR OTHER THAN U.S.A.] (1993.1 1998.8) [FoRu.s.A.1 (1993.1 -1

[FOR OTHERTHAN U.s.Ad(199889 -I

A

A

MOTOR FRONT AXLE & TRANSMISSION (lgg3.1 - lgg8-l) FRONT AXLE & DRIVE UNIT (1998-2-1 REAR AXLE (1993.1- 1998.1)

1 A

STEERING -

BRAKE (1998.2- I BODY & FRAME MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL ] APPENDIX

GENERAL Page

...........................

VEHICLE MODEL ...........................

FRAME NUMBER ...........................

HOW TO USE THIS MANUAL ................

EXTERIOR VIEWS

0-2 0-3 0-3 0-4

.......................... 0-4 TERMINOLOGY .................................. 0-5 ABBREVIATIONS ................................. 0-5

EXPLANATION METHOD

.......... 0-6 OPERATIONAL TIPS ......................... 0-7 JACK-UP POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 CIRCUIT TESTER ............................ 0-9 LIST OF ABBREVIATIONS AND SYMBOLS

STANDARD BOLT & NUT TIGHTENING TORQUE ................................. 0-11 BOLT STRENGTH TYPE IDENTIFICATION METHOD ....................................... 0-11 TIGHTENING TORQUE TABLE

PRECOAT BOLTS

.....................

...........................

0-12 0-13

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ..................... 0-13 WIRE ROPE SUSPENSION ANGLE LIST

.......

0-14

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ..................... 0-14 COMPONENTS WEIGHT ..................... 0-15 RECOMMENDED LUBRICANTS AND CAPACITIES ......................... 0-15 LUBRICATION CHART ....................... 0-16 PERIODIC MAINTENANCE ................... 0-17 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ........................ 0-22

0-2

EXTERIOR VIEWS

VEHICLE MODEL Load capacity

Model

Battery capacity AH/5HR

Voltage V

Control circuit

1.0 ton

5FBE10

280

*36 or 48

MCS-IIIA

1.25 ton

5FBE13

t

t

1.5 ton

5FBE15

390

1.75 ton

5FBE18

t

1.815 ton

5FBE20

375

t t t t

t t t

*: 36 V is provided for UL specification.

FRAME NUMBER

Punching position

Upper face of side member of frame RH

Vehicle model 1 ton series

1.5 ton series 2.0 ton series

5FBE10 5FBE13 5FBE15 5FBE18 5FBE20

Punching format 5FBE13-10011 5FBE13E10011 (EEC spec.)

(1993.1 1993.9) 5FBE130 10011 (EEC spec.)

(1993.10 )

-

-

5FBE18-10011 5FBE18E10011 (EEC spec.)

(1993.1 1993.9) 5FBE18010011 (EEC spec.)

(1993.10 )

-

-

5FBE20-10011

HOW TO USE THIS MANUAL EXPLANATION METHOD 1.

Operation procedure (1) The operation procedure is described in either pattern A or pattern B below.

Pattern A: Explanation of each operation step with a photo or illustration.

Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations.

Example of description in pattern B

DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T=N.m (kgf-cm)[ft-lbfl

--

T = 46.09 48.05 (470 490) 134.00- 35.451

8

Disassembly Procedure 1

Remove the cover. [Point 11

2

Remove the bush [Point 21

3

Remove the gear.

Operation explained later

Point operations Explanation of key point for operation with an illustration [Point 11 Disassembly: [Point 21 Inspection:

J

Put a match mark when removing the pump cover.

Measure the bush inside diameter.

Bush inside diameter limit: 19.12 mm (0.7528 in)

2.

3.

How to read components figures (1) The components figure use the illustration in the parts catalog for the vehicle model. Please refer to the catalog for checking the part name.

The number at the right shoulder of each components figure indicates the Fig. number in the parts catalog.

(Example)

fl FIG number in parts catalog

Matters omitted in this manual (1) This manual omits description of the following jobs, but perform them in actual operation: @ Cleaning and washing of removed parts as required @ visual inspection (Partially described)

TERMINOLOGY Caution: lmportant matters of which negligence may cause accidents. Be sure to observe them.

Note: lmportant items of which negligence may cause accidents or matters in operation procedure requiring special attention.

Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS Abbreviation (code)

Meaning

Abbreviation (code)

Meaning

ASSY

Assembly

RR

Rear

EHPS

Electrical hydraulic power steering

SAE

Society of Automotive Engineers (USA)

FR

Front

SST

Special service Tool

I-/

Less

STD

Standard

LH

Left hand

T=

Tightening torque

0PT

Option

OOT

01s

Oversize

U/S

PS

Power steering

w/

RH

Right hand

Number of teeth Undersize With

(00)

LIST OF ABBREVIATIONS AND SYMBOLS Symbol BATT BZ CA CADIP

Name

Battery Buzzer Absorber Capacitor Drivelpump Absorber Capacitor Charger CH Forward Chime CHIF Reverse Chime CHIR CSDIP DriveIPump Current Sensor Power Steering Current CSps Sensor DADIP Drivelpump Absorber Diode Charger Diode DCH DC-SDD DC-DC Converter & Source Drive (Drive) DC-SDP DC-DC Converter & Source Drive (Pump) FLY-WHEEL Diode, DF112 No.112 DF314 FLY-WHEEL Diode No.314 DlSP Display DriveIPump Motor DMDlP Power Steering Motor DMps Back-up Direction Switch DSBu Forward Direction Switch DSF Forward Optional DSFo Direction Switch Reverse Direction Switch DSR F1 Drive Fuse F2 Pump Fuse F3 Power Steering Fuse F4 Lamp Fuse F5 Control Circuit Fuse Charger Fuse FCH

Symbol

Name

Flasher Relay Horn Wheel Position Indicator Back-up Lamp, LH Back-up Lamp, RH Clearance Lamp, LH Clearance Lamp, RH Flasher Lamp, LH ~Flasher Lamp, LH (Rear) Flasher Lamp, RH Flasher Lamp, RH (Rear) Head Lamp, LH Head Lamp, RH Rotaly Forward Lamp Rotaly Reverse Lamp Attachment Limit Switch No.112 Brake Limit Switch LSB Dead Man Limit Switch LSD LSL1/2 Lift Limit Switch No.112 Stop lamp limit Switch LSsT L S T - ~ Stop Lamp, LH L s T - ~ Stop Lamp, RH Tilt Limit Switch LST Tail Lamp, LH LT-~ Tail Lamp, RH LT-~ Working Lamp Lw Forward Contactor, LH MFL Forward Contactor, RH MFR MP Pump Contactor Power Steering Contactor MPS Reverse Contactor, LH MRL Reverse Contactor, RH MRR Charger Magnet Switch MScH PBcpu Computer Print Board PBEHPs EHPS Print Board FRY H IWP LBU-~ LBU-~ LC-L LC-R LF-L L F - ~ LF-R LF-RR LH-L LH-~ LR-F LR-~ LSAnI2 l

Symbol

Name

Snubber Print Board Working Pilot Lamp Absorber Resistor Drivelpump Absorber Resistor PCKI I 2 Check Resistor No.112 SA Surge Absorber SLL Lequid Level Sensor Sunbber No.1 SN1 SNCI 12 Snubber Capacitor 112 SNR112 Snubber Resistor 112 SSP Steering Pressure Sensor Speed Sensor, LH SSL Speed Sensor, RH SSR Thermo Sensor STH SWAC Accel Switch Flasher Switch SWF Horn Switch SWH Key Switch SWKy Light Switch SWL SWPB Parking Brake Limit Switch Speed Control Switch SWsc Transformer TF Thermal Relay THR Main Transistor TM Main Drive Transistor TMD Main Pump Transistor TMP Main Power Steering TMps Transistor Timer Unit TU VRAD Accel Drive Variable resistor VRSP Steering Position Variable resistor (Steering potentiometer) PBsN PLw RA RADIP

OPERATIONAL TIPS 1.

Safe operation (1) After jacking up, always support with wooden blocks on rigid stands.

(2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve in load capacity.

(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.

2.

Tactful operation (1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation.

(2) Before disconnecting wiring, always check the cable color and wiring state.

(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion.

(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location.

(5) Follow the described procedures for disassembly, inspection and reassembly.

(6) Replace, gaskets, packings and O-rings with new ones each time of disassembly.

(7) Use genuine Toyota parts for replacement.

(8) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassembly. If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.

3.

Grasping the troule state When a trouble occurs, du not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for remedying.

4.

How to treat liquid waste When draining liquid waste from a vehicle, use a pan or other suitable container to collect the liquid.

Do not throw away oil, fuel, cooling water, oil filters, batteries, or other injurious materials since these materials may adversely affect human health and the environment. Sort liquid waste into different types and seek the service of experts for proper disposal.

Hoisting the vehicle Loop wire ropes on the mast hook hole and the rear of the head guard to hoist the vehicle.

JACK-UP POINTS The vehicle often needs to be jacked up during assembly and reassembly.

Be sure to jack up the vehicle at the right positions. Placing a jack in the wrong position or jacking up the vehicle in the wrong manner may cause an unexpected accident.

Front jack-up

Rear jack-up

Front jack-up If a jack with a short bearing plate is used, the vehicle may fall off the jack. Be sure to use jacks with a bearing plate at least 80 m m long.

Rear jack-up When jacking up only one side (right or left) of the vehicle, be sure to fit a suitable stock under the weight on the opposite side.

The vehicle may tip over if it is jacked up on one side in an unsafe manner. Make sure that the vehicle maintains its balance during jack-up.

CIRCUIT TESTER Circuit testers are available in both the analog and digital types. They should be used selectively according to the purpose of measurement.

Analog type: This type is convenient for observing movement during operation, but the measured value should only be used for reference or rough judgement.

Digital type: 1.

Fairly accurate reading is possible, but it is difficult to observe the variation or movement.

Difference in measurement results with the digital type and analog type *The result may be different between measurements with the analog type and digital type.

Always use a circuit tester according to its operation manual. Cautions when the polarities are different between the analog type and digital type are described below.

(1) Analog circuit tester

I Measurement result example Forward direction

Reverse direction

Tester range:

I

KR range Analog type Continuity Forward I shall exist

I

No continuity

Reverse

(2) Digital circuit tester Forward direction

Reverse direction

Measurement result example Tester range: 2 M Q range Digital type

I

I

I

Forward

Reverse

NO continuity 1 Continuity shall exist 2 MR

I

2. Difference i n result of measurement with circuit tester The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used. The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.

The diode characteristics are shown in the figure below. (m~)

The resistance values of the same semiconductor measured with t w o types of circuit testers having different power supply voltages are different.

5 Current 4 in forward direction

This manual describes the results of measurement with a circuit tester whose power supply voltage is

3.0 V.

2 1

0

0.1

0.3 0.4

0.2

0.5

0.7 0.8

0.6

Voltage in forward direction

lV)

3. Difference in measurement result by measurement range (analog type) In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the circuit resistance. Even when the same diode is measured, the measurement result varies with the measurement range.

Always use the range described in the repair manual for measurement.

Current flow

I

Variable resistor

,

Resistor

,-

Range: x 10

,,

(SW 1)

Resistor 41

TEwer

4

,

(SW2)

Range: x 1

source: 1.5 V

"0 Red

6@ Black

STANDARD BOLT AND NUT TIGHTENING TORQUE How to judge tightening torque of a standard bolt or nut.

1.

How to judge tightening torque of a standard bolt.

Find out the type of the bolt from the list below.

Then, find the bolt tightening torque from the table.

2. How to judge tightening torque of a standard nut.

The nut tightening torque can be judged from the bolt type. (See the item above.)

BOLT STRENGTH TYPE IDENTIFICATION METHOD 1. Identification by bolt shape Shape and class

2.

Class 4=4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T

@-

Bolt head No.

0

No mark

4T

Hexagon flange bolt

No mark

4T

Hexagon head bolt

Two protruding lines

5T

Hexagon head bolt

Identification by part No.

Hexagon head bolt

I

Part No. 91611-40625 T L e n g t h (mml Diameter (mm)

iameter

Stud bolt Two protruding

Part No. 921 32-40614 Four protruding

Length (mm) Diameter (mm)

0-12

TIGHTENING TORQUE TABLE

I

I

14

1.5

75

1

16

1.5

113

j

760 1150

6

1 .O

1

65

8

1.25

j j j

160 330 600

i

930

6.4 16

I

5T

10

1.25

32

12

1.25

59

1.5

91

1.5

6

1 .O

137 7.8

1 1400

j

80

I

8

1.25

19

1

10

1.25

38

j

195

1.25

72

1

7T

1.5

16

1.5

6

1.O

8

1.25

10

1.25

110

730

14

1.5

67

100

1 101 69 in-lbf

1 14 29

1 53

11750

1127

l1 I1 1 1 0 25 1260

8 119

52

i

95

1

226

6

1.O

12

j

8

1.25

29

10

1.25

61

12

1.25

108

14

1.5

172 265

1

38

970

1 70 I

1500

i 108

I

I

1 2300

1 166

L

i

125

_

1

75

j j j

175

300

j

620

21 43 79

65 in-lbf

I

I

1 1050

1

76

9

360 670

26 48

11600

j I

1

90 215

1 1

ill6

j I

1

78 in-lbf 16

I

440

j

32

I

1810

159

I

I

1 1250

j I

191

11950

1141

12

j

120 1290

9 121

I

I

I

28 58

j

590

I

103

-

1 1050

j

l4 1I

43

:

76

I

11700 , I I I

j

I

I

I

167

90

-

j123 I I I

145

9

I

1 22

I

j

13

I

I

j

_

I

123

45

32

I

I

11100

180

68 123

i 127

196

1750

I I

j j j j

I

1

I

8.8

I

I

147

157

I

j

I I

I

I

530

I

161

I

i 8 0

170

65

I

I

1.5

1.5

i

j1100

16

16

36

I

I

8T

24 43

1

I

1850

I

I

I

1.25

18

I

I

12

12

j j

400

I

14

7.5

I

I

12

56 in-lbf

-

I

I

6T

83

I

I

16

i i

55 83

I

I

14

j

I

I

1 2700

1 195

1

330

1

690

I

24

j

50

I

1 1250 ,1 2000 1 3050

I

299

1I 1

90

j

145

I

1 221

PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1.

I

I

Do not use the precoat bolt as it is in either of the following cases: (a) After it is removed. (b) When the precoat bolt is moved (loosened or tightened) by tightness check, etc.

Note: For toraue check. use the lower limit of the allowable tighteni;lg torque range. If the bolt moves, retighten it according to the steps below.

2.

Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.)

(2) Perfectly dry the washed parts by air blowing.

(3) Coat the specified seal lock agent to the threaded portion of the bolt.

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1.

When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation.

2.

When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.

3.

The maximum tightening torque must not exceed twice the standard tightening torque.

Nominal diameter of screw 7/16 9/16 314 718 718 1.1116 1.5116

- 20UNF - 18UNF - 16UNF - 14UNF - 14UNF - 12UNF - 12UNF PF1/4 PF3/8 PF1/2 PF314 PF1

Standard

Tightening range

Hose inside diameter m m (in)

25 (250) [18.1 1 49 (500) [36.2] 59 (600) [43.4] 59 (600) [43.4] 78 (800) [57.9] 118 (1200) [86.8] 137 (1400) [101.3] 25 (250) [18.1] 49 (500) [36.2] 59 (600) [43.4] 118 (1200) [86.8] 137 (1400) [101.3]

24-26 (240-270) [17.4-19.51 47-52(480-530) 134.7-38.31 56-62 (570-630) [41.2-45.61 56-62 (570-630) [41.2-45.61 74-82 (760-840) [55.0-60.81 112-123 (1140-1250) [82.5-90.41 130-144 (1330-1470) [96.2-106.41 24-26 (240-270) [17.4-19.51 47-52 (480-530) [34.7-38.31 56-62 (570-630) 141.2-45.61 112-123 (1140-1250) [82.5-90.41 130-144 (1330-1470) [96.2-106.41

6 (0.24) 9 (0.35) 12 (0.47) 12 (0.47) 15 (0.59) 19 (0.75) 25 (0.98) 6 (0.24) 9 (0.35) 12 (0.47) 19 (0.75) 25 (0.98)

Standard tightening torque

N-m (kgf-cm) [ft-lbf]

WlRE ROPE SUSPENSION ANGLE LIST Lifting angle

o0

Compres~~~~i~~ sion

1.00 time

Lifting angle

Suspension method

-Ll

0 time

Tension

Compression

Suspension method

1.41 time 1.00 time

90"

7

30'

1.04 time 0.27 time

60'

1.16 time 0.58 time

h0

-

2.00 time 1.73 time

120'

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE Rope Cutting Single-rope diameter load suspension 0" 3040 21380 6 mm (0.31) (2.18) (0.24 in) [48071 [683.6] 31480 4410 8 mm (3.21) (0.45) (0.32 in) [992.3] [7078] 49230 6960 10 m m (0.71) (5.02) (Om4 in) [ I1.691 L1565.61 10980 12.5 m m 76880 (7.84) (1.12) (0.5 in) [173871 [2469.5] 96400 13730 14 m m (9.83) (1.4) (0.56 in) [216751 [3087]

Two-rope suspension 0" 6080 (0.62) [I3671 8830 (0.9) [I9851 14020 (1.43) [31531 21570 (2.2) [4851] 27460 (2.8) [61741

30' 5880 (0.6) [I3231 8530 (0.87) [I9181 13440 (1.37) [30211 21280 (2.1) [4631] 26480 (2.7) [59541

A

by5

2'

60" 5200 (0.53) [ I 1691 7650 (0.78) [I7201 11770 (1.2) [26461 18630 (1.9) [4190] 23540 (2.4) [5292]

unit: N (ton) [lbf]

Four-rope suspension

o0 90° 12160 4310 (1.24) (0.44) [27341 [9701 17650 6280 (0.64) (1.8) [I4111 [39691 9810 27460 (1.0) (2.8) [22051 L61741 14710 43150 (1.5) (4.4) [33081 [97021 18630 54920 (1.9) (5.6) [41901 [I23481

30° 11770 (1.2) [26461 17060 (1.74) [39371 26480 (2.7) [59541 41190 (4.2) [9261I 52960 (5.4) [ I19071

60' 10400 (1.06) [2337] 15300 (1.56) [34401 23540 (2.4) 152921 37270 (3.8) [83791 47070 (4.8) [I05841

90" 8630 (0.88) [I9401 12550 (1.28) [2322] 19610 (2.0) [44101 29420 (3.0) [6615] 37270 (3.8) [83791

COMPONENTS WEIGHT Item

Weight kg [Ibl

Drive motor

Approx. 41 1901

(One unit) Pump motor

Approx. 35 [771 5FBE10: Approx. 393 I8671 5FBE13: Approx. 556 112261

Counter weight

5FBE15: Approx. 620 [I3671 5FBE18: Approx. 785 11731I 5FBE20: Approx. 1070 I23601

Mast Wllift bracket

*Approx. 400 [8821

(with lift cylinder, less fork)

**Approx. 410 19041

[max. fork height = 3000 m m (118 in)]

RECOMMENDED LUBRICANTS AND CAPACITIES Application Transmission

STD:

Type Hypoid gear oil SAE85W-90

(API GL-4) 45s:

Hypoid gear oil SAE75W-80W

(API GL-4) Hydraulic (total) Brake line

STD:

Hydraulic oil IS0 VG32

45s:

MIL-H-5606-D

STD:

SAE J-1703 DOT-3

45s:

SAE J-1703 DOT-3 (1993.1

- 1998.1)

Capacity Right side: 1.7 t? (0.45 USgal) Left side: 1.8 (0.47 USgal) (1993.1 1998.1) 1.5 e (0.40 Usgal) (1.998.2 - )

-

*I6 **21

e (4.2 USgal) e (5.5 USgal)

Proper quantity

Brake fluid arctic S (1998.2 Chassis part

45s:

*: **:

STD:

MP grease No.2

45s:

MIL-G-3278-A

Refrigerator specification vehicle For 3000 mm (118 in) maximum fork height For 6000 mm (236 in) maximum fork height

Proper quantity

LUBRICATION CHART

1.

Chain

I

lnspect every 8 hours (daily)

2.

Mast strip

I1

lnspect every 40 hours (weekly)

3.

Tilt cylinder front pin

111

lnspect every 170 hours (monthly)

4.

Mast support bushing

IV

lnspect every 1000 hours (6 monthly)

5.

Front axle hub

V

lnspect every 2000 hours (annually)

Transmission housing

0

lnspect and service Replace

Reservoir tank Oil control valve link pin Accelertor pedal link

@

Tilt steering locking mechanism Brake pedal link Oil tank Rear wheel bearing Rear axle bearing Steering rack & pinion Limit switch controller (cold storage models only)

MP grease (STD) MIL-G-3278-A (45s)

@ @ @ @

Engine oil Hypoid gear oil Brake fluid Hydraulic oil

PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required.

M : Measurement. Repair or adjustment i f required.

T : Retightening C: Cleaning L: Lubrication * : For n e w vehicle * 1: Flaw detector Every 1 month

Every

Every

Every

3 months

6 months

12 months

Every 170 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Abnormal sound during revolution

I

t

c

t

Loose terminal

T

c

+-

t

M

t

c

Brush wear and sliding contact status

I

c

Commutator fouling and damage

I

c

Inspection Period Item ELECTRICAL SYSTEM

Motor

Insulation resistance

M

Brush spring fatigue Charge

I

+-

c

t

Battery fluid level

I

t

c

t

M

c

+-

c

Loose terminal

I

C

+-

C

Abnormality at top of battery and battery case

I

C

C

t

M

c

t

Battery fluid specific gravity Battery

Insulation resistance Cell voltage measurement after charging

Charger

M

Timer operation

I

t

c

t

Terminal loosening

I

c

c

t

M

t

+-

Operating voltage measurement Magnet switch function, contact fouling and roughening

Magnet contactor

Microswitch

I

Loose contact, damage and wear

I

t

t

c

Auxiliary contact function, fouling and wear

I

C

t

C

Arc chute installation status

I

Timing and functioning

I

Loose coil installation

I

Loose main circuit lead installation

I

Timing and operating function

I

t

c

c

Damage and loose installation

I

t

t

c

Every 1 month

3 months

6 months

Every

Every 12 months

Every 170 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Operating conditions and damage

I

c

c

c

Operation

I

c

C

+-

Inside fouling and damage

C

c

c

t

Inspection Period Item Direction lever

Controller

Every

M

Overcurrent limit valve Fuse

Wiring (including charging cord)

Accelerator

Loosening

I

c

C

c

Damage of wiring harness and loose clamp

I

t

C

C

Loose connection and taping status

I

c

c

c

Battery connector damage and connection status

I

C

C

C

Operating and damage

I

c

c

t

Oil leak

I

c

c

c

Oil level

I

c

c

c

Gear function and sound

I

c

c

c

M

t

c

c

Tire cuts, damage and uneven wearing

I

t

c

c

Loose rim and hub nuts

T

t

t

t

Tire groove depth

M

t

t

c

Metal chips, pebbles and other foreign matter trapped in tire grooves

I

t

C

C

Rim and disc wheel damage

I

t

@

C

Abnormal sound and looseness of front wheel bearing

I

C

C

C

Abnormal sound and looseness of rear wheel bearing

I

C

C

C

POWER TRAIN

Transmission

TRAVELING EQUIPMENT Tire air pressure

Wheels

Front axle

Cracks, damage and deformation of case

I

Rear axle

Cracks, damage and deformation of rear axle

I

Inspection Period

Every

Every

Every

Every

1 month

3 months

6 months

12 months

Every

Every

Every

Every

170 hours

500 hours

1000 hours

2000 hours

Play and looseness

I

t

t

t

Function

I

t

t

t

Oil leak

I

t

t

t

Looseness of mounting

T

t

t

t

Oil leak

I

t

t

t

Mounting and linkage Looseness

I

t

t

t

Item STEERING SYSTEM Steering wheel Hydraulic control valve

Power steering

I

Damage of power steering hose BRAKING SYSTEM Brake pedal

Parking brake

M

t

t

t

Braking effect

I

t

t

t

Pull margin

I

t

t

t

Braking effect

I

t

t

t

Rod and cable looseness and damage

I

t

t

t

Play and reserve

I

Ratchet wear and damage Brake pipe and hose

Leakage, damage and mounting status

I

t

t

t

Brake fluid

Fluid level

I

t

t

t

M

t

t

t

Clearance between diskwheel and lining Pad wear and damage

M

Disk brake wheel wear and damage

M I

Disk brake lever operating status Disk brake

t

t

Disk brake wheel set bolt loose

T

Return spring fatigue

M

Caliper body leak brake fluid

I

t

t

t

Master cylinder and wheel cylinder operation

I

Cylinder and piston cup wear and damage

I

Every

Every

Every

Every

1 month

3 months

6 months

12 months

Every 1 70 hours

500 hours

Every

Every 1000 hours

2000 hours

Abnormality of fork and stopper pin

I

c

c

c

Misalignment between left and right fork fingers

I

c

c

4-

Inspection Period Item

Every

MATERIAL HANDLING SYSTEM

Forks

I *'

Cracks at fork root and welded part

Mast and lift bracket

Deformation and damage of each part and crack at welded part

I

4-

C

t

Mast and lift bracket looseness

I

+-

t

+

Wear and damage of mast support bush Wear, damage and rotating condition of rollers

I

I

C

t

Wear and damage of roller pins

Chain and chain wheel

Various attachments

t

I

Wear and damage of mast strip

I

c

c

c

Tension, deformation and damage of chain

I

C

t

t

Chain lubrication

I

t

4-

C

Abnormality of chain anchor bolt

I

t

c

c

Wear, damage and rotating condition of chain wheel

I

t

t

C

Abnormality and mounting condition of each part

I

4-

4-

4-

Loosening and damage of cylinder mounting

I

C

C

C

Deformation and damage of rod, rod screw and rod end

I

t

C

C

Cylinder operation

I

c

c

c

M

c

c

C

Oil leak and damage

I

+-

@

t

Wear and damage of pin and cylinder bearing

I

C

4-

t

Lifting speed

M

+-

t

c

Uneven movement

I

t

t

t

Oil leak and abnormal sound

I

t

t

c

Oil level and contamination

I

t

4-

c

C

t

t

4-

HYDRAULIC SYSTEM

Cylinder

Oil pump Hydraulic oil tank

Natural drop and natural forward tilt (hydraulic drift)

Tank and oil strainer Oil leak

I

+-

Every 1 month

Every

Every

3 months

6 months

Every 12 months

Every 170 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Loose linkage

I

t

c

t

Operation

I

c

C

+

Oil leak

I

t

c

t

Inspection Period Item

Control lever

Oil control valve

Relief pressure measurement

M

Relief valve and tilt lock valve functions

I

C

t

t

Oil leak

I

t

c

c

Hydraulic

Deformation and damage

I

t

c

c

piping

Loose joint

T

c

t

t

Hose tension and twisting

I

c

c

c

Cracks at welded portion

I

+-

c

c

Deformation and damage

I

+

t

c

Loosening of mounting

I

+-

c

C

Deformation, crack and damage

I

t

c

t

Lighting system

Function and mounting condition

I

t

c

c

Horn

Function and mounting condition

I

t

t

c

Direction indicator

Function and mounting condition

I

t

t

c

Instruments

Functions

I

c

c

c

Back up buzzer

Function and mounting condition

I

t

c

c

Rear-view mirror

Dirt, damage

I

c

t

c

Rear reflection status

I

t

c

t

Seat

Loosening and damage of mounting

I

t

c

t

Body

Damage and cracks of frame, cross members, etc.

I

Bolt looseness

T

SAFETY DEVICES, ETC. Head guard

Back-rest

Other

Grease up

L

c

t

t

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS Inspection (operating hours or months, whichever is earlier)

Every 1 month

Every 3 months

Every 6 months

Every 12 months

Every 1 70 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Brake fluid

C

Hydraulic oil

c

Hydraulic oil filter

C

(New vehicle)

Transmission oil Wheel bearing grease Master cylinder rubber parts Wheel cylinder rubber parts Reserve tank tube Power steering hose Internal rubber parts of power steering system Material handling house Chain

(Every 2 years)

(Every 2 years)

(Every 2 years)

(Every 2 years)

(Every 3 years)

BATTERY Page

........................................ 1-2 DISPLAY INDICATION ........................................... 1-2 OVERDISCHARGE ALARM FUNCTION ..................... 1-2

SERVICE STANDARDS

BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED .......................................... 1-3

........................................... 1-4 ................................................... 1-5

TROUBLESHOOTING BATTERY ASSY INSPECTION

.....................................................

1-6

SERVICE STANDARDS Specific gravity in fully charged state

(OC) [OF1

1.280 (20) [681

Specific gravity in fully discharged state

(OC) [OF]

1.150 (20) I681

Discharge end voltage V

3 6 V specification

32.0

4 8 V specification

42.5 Sulfuric acid diluted with distilled water

Electrolyte

Distilled (deionized) Water

Fluid t o be spplied Insulation resistance

Mfl

I or more

DISPLAY INDICATION 1.

The display indicates the remaining battery charge level in 1 0 stages. When the remaining charge drops to the set level or below, the indication flashes the warn the timing for charging.

2. When the battery is discharged fully (100 %), the overdischarge alarm function operates as follows:

OVERDISCHARGE ALARM FUNCTION 1.

Material handling with traveling becomes impossible.

If simultaneous operation is attempted, priority is given to traveling and material handling is not effected. (For prevention of battery from damage by large current flow)

2. When material handling is attempted, all indicators on the display flash and the buzzer sounds to alarm overdischarge.

Note: Material handling operation becomes impossible on the vehicle with chopperless material handling circuit.

For thirty seconds after the key switch is turned on, however, material handling operation can be performed.

BATTERY COMPARTMENT & MINIMUM WEIGHT REQUIRED When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by referring to the table below. Always use a case allowing fixation of the battery stopper.

Compartment dimensions m m (in) Vehicle model

Front t o rear

battery weight Width Y

Height Z

length X 451

5FBE 10

(17.76)

Minimum required

(with case)

N (kg) [Ibl 928 (36.54)

641 (25.24)

5099 (520) I 11471

Maximum battery weight (with case)

N (kg) [Ibl 6796 (693) 115301

5FBE13

t

t

t

551 (21.69)

997 (39.25)

t t

t

5FBE15

6865 (700) 115451

9591 (978) [21591

5FBE18

t t

t t

f f

t t

t t

5FBE20

f

38 mm (1.5 in)

z

Y 4

Y

-

i

TROUBLESHOOTING Pole plate corrosion

Pole plate warping and fallen acting substance Insufficient charge

Shorting between service

Deposition of fallen - acting substance in

Dirty terminal or plug-

Electrolyte leakage and decrease

Loosened or corroded connections

1-5

BATTERY ASSY REMOVAL-INSTALLATION

Removal Procedure 1

Disconnect the battery plug.

2

Remove the battery hood catch.

3

Open the battery hood.

4

Remove the battery stopper.

5

Remove the battery ASSY.

Installation Procedure The installation procedure is the reverse of the removal procedure.

INSPECTION 1.

Electrolyte level inspection GS battery: Open the cap and add distilled water if the white line on the red float is invisible. Add water until the white line on the float appears and stop addition there because further addition until the contact between the float and stopper results in overfilling.

YUASA battery: Open the cap and add distilled water if the ring of the red float is dropped. Add water until the float ring comes into contact with the top portion.

As the level gauge is provided on the side surface of the battery case, the electrolyte level can generally be checked at a glance. However, periodically inspect the level by opening the cap.

The green indicator of the level gauge is lit to indicate activation of the level gauge sensor, and the red indicator flashes to indicate the necessity of water addition.

Insufficient electrolyte level

Flashing

Caution: Never change the mounting position of the plug with sensor.

Note: The electrolyte consumption can be calculated by the following equation: Consumption (CC) = 5 hour rating capacity x 0.0336 x number of cells x charging frequency

2.

Electrolyte inspection (1) The battery electrolyte should be colorless and transparent in normal state. Check turbidity, etc. at the time of specific gravity inspection.

If clear confirmation is impossible, put in a beaker for inspection.

3.

Inspection of electrolyte specific gravity (1) Use a hydrometer and measure the specific gravity of the electrolyte

Specific gravity in fully charged state: 1.280 (at 20 O C ) Specific gravity in fully discharged state: 1.150 (at 20 OC) The specific gravity of the electrolyte is expressed by the value at 20 O C as the standard.

Specific gravity conversion equation ,S , = St 0.0007 (t-20) :S ,, Specific gravity at 2 0 OC St : Specific gravity at t O C t : Temperature at the time of measurement

+

"How to use the hydrometer Insert the nozzle of the hydrometer into the water supply port and suck the electrolyte into the outer cylinder. @ Let the hydrometer in the outer cylinder float correctly without contact with the top, bottom and side wall of the outer cylinder, and read the graduation at the electrolyte surface as shown at left after disappearance of bubbles in the sucked electrolyte. @ After the measurement wash outside and inside of the hydrometer with clear water and wipe thoroughly with clean cloth for storage.

a

Nozzle

4.

Insulation resistance inspection Use an insulation resistance meter (megger) and measure the resistance between the battery and battery case.

Insulation resistance: 1 MQor more Note: If the insulation resistance is less than 1 MQ, remove the battery from the vehicle and wash it with water.

Dry the battery case roughly, and measure the insulation resistance again. Install the battery on the vehicle after checking that the insulation resistance is 1 MQor more.

* Battery control table Prepare the control table for each battery to record and retain the inspection result.

Inspection date and time

Inspected cell No.

Specific gravity

Electrolyte temperature

Added water volume

Remarks

Inspector

CONTROL CIRCUIT (1993.1 - 1998.8) (1993.1 - 1999.1)

[FOR OTHER THAN U.S.A.] [FOR U.S.A.]

Page MCS-IIIA CONTROLLER 2-2 GENERAL ........................................ 2-2

.....................

SPECIFICATIONS ................................. 2-3 COMPONENTS ................................... 2-4 CONTROL PANEL REMOVAL. INSTALLATION ....... 2-9 CONTACTOR PANEL REMOVAL . INSTALLATION .... 2-10 INSPECTION .....................................2-11 DISASSEMBLY ................................... 2-29 REASSEMBLY

.................................... 2-30

PANEL PARTS TIGHTENING TORQUE .............. 2-33 CONTINUITY CHECK WITH CIRCUIT TESTER ....... 2-34 OCL (OVERCURRENT LIMIT) VALUES

.............. 2-35

ACCELERATION POTENTIOMETER ADJUSTMENT ............................

BRAKE SWITCH-STOP LAMP SWITCH ADJUSTMENT ............................

PARKING BRAKE SWITCH ADJUSTMENT .....

MATERIAL HANDLING SWITCH ADJUSTMENT ............................

DIRECTION SWITCH ........................

DISASSEMBLY-INSPECTION-REASSEMBLY

PS CONTROLLER

2-37 2-38 2-39 2-40 2-41

........ 2-42

...........................

COMPONENTS ...................................

INSPECTION (STD) ...............................

REMOVAL.INSTALLATION(EHPS) .................

2-44 2-44 2-45 2-46

EHPS CONTROLLER VOLTAGE MEASUREMENT .... 2-47 INSPECTION (EHPS) .............................. 2-48 REASSEMBLY (EHPS) ............................. 2-49

STEERING POTENT10 INSTALLATION ADJUSTMENT ............................ 2-50

MCS-IIIA CONTROLLER GENERAL The 5FBE series is provided with the diagnostic (self-diagnosis) function for automatically detecting any abnormality in the main traveling/material handling circuit, operating system such as the accelerator and sensors t o sound the buzzer (bleep, bleep) and t o display the abnormal portion by the corresponding error code on the multi-display.

A t the same time, such an action as traveling stop, material handling stop or traveling speed restriction is taken t o ensure safety.

When the display is set t o the analyzer (fault analysis) mode, defect detection and functional check of the main drivelmaterial handling circuit, operating systems, and sensors are performed.

See the Multi-display section (page 3-21 for the diagnosis. See the Multi-display section (page 3-7) for the analyzer.

Control Panel ASSY

Contactor Panel ASSY

SPECIFICATIONS Portion

Fuses

Transistors

Diodes

F1 (Drive circuit)

225 A "'275 A

F2 (Pump circuit)

225 A "'275 A

F3 (PS circuit)

50 A

F4 (For lamps)

10 A

F5 (Control circuit)

10 A

T M (For drive motor)

TSM003 (3 pcs.)

TMP (For material handling pump: OPT)

TSM003 (2 pcs.)

TMps (For PS: OPT)

~~1MI1 0 0 ~ - 0 2 5

DAD (For drive motor)

30M F40

DAP (For material handling pump: OPT)

30M F40

DFI (DM flywheel)

SR250L-6s

D F ~ (DM R flywheel)

70M30

DF2L (PM flywheel)

70M30

DF3 (PM flywheel: OPT)

45M30

DF4 (PS flywheel) Current sensor Capacitors Resistors

Contactors

*21M1100H-025

CSD (For drive motor)

HS800RT

CSP (For material handling pump: OPT)

HS800RT

CSps (For PS: OPT)

MBP20A-10MJN

CAD (Absorber for drive motor)

60pF (2 pcs.)

CAP (Absorber for pump motor: OPT)

60pF (1 pcs.)

RAD (Absorber for drive motor)

1.5 R 120 W

RAP (Absorber for pump motor)

1.5R 1 2 0 W

MFR.MFL(For forward drive)

ME250

MRR.MRL(For reverse drive)

ME250

MP (For material handling)

ME251

MPS(For PS)

*' : 36V specification **: The PS transistor and diode are integrated. *3:

5FBE10.13.15.18~20

UL specification (36VI48V)

C48-A11 * 3 ~ 3 6 / 4 8 ~ 1

COMPONENTS Control panel

Resistor panel

Control panel Wlmaterial handling chopper (OPT)

2-7 Contactor panel

2-8 MF-MR contactor

MP contactor

CONTROL PANEL REMOVAL-INSTALLATION

1 Battery plug

4

5 Connector 6 Wiring

Removal Procedure 1

Disconnect the battery plug.

2

Remove the side panel LH.

3

Remove the side panel under cover.

4

Remove the control panel cover.

5

Disconnect the connector.

6

Disconnect the wiring.

7

Remove the control panel.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Check insufficient cable tightening or cable tightening failure before inserting the battery plug. If loose, the control panel elements may be damaged.

CONTACTOR PANEL REMOVAL.lNSTALLATlON

-

1 Banery plug 2 Toe board 5 Wiring

Removal Procedure 1

Disconnect the battery plug.

2

Remove the toe board.

3

Remove the side panel LH.

4

Remove the side panel under cover.

5

Disconnect the wiring.

6

Remove the contactor panel.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Check insufficient cable tightening or cable tightening failure before inserting the battery plug.

INSPECTION Some parts can be inspected after removal from the vehicle while others can only be inspected on the vehicle.

As the CPU board and DC-SD boards require battery voltage application, they must be inspected while being mounted on the vehicle. (Use SST 09240-1 2240-71 .)

Inspection after control panel removal from the vehicle is mainly explained here.

1.

(1

Insulation resistance measurement (Always inspect before starting control panel inspection.)

Disconnect the battery plug and measure the insulation resistance between the battery plug and body.

Measurement terminals Standard

Controller side of battery plug

- Body

The resistance should be as high as possible, but it varies greatly, depending on the vehicle use status, place and weather. (Approx. 1 MQ)

2. CAD (drive circuit absorber capacitor) and CAP (material handling circuit absorber capacitor) (OPT) (1) lnspection method Disconnect the wiring of CAD and CAP after discharging the CAD and CAP with a resistor of about 1 0 0 Q. Inspection point

Circuit tester range

Measurement terminals

CAD (Control panel)

Both terminals of CAD (DAD side - TM side)

CAP (Control panel)

Both terminals of CAP (DAP side - TMP side)

Q X ~ K

Standard When circuit tester probes are brought into contact with both terminals of CAD or CAP, the pointer deflects once to the 0 Q side and gradually deflects toward the oo Q side.

3. T M (drive circuit main transistor).TMP (pump circuit main transistor) (1) lnspection method Disconnect wiring from each of TM-TMP Measurement terminals

Inspection point

TM (control panel) TMP (control panel)

Standard

D-S

D: (-1 probe - S: ( + ) probe D: ( + ) probe - S: (-1 probe

D -G

D: (-1 probe - G: ( + ) probe D: ( + ) probe - G: (-1 probe

(conduction)

G-S

G: (-) probe - S: ( + probe G: ( + ) probe - S: (-1 probe

(conduction) cx, Q

Clrcuit tester range

w Q con 00

Q QXIK

If any T M or TMP is found abnormal in inspection replace them (all TMs or all TMPs) as a set.

3- 1. DRD (Direction of Reverse Conductive Diode) (1 lnspection method Remove the DRD. Inspection point DRD

Measurement terminals Forward Anode: - probe - Cathode: Reverse Anode:

+

probe Approx. 1.6 k 0

+ probe - Cathode: - probe

n

x IK

0352

u

u N o Conduction

Conduction

4.

Circuit tester range

Standard

DF1 (flywheel diode No.1) (1) lnspection method Disconnect the wiring from DF1 Inspection point

DF1 (control panel)

Measurement terminals (Forward) Anode: (-) probe - Cathode: ( + probe (Reverse) Anode: ( + ) probe - Cathode: (-1 probe

Standard Approx. 3 KQ co Q

Circuit tester range

n

x

i

~

5.

DF2,-DF2, (flywheel diode No.2) (1 ) lnspection method Disconnect the wiring from DF2,-DF2, Measurement terminals

Inspection point DF2,.DF2, (contactor panel)

6.

(Forward) Anode: (-) probe (Reverse) Anode: ( ) probe

+

- Cathode:

(

+ ) probe

- Cathode: (-1 probe

Standard Approx. 3 KQ co

Circuit tester range

0

x

1

~

fl

DF3 (flywheel diode No.3 in panel with pump chopper) ( 1 ) lnspection method

Inspection point DF3 (control panel)

Measurement terminals (Forward) Anode: (-1 probe - Cathode: ( + 1 probe (Reverse) Anode: ( ) probe - Cathode: (-1 probe

+

Standard Approx. 3 Kn con

Circuit tester range

n x l K

7. DAD (drive circuit absorber diode).DAP (pump circuit absorber diode) (1) lnspection method Disconnect the wiring from DAD-DAP. Measurement terminals

Inspection point DAD DAP (control panel)

(Forward) Anode: (-) probe - Cathode: ( + ) probe (Reverse) Anode: ( + ) probe - Cathode: (-1 probe

Standard Approx. 6 KQ 00

Circuit tester range

62xIK

Q

8. MFR.MFL (forward contactors).MR,.MR, (reverse contactors)-MP (material handling pump con(1

tactor) Measure the coil resistance of each of MFR.MFL.MRR.MRL.MP. Inspection point

Measurement terminals

Standard

Circuit tester range

Approx. 20 Q (at 20°C)

Q x l

(In control panel) MFRcoil

,

MFRcoil connector

MFL coil

MFL coil connector

MRRcoil

MRRcoil connector

MRL coil

MRL coil connector

MP coil

MP coil connector

9.

RAD (drive circuit absorber resistor)-RAP (pump circuit absorber resistor) (1 ) lnsepction method Battery removal Disconnect the wiring from RAD-RAP (RAD: CN 1 18-RAP: CN 1 1 9).

Inspection point RAD RAP

Measurement terminals Both terminals of RAD-RAP

Standard

Circuit tester range

Approx. 1.5 62

62x1

When inspecting with the battery installed, disconnect the CN1 17 connector.

Inspection point RAD RAP

Measurement terminals RAD: CN117-2- CN117-3 RAP: CN 1 1 7-1 - Controller P I I terminal

CN 1 17 (Main harness side)

Standard

Circuit tester range

Approx. 1.5 62

62x1

10. CPU board-DC-SD board If the trouble cause is judged to be in the CPU board or DC-SD board, apply the battery voltage, install SST09240-12240-71, and measure the applied voltage and resistance at each connector.

Caution: Always disconnect the battery plug before removing or installing the CPU board or DC-SD board.

Note: When replacing the CPU board or DC-SD board judged to be causing the trouble as a result of troubleshooting, always measure the applied voltage and resistance at related portions before replacement.

Use SST 09240-12240-71 for the measurement.

(1) SST connection method @ Turn the key switch to OFF. @ Disconnect the battery plug. @ Disconnect the CPU board-DC-SD board connectors (CN101 to CN 107.CN11 1 .CN1 12). @) Connect the SST.

Inspection side connector

CN107

(2) Lists of measurement methods and standards @ Explanation on list format

r

Circuit tester (

+

probe

Circuit tester (-1

probe

Connector pin No.

1 Connector No.

-

CN102-1 (43, K36 V)

I

C

Connector No.

Conditions

Standard

Remarks

1

CN102-9 (N,,GND)

A

SWKy: ON SW :, OFF

C Signal (part) name

-conditions

for measurement

L ~ e v eNo. l

@ Lists C N 101 connector Basic conditions (battery plug ON.SWKy ON) Connector No. CNIOI-I CN101-2 CN101-3 (15,+30V) CN101-4 (15,+30V)

* Connector No.

I

I I I

Remarks

Standard

Conditions Unused

CN101-20 (N1,GND)

3V

Approx. 18

CN101-20 (N1,GND)

Unused

Approx. 18

I

CN101-20 (NI, GND)

SWKy ON SW, OFF

Approx. 4 8 Vl36 V OV

CN101-6 I I (32, CHOPD + ) I

CN101-20 (NI, GND)

CN101-5 (10, C36 V)

CN101-7 (30,VDD+) CN101-8 ( ,- 5V) CN101-9 (14, VBKY)

I

I I I

I I

I

CN101-11 (43, K36 V)

I I

CN101-12 CN101-13

I

&

3V Voltage after key switch

* 0.25 V 5 * 0.25 V 5

CN101-20 (N1,GND)

- -6 V

CN101-20 (N1,GND)

Unused

CN101-20 IN1, GND)

SWKy ON SW, OFF

Approx. 4 8 Vl36 V OV

Voltage after key switch

CN101-20 (N1, GND)

SW, SW,

Approx. 4 8 Vl36 V 0V

Voltage after key switch

ON OFF

Unused

- 5V

-

Connector No.

* Connector No.

CN101-14 (11, GND)

I I I

CN101-15

I

CN101-16 (11,GND)

I I

CN101-17 (33, CHOPD-) I

Conditions

CN101-20 (NI, GND)

Standard

Remarks

ov Unused

CN101-20 (N1,GND)

ov

CN101-20 (Nl, GND)

Traveling stop state

4 - 5 V

CN101-20 (NI, GND)

Traveling stop state

4 - 5V

I

CN101-18 (31, VDD-1 CN101-19

I

I I

CN101-20 (N1, GND) CN101-21 (13,VBBT)

Unused

I

Panel N1 terminal

I

CN101-20 (N1,GND)

Approx. 48 Vl36 V

CN101-20 ( N l , GND)

Approx. 48 Vl36 V

Battery voltage

Standard

Remarks

Approx. 4 8 V l 3 6 V OV

Voltage after key switch

Approx. 4 8 V l 3 6 V

Battery voltage

I

Battery plug OFF SW, OFF

on

I

CN101-22 (41, 836 V )

I

I

CN102 connector: Connector No.

Basic conditions (Battery plug ON.SWKy ON)

* Connector No.

CN102-1 (43, K36 V)

j

I

CN102-9 ( N l , GND)

CN102-2 (41, 836 V I

1

CN102-9

CN102-3

j

Conditions SWKy ON SW, OFF

(N1, GND)

1

Unused

I

CN102-9 (N1,GND)

4 8 V vehicle: 43f 5V 36 V vehicle: 32f 5V

I

CN102-4 (P8,RCKl)

I I

I

CN102-5 (P9,RCKl)

I I

CN102-9 (N1,GND)

Approx. 48 Vl36 V

CN102-6 (N2, TMS)

I

CN102-9 (NI, GND)

ov

I

I

CN102-7 (41, B36 V )

I I I

CN102-9 (N1, GND)

CN102-8 (41, D36 V)

I

CN102-9 ( N l , GND)

I

Unused

Approx. 48 Vl36 V

Battery voltage

Approx. 4 8 Vl36 V

Battery voltage

Connector No.

o

Connector No. Panel N1 terminal

CN102-9 (NI, GND) CN102-10 CN102-11 (P8, TMD)

Conditions Battery plug OFF SW, OFF

I I I

48 V vehicle: 43* 5V 3 6 V vehicle: 32 5V

CN102-9 (N1, GND)

*

I

I

CN102-9 ( N l , GND)

I

CN103 connector: Connector No.

Traveling stop state

-5

- - 6V

Basic conditions (Battery plug ON.SWKy ON)

++

Connector No.

I

CN103-3 (11, GND)

5 * 0.25 V

+) I

CN103-3 (11, GND)

5 * 0.25 V

CN103-1 (35, VDP+) CN103-2 (37, CHOPP

on

Unused

I

CN102-12 (92, TMG)

Remarks

Standard

Conditions

Standard

Remarks

+ 5V

I

CN103-3 (11, GND) CN103-4 (10, C36V) CN103-5 (15, +30V) CN103-6 (30, VDD +

I

Panel N1 terminal

Battery plug OFF.SWKy OFF

I

CN103-3 (11, GND)

SW, SW,

I

CN103-3 (11, GND)

I

I I

I

1 CN103-7 I (32, CHOPD + ) I CN103-8 (11, GND) CN103-9 (36, VDP-) CN103-10 (38, CHOPP-)

I I

I

I I I I

ON OFF

on Approx. 4 8 Vl36 V Voltage after OV key switch Approx. 1 8

CN103-3 (11, GND)

5 * 0.25 V

CN103-3 (I 1, GND)

5 0.25 V

CN103-3 (11, GND)

ov

CN103-3 (11, GND)

3 V

*

Material handling stop state

4- 5V

CN103-3 (11, GND)

4- 5v

I

CN103-3 (11, GND)

ov

CN103-12 (13, VBBT)

I

CN103-3 (1 1, GND)

Approx. 4 8 Vl36 V

CN103-13 (14,VBKY)

I

CN103-3 (11,GND)

SW, ON SWKyOFF

I

CN103-3 (11, GND)

Traveling stop state

CN103-11 (11, GND)

CN103-14 (31, VDD-1

Approx. 48 Vl36 V OV 4- 5V

Connector No.

* Connector No. I

CN103-15 I (33, CHOPD-1

CN103-3 (I I,GND)

I

I I

CN103-16 (11,GND)

I

I

(41MFR)

Remarks

4- 5v

Basic conditions (Battery plug ON.SWKy ON)

* Connector No.

CN104-1

Standard

Unused

I

CN104 connector: Connector No.

Conditions

CN104-14 (Ir+ )

Standard

Remarks

Battery plug OFF.SWKy OFF Measure with the tester negative probe connected to CN104-14.

Approx. 20 Q

MFR contactor

Measure with the tester positive probe connected to CN104-1.

Approx. 46 Vl35 V

MFRcoil

Battery plug OFF.SWKy OFF Measure with the tester negative probe connected to CN104-1 4.

Approx. 20 Q

MRR contactor

Measure with the tester positive probe connected to CN104-2.

Approx. 46 Vl35 V

MRRcoil

Battery plug OFF.SWKy OFF Measure with the tester negative probe connected to CN104-1 4.

Approx. 20 Q

MFLcontactor

Measure with the tester positive probe connected to CN104-3.

Approx. 46 Vl35 V

MFL coil

Battery plug OFF.SWKy OFF Measure with the tester negative probe connected to CN104-1 4.

Approx. 20 Q

MRL cotactor

Conditions

I

CN104-1 (4, MFR)

I

1 I j

CN104-8 (74, CSD -1

I

CN104-2

15' MRR)

CN104-14 (I'

I

CN104-2 (5, MRR)

I

1

CN104-8 (74, CSD -1

I

CN104-3

CN104-14

(2' MFL)

II

CN104-3 (2, MFL)

I

1

(I '

+

)

CN104-8 (74, CSD-1

CN104-4

1 I I

13' MRL)

I

(I ' +)

1

CN104-8 (74, CSD-1

Measure with the tester positive probe connected to CN104-4.

Approx. 46 Vl35 V

MRL coil

CN104-15 (I,M+)

Battery plug OFF.SWKy OFF Measure with the tester negative probe connected to CN104-1 5.

Approx. 20 Q

MP contactor

f

CN104-8 (74, CSD-)

Measure with the tester positive probe connected to CN104-5.

Approx. 46 Vl35 V

MP coil

1

CN104-8 (74, CSD-)

5 f 0.25 V

+ 5V

CN104-4 (3, MRL)

CN104-14

I

CN104-5 (7,MP) 7

CN104-5 (7, MP) CN104-6 (75, STH)

I I

Connector No. CN104-8 (74, CSD-) CN104-9 (71, CSD) CN104-10 (73, CSD + I CN104-11 (P2, VBP2)

* Connector No.

I

I I I

I

1 I 1

I

~ ~ 1 0 4 - 1 I2 (6' Mps)

CN104-1 2 (6, Mps) CNl04-13 (I,M+) CN104-14 (1, M + ) CN104-15 (1, M + ) CN104-16 (76, STHl CN1 04-1 7 (P9, VBP9) CN104-18 (74, CSP-) CN104-19 (72, CSP) CN104-20 (73, CSP )

+

Panel N1 terminal CN104-8 (74, CSD - 1

Conditions Battery plug OFF.SWKy OFF Traveling stop state

1

Approx. 1.2 V 1 2 f 0.6 V

CN104-8 (74, CSD-)

Approx. 4 8 V l 3 6 V

Battery plug OFF.SWKy OFF ~~104-13 Measure with the tester negative (I probe connected to N 104-13.

CN104-8 (74, CSD -)

Measure with the tester negative probe connected to CN104-1 2.

Approx. 4 6 Vl35 V

CN104-8 (74,CSD-)

Approx. 4 6 Vl35 V

1

CN104-8 (74, CSD-)

Approx. 4 6 V l 3 5 V

I

CN104-8 (74, CSD-)

Approx. 4 6 V l 3 5 V

C N l 0 4 -8 (74, CSD-)

Greater than 0 V and smaller than 5 V

I I

I

1 I 1 I 1

I

1 I 1

CN104-8 (74, CSD-)

Traveling and material handling stop state

CN104-8 (74, CSD-) CN104-8 (74, CSD-)

+12V

Approx. I 10n Mps contactor (USA spec..: 68 n)

1

I

Remarks

On

CN104-8 (74, CSD -

+

I

Standard

Mps coil

Approx. 4 8 Vl36 V

ov Material handling stop state

CN104-8 (74, CSD -)

Approx. 1.2 V 1.2* 0.6 V

+ 12 V

Standard

Remarks

CN105 Connector: Basic conditions (Battery plug ON.SWKy ON) Connector No. CN105-1 (60, LS,)

* Connector No. I I

CN105-2 I (68, LSL21

I

Conditions

CN105-10 (1 I,GND)

LSLOFF LS, ON

CN105-10 (1I,GND)

LSL2OFF LSL2ON

* 5 *0.25 V 5 0.25 V OV OV

Connector No. CN105-3 (61, LS,) CN105-4 CN105-5

-

Connector No.

I

CN105-10 (11, GND)

I

I I

Conditions

Unused

I

Unused

I

I

CN105-10 (1 1, GND)

CN105-8 (55, VRSP +

I

CN105-10 (1 1, GND)

CN105-9 (56, VRSP)

I

CN105-10 (1 1, GND)

CN105-10 (11, GND)

I

Panel N 1 terminal

CN105-11

I

Unused

CN105-12

I

Unused

-

C N 1 0 6 Connector:

5 f 0.25 V OV

LSATTl ON LSArrl OFF

Approx. 5 V Approx. 0.9 Battery plug OFF SW, OFF

- 3.9 V

on

Basic conditions (Battery plug ON.SWKy ON) Conditions

Connector No.

Standard

I

-

CN106-1 (82, SSR)

1

CN106-2 (81, SSR)

Traveling stop state

OV

CN106-2 (81, SSR)

1

CN106-1 (82, SS,)

Traveling stop state

OV

CN106-3 (84, SSL)

I

CN106-4 (83, SSL)

Traveling stop state

OV

1

CN106-3 (84, SSL)

Traveling stop state

OV

CN106-5 (45, DSF)

1

CN106-13 (51, GND)

DSFOFF DSF ON

5 f 0.25V OV

CN106-6 (46, DSR)

I

CN106-13 (51, GND)

DSROFF DSRON

5f0.25 V OV

CN106-13 (51, GND)

SWAc OFF SWAc ON

550.25 V OV

I

I

I

CN106-4 (83. SSL)

I

I

I

CN106-7 I (64, SWAc) CN106-8 (53, VRAD

+

CN106-9 ( , OPTl)

1 I

Remarks

5 f 0.25 V OV

LSTOFF LS, ON

CN105-6 (63, LSATT1) ]

Connector No.

Standard

1

CN106-13 (51, GND)

1

CN106-13 (51, GND)

3 -

5 v

Remarks

Connector No.

* Connector No. I I

CN106-10 (P6, VBP6)

I

1 I I

CN106-1 3 (51, GND)

I I

CN106-15 (77, SWsc)

f

5V

f

5V

1

CNlO6-13 (51, GND)

LSD OFF LSD ON

I

Panel N1 terminal

Battery plug OFF SW, OFF

I I

CN106-14 (51, GND)

4 8 V vehicle: Traveling and material handling stop 43 state 36 V vehicle: 32

CN106-1 3 (51,GND)

I

CN106-13 (51, GND)

Remarks

Standard

4 8 V vehicle: 43f 5V Traveling and material handling stop state 3 6 V vehicle: 32f 5V

CN106-1 1 (P61,VBP61) 1 CNlO6-12 (67, LSD)

Conditions

I

I

5 * 0.25 V OV

on

CN106-13 (51, GNDl

ov

1

CNlO6-13 (51, GND)

SWscOFF SWsc ON

5 f 0.25 V OV

CN106-16 I I (66, SWpB) 1

CN106-13 (51, GND)

SWpBOFF SWpB ON

5 f 0.25 V OV

CN106-17 (65,LSs)

1

CN106-13 (51,GND)

LSB OFF LSBON

OV 5 f 0.25 V

1

CN106-13 (51, GND)

Shall vary smoothly according t o the traveling acceleration state.

CN106-18 (52, VRAD)

I

CN107 connector: Connector No. CN107-1 (141, SMTDA)

Basic conditions (Battery plug ON.SWKy ON)

* Connector No. CN1 07-6 (17, GND)

CN107-2 (142, SDTMA) CN107-6 (17, GND)

CN107-4 (144, SMTDK)

CN107-6 (17, GND)

CN107-5 (143, SDTMK)

0 -

1 v

Unused

Approx. 4 8 Vl36 V OV

ov Cannot be measured with a circuit tester

Panel N1 terminal

CN107-7 CN107-8 (16, +30V)

Standard

Cannot be measured with a circuit tester

CN107-3 ( , VBKY)

CN1 07-6 (17, GND)

Conditions

Battery plug OFF SW, OFF

ov

Unused CN107-6 (17, GND)

18

*3V

Remarks

2-26

-

CN 1 1 1 connector: Basic conditions (Battery plug ON.SWKyON) Connector No. CN111-1 CN111-2

I

CNlll-3 (15,+30V)

I

-

I

Connector No.

Standard

Conditions

Remarks

Unused CN111-20 (N1,GND)

Unused

Approx. 1 8

+3V

CN111-4 I (15, + 3 0 V)

CN111-20 (NI, GND)

Unused

Approx. 1 8

&

CNlll-5 (10, C36 V )

1

CNlll-20 (NI, GND)

Unused

Approx. 4 8 Vl36 V OV

CNlll-6 (37, CHOPP + I

CNlll-20 (N1, GND)

I

/ I

/

CN111-7 (35,VDP+) CNlll-8 ,-5V)

I

I

I

(

I

CN111-9 (14, VBKY)

I

CN111-10

/

CN111-11 (43, K36 V)

/

CNIII-I2 CN111-13

I

* 0.25 V 5 * 0.25 V 5

CN111-20 (N1,GND) CNlll-20 (N1,GND)

Unused

CN111-20 (NI, GND)

Unused

I

- 5V

- - 6V

Approx. 4 8 V l 3 6 V

ov

Unused CN111-20 (NI, GND)

/

SWKyON SW, OFF

Approx. 4 8 Vl36 V OV

Unused

I

CN111-14 (11, GND)

I

/

CN111-20 ( N l , GND)

CN111-15 CNlll-16 (11,GND)

Unused

OV

Unused

f

CNlll-20 (N1,GND)

Unused

CNlll-17 (38, CHOPP-) I

CNlll-20 (NI, GND)

Material handling stop state

4 - 5 V

CN111-20 (NI, GND)

Material handling stop state

4 - 5 V

I

CNlll-18 (36, VDP-1 CNlll-19

I

3V

Unused

OV

Connector No.

* Connector No.

CN1 1 1-20 (N1, GND)

1

Panel N 1 terminal

CN111-21 (13, VBBT)

I

CNlll-20 (NI, GND)

CNlll-22 (41, B36 V)

I

I

I

I

Conditions

Standard

Battery plug OFF SW,, OFF Unused

Remarks

on Approx. 48 Vl36 V

CN111-20 (N1, GND)

Approx. 48 V136 V

Battery voltage

Standard

Remarks

CN112 connector: Basic conditions (Battery plug ON.SWKy ON) Connector No. CN112-1 (43, K36 V )

* Connector No.

I

I 1

CN112-2 (41, B36 V)

I

CN102-3

I

Conditions

CN112-9 (NI, GND)

Unused

CN112-9 (N1, GND)

Unused

Approx. 4 8 Vl36 V

ov Approx. 48 V l 3 6 V

Unused CN112-9 IN1,GNDl

4 8 V vehicle: 27f 5V 3 6 V vehicle: 20f 5V

CN112-5 I (PI 5, RCK2)

CN112-9 (Nl, GND)

Approx. 4 8 V136V

CN112-6 (N2, TMPS)

CN112-9 (NI, GND)

ov

I

CN112-4 IP14,RCKP)

I I

I II

I I

CN112-7 (41, 8 3 6 V)

I

CN112-9 (N1, GND)

Unused

Approx. 4 8 Vl36V

CN112-8 (41, D36 V)

1

1

CN112-9 (NI, GND)

Unused

Approx. 4 8 Vl36V

CN112-9 (NI, GND)

I

PanelN1 terminal

Unused

Conduction

CN112-10

I

CN112-11 (P14,TMPD) CN 2-1 (93, TMPG)

I

Unused

I

CN112-9 (N1,GND)

I

CN1 2-9 (N1, GND)

- 25V - 5 - - 6V 10

Material handling stop state

11. Display If the cause of a trouble is judged to exist in the display, apply the battery voltage and measure the voltage at the connector.

CN 1 20 connector basic condition (battery plug ON) Connector No. CN120-9 (16, + 3 0 V ) CN 120-10 (104, BL)

* Connector No.

I 1

CN 120-19 (17, GND)

I

CN 120-20 ( N I , GND)

Conditions

Standard Approx. 18

=t3

Approx. 4 8 V

Remarks

V

DISASSEMBLY The control panel is overhauled infrequently. Defective part replacement according to the cause of the trouble by inspection is performed in most cases. Please perform correct operation by referring to the component parts drawing, assembly drawing and internal connection diagram.

Cautions for Parts Replacement Tighten the bar and harness set nuts and screws to the specified torques.

Looseness or insufficient tightening will cause other troubles.

When disconnecting a bar or harness, take a memo on the mounting position or attach a tag indicating the mounting position. At the time of reassembly, prevent incorrect installation or wiring by referring to the memo or tag. Incorrect installation or wrong wiring will cause other troubles.

Always coat silicone grease on parts which have been coated with silicone grease. Omission of coating may cause overheating.

After reassembly, check no contact of the bars and cables at other than the contact portions. Before installation on the vehicle, check continuity at points with a circuit tester. (See page 2-34 for the inspection points with the circuit tester.)

2-30

REASSEMBLY Control panel assembly drawing (STD)

DAD

(B)

CAD ( B )

(Y

P7

CSD P2

DF 1

N1

DCISD b

TMD

Control panel assembly drawing (with pump chopper)

DAD

(B)

CAD

(B)

CAP

(L)

DF3

(Y)

P7 CSD P2 DF 1

v

N1

TMD

P I 3 P 1 2 CSP

CNlOO

TMP

CN1 15

D'AP

CN1 17

T?!AiF?d DClSD board

DCISD b

2-32 Contactor panel assembly drawing

PANEL PARTS TIGHTENING TORQUE (Control panel) Tightening torque N.m (kgf-cm) [ft-lbfl

ltem TM-TMP

Main terminals

M5 M4

For installation

M5

Main terminals

M6

For installation

M6

Main terminals

M6

For installation

MI2

DAD-DAP

For installation

M6

Heat sink

For installation

M5

DF1 DF3

Terminal set nuts for external connection

M8

- 2.75 (22 - 28) 11.59 - 2.031 1.18 - 1.77 (12 - 18) 10.87 - 1.301 2.16 - 2.75 (22 - 28) [ I.59 - 2.031 3.14 - 3.73 (32 - 38) i2.32 - 2.751 5.10 - 5.69 (52 - 58) i3.76 - 4.201 2.1 6 - 2.75 (22 - 28) [ I.59 - 2.031 13.44 - 14.02 (137 - 143) 19.91 - 10.351 2.16 - 2.75 (22 - 28) f1.59 - 2.031 2.13 - 2.75 (22 - 28) 11.59 - 2.031 7.85 - 11.77 (80 - 120) l5.79 - 8.681 2.16

(Contactor panel) Tightening torque N.m (kgf-cm) [ft-lbfl

ltem DF2,-DF2,

Main terminals

M6

For installation

M 20

MFL.MFR MRL.MRR MP

Main terminals

M8

For installation

M5

Heat sink

For installation

M5

Terminal set nuts for external connection

M8

- 2.75 (22 - 28) [1.59 - 2.031 21.28 - 21.87 (217 - 223) [15.70 - 16.131 7.85 - 11.77 (80 - 120) 15.79 - 8.681 2.13 - 2.75 (22 - 28) l1.59 - 2.031 2.13 - 2.75 (22 - 28) [1.59 - 2.031 7.85 - 1 1.77 (80 - 120) [5.79 - 8.681 2.16

(For power steering) Tightening torque N.m (kgf-cm) [ft-lbfl

Item TMPS

Main terminals

M5

For installation

M5

- 2.94 (20 - 30) [ I.45 - 2.171 1.96 - 2.94 (20 - 30) 11.45 - 2.1 71 1.96

CONTINUITY CHECK WITH CIRCUIT TESTER

Control panel (Wlchopper)

Control panel (STD)

Contactor panel

Positive ( + ) probe: Red probe Negative (-1 probe: Black probe

Inspection method

Standard

Inspection points Between P2 and N 1

Between P 1 2 and N 1

+ probe - N1:

- probe

Approx. 1 0 to 2 5 Q

P2: - probe - N1:

+ probe

*an

P2:

+ probe - N l : - probe P I 2: - probe - N 1: + probe

P12:

Approx. 1 0 t o 2 5 62

*an

Circuit tester

Q xlK Q x 1K

Between P2 and frame

Tester probes may be used in either direction.

a0

Q

ax

Between N1 and frame

Tester probes may be used in either direction.

a

Q

Q x 1K

IK

* In the initial stage, the pointer indicates the capacitor characteristic because the capacitor is charged. Capacitor characteristic: The pointer deflects t o 0 Q and returns t o 00 Q then.

OCL (OVERCURRENT LIMIT) VALUES 1.

Drive circuit OCL value measurement (1) Lock the front and rear wheels with the vehicle in the traveling state. Connect the ammeter and shunt as illustrated below and measure the drive motor lock current.

Standard OCL value: 48 V vehicle: 460 3 6 V vehicle: 6 10

;+*: 6 0A A

Ammeter: 5 0 mV, 7 5 0 A Shunt: 5 0 mV, 7 5 0 A

(2) Judgment method If the measured OCL value is not within the standard range, the current sensor (CS) or CPU board may be defective. Make judgment as follows: @ Jack up the vehicle and support the front and rear sides of the frame with wooden blocks. @ Measure the output voltage of the current sensor. (Measured offset voltage value: B) Conditions: Battery plug ON.SWKy ON Measurement terminals: CN104(9)71 @ - CN104(8) 74 @ Standard: Approx. 1.2V * Use a digital voltmeter for measurement. @ Operate the accelerator t o set the speed t o approx. 8 kmlh ( 5 milelh). Read the ammeter and measure the current sensor output voltage on the CPU board side at the same time.

(Ammeter reading: A) (Measured current sensor output voltage: C) Measurement terminals: CN104(9)71 @ - CN 104(8)74 @ * Use a digital voltmeter for measurement. @ Calculation Measured value C - measured value B = D Convert the calculated value D according t o the following equation. (Converted value: E) 1V = 100A @ Judgment Compare converted value E with measured value A in step @.

The current sensor can be judged normal if the result is within 5.

The CPU board may defective if the current sensor is judged normal. Replace the CPU board in that case.

*

Pump circuit OCL value measurement The OCL value of the pump circuit cannot be measured because of the following reason: In the material handling system the relief valve in the control valve operates at the stroke end of each cylinder.

The OCL value for the pump circuit is set at a higher level than the current at the relief valve set pressure.

As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the OCL valve cannot be measured.

ACCELERATION POTENTIOMETER ADJUSTMENT Make adjustment in the state of acceleration potentiometer wlfront toe board.

Set screw

T = 1.57-2.35 N.m

1.

Operate the accelerator pedal and check if the acceleration switch is turned ON and OFF. Measurement terminals: 51 and 64 Standard When the pedal is not depressed: co When the pedal is depressed: 0 S2

2.

Acceleration potentiometer installation adjustment (1) Insert a 1.5 mm (0.06 in) thickness gauge between the accelerator link stopper and accelerator bracket.

(2) Temporarily install the potentiometer so that the is set to ON. switch (SW), (3) Inspect the switch (SW), ON and OFF changeover points.

When 1.0 mm (0.04 in) thickness gauge is inserted: OFF When 2.0 mm (0.08 in) thickness gauge is inserted: ON (4) After the end of switch ONmOFF adjustment, fully tighten the set screws.

BRAKE SWITCH-STOP LAMP SWITCH ADJUSTMENT 1.

2

Adjust protrusion (A) of the brake switch (LS,) stop lamp switch (LS,).

A = 26 m m (1.02 in)

and

,, check ON and OFF. After installing LS, and L,S (1) Operate the brake pedal and check conduction at each switch connector.

Standards Switch

LSS LSST

Not operated

on a0 n

Operated

n on

00

(2) Adjust each switch ONIOFF timing when the brake pedal is operated. Make adjustment by turning the adjusting bolt so that each switch is operated when the brake pedal is depressed by dimension B in the figure from the free state.

Switch

10 mm (0.39 in.)

on-an an- on

2-39

PARKING BRAKE SWITCH ADJUSTMENT 1.

Inspect parking brake switch (SW,,)

ONIOFF.

Standard Lever state

Returned

Pulled

SWPB

on

con

Adjust the SW, installation state.

(1) Return the lever fully to the stroke end.

(2) With the limit switch pushed to its stroke end toward the lever side, fix the switch by tightening the switch bracket set bolts 1 and limit switch set screws 2 .

MATERIAL HANDLING SWITCH ADJUSTMENT 1.

Adjustment the switch (LS,,-LS,) ON timing when the control lever is operated.

(1) Adjust LS, .LS, roller protrusion (A).

Dimension A is a reference value for reassembly.

A = 26 mm (1.02 in)

(2) The switch shall be turned ON at dimension A at the tip end of the control lever.

Standard B= 5

- 20 mm (0.20 - 0.79 in)

If the standard is not satisfied, make adjustment by changing the roller protrusion and mounting position.

1

When pump chopper (OPT) is provided: 2.

Adjust the pump chopper switch (LS,) (1) Adjust LS, roller protrusion (C).

ON timing.

C = 26 mm (1.02 in)

10-15mm

(2) Adjust by turning the adjusting bolt so that the switch (LS,) fulled to 1 0 stroke end.

Stroke end

is turned on when the lift lever is

- 15 mm (0.39 - 0.59 in) before its

DIRECTION SWITCH REMOVAL-INSTALLATION

Removal Procedure 1

Remove the steering rear cover.

2

Disconnect the direction switch connector.

3

Remove the steering tilt lever.

4

Remove the steering front cover and display.

5

Remove the direction switch.

Installation Procedure The installation procedure is the reverse of the removal procedure.

Disassembly Procedure 1

Remove the plate.

2

Remove the micro switch base.

3

Remove the microswitch Wlwire harness. [Point 11

4

Remove the cam roller and spring.

5

Remove the direction lever Wlknob.

6

Remove the cam.

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

Point Operation [Point 11 Reassembly: Install the microswitches in the correct positions.

Reassembly: When replacing a microswitch, connect the cables according t o the cable colors in the figure.

Inspection: After assembling the direction switch, check conduction of each microswitch before installing the direction switch.

PS CONTROLLER COMPONENTS STD (Mpscontactor: The Mpscontactor is installed on the PS motor.)

EHPS

INSPECTION (STD) 1.

P22-N 1 voltage measurement Battery plug ON.SWKyON Measurement terminals

P22 - N1

Circuit tester range

DC 5 0

Standard

Battery voltage

As seen from the motor

2. Mps contactor coil conduction measurement Battery plug OFF.SWKyOFF Measurement terminals

Both terminals of connector (CN42) of Mps Contactor

Circuit tester range

Q x l

Standard

Approx. 1 1 0 Q (at 20°C (68OF))

REMOVAL.INSTALLATION (EHPS)

1

Battery plug

Removal Procedure 1

Disconnect the battery plug.

2

Remove the side panel.

3

Remove the toe board.

4

Disconnect the wiring connectors.

5

Remove the PS controller.

Installation Procedure The installation procedure is the reverse of the removal procedure.

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