North American T6 Snj Harvard And Wirraway Book

GENERAL

¥ 00 Ð 01 REVISION HISTORY ¥ 00 Ð 02 FOREWORD Ð Foreword Ð How to read this manual ¥ 00 Ð 03 SAFETY Ð General precautions Ð Preparations for work Ð Cautions during operation Ð Cautions during check ¥ 00 Ð 04 STANDARDS Ð Measurement conversions Ð Standard tightening torque

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2000. 06.

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L FOREWORD

FOREWORD

00 02 1

This service manual has been prepared as an aid to improve quality of repairs by giving the serviceman an accureat understanding of the product and by illustraiting the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to the full effect at every opportunity.

! WARNING ¥ Improper operation and maintenance of this machine could result in serious injury or death. ¥ Read the Operation and Maintenance Manual carefully BEFORE operating the machine. ¥ Always keep the Operation and Maintenance Manual and Parts catalogue near the work area. ¥ Perform the operation, inspection and maintenance carefully. ¥ To prevent injury to workers, this symbol ! is used to mark safety precautions in this manual. The precautions accompanying this symbol should always be followed carefully. ¥ The specifications contained in this service manual are subject to change at any time and without any advance notice. Contact your CLARK distributor for the latest information.

HOW TO READ THIS MANUAL CHAPTER AND SECTION This service manual mainly contains the technical information necessary for operation performed in a servive workshop. For ease of understanding, the manual is divided into sections for each main system of the machine, and the sections are further divided into groups.

Example) 10 Ð 01 Section number (01 : Structure and function) Chapter number (10 : Engine)

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PAGE Page numbering is started from each section. Therefore, revised pages can be easily inserted.

Also additional pages and revision number can be indicated.

Example) 15 Ă? 1

c 15th page of the section Additional page from page 15 3rd revision

For the revision status in this manual, refer to REVISION HISTORY.

SYMBOLS The following symbols as defined below are used in this manual.

Symbol

Item

Remark

Safety

Special precautions for safety, warning or danger are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Tool

The size of proper tools which is used in assembling and disassembling.

!

Adhesive

Places to be applied with adhesive.

Lubricating

Places where oil or lubricant must be added.

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! For safety observe the precautions.

00 03 1

SAFE

TY

FIRST

FX1090

GENERAL PRECAUTIONS SAFETY PRECAUTIONS ¥ When carrying out any operation or maintenance, have trained and experienced personnel carry out the work. ¥ When carrying out any operation or maintenance, carefully read out Operation and Maintenance Manual.

Read all the precautions given on the decals which are fixed to the machine.

SAFETY DEVICE ¥ Make sure that all guards and covers are mounted in their proper position. Repair or replace if damaged. ¥ Pay attention to the method of using any safety locking device or safety belt.

SAFETY CLOTHES AND HELMET ¥ Wear the specified work clothes in the correct manner. Do not wear any loose wearings which may be caught by control levers or oily clothes which may be fired. ¥ Use the specified protective gear (helmet, safety glasses, safety shoes, mask, gloves).

Guard against injury from flying pieces of metal or debris, wear goggles, gloves and helmet.

Always have a trained and experienced welder carry out any welding work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suitable EX048 for welding work.

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PREPARE FOR EMERGENCIES ¥ Know where fire extinguishers are located and how to use them. ¥ Keep a first aid kit and an eye wash kit near the work area. ¥ Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

EX036

HANDLE FLUIDS SAFETYÐAVOID FIRES ¥ Keep the electric system and the lubricating oil away from fire hazards. It is highly flammable. ¥ Keep the flammable things away from the machine.

Do not smoke in the working site. ¥ Store all the oils in a specified place.

DISPOSE OF FLUIDS PROPERLY ¥ Improperly disposing of fluids can harm the environment and ecology.

When oil can be leaked during maintenance or changing of lubricating oil, prepare suitable containers. Do not pour oil into the ground. ¥ Do not use food or beverage containers that may mislead someone into drinking from them.

EX043 ¥ Label the containers of used oil and lubricating oil not to misuse for others. ¥ Observe relevant environmental protection regulations when disposing of lubricating oil, battery liquid or other harmful waste.

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AVOID HARMFUL ASBESTOS DUST

00 03 3

ÂĽ Avoid breathing dust that may be generated when handling components containing asbestos fibers. Wear a gas mask if necessary.

EX025

ÂĽ Even if not depicted in this manual, pay attention to the safety precautions to prevent the injury of operator and the damage of machine.

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PREPARATIONS FOR WORK

4

WARN OTHERS OF SERVICE WORK

Do not operate

¥ Unexpected machine movement can cause serious injury. Before performing any work on the machine, attach a ÒDo not operateÓ or ÒUnder operaionÓ tag to the steering wheel or the right control lever. ¥ When the lift should be parked with raised fork, attach a warning tag to the tip of fork.

Passengers or other cars may be hit.

FX044 ¥ Park the lift on a certain place where no car or person is passed. (Passing under the forks is very dangerous.) ¥ Remove the start switch of disordered machine, and attach a ÒDo not operateÓ tag.

Dangerous

SAFETY OF WORKSHOP ¥ Keep all tools in good condition and know the correct way to use them. ¥ Decide on a place in the repair workshop to keep tools and the removed parts. Prepare the cloth to wipe oil and the bottle for drained oil. ¥ Always keep the work area clean and make EX033 sure that there is no dirt or oil on the floor. ¥ Before adding oil or making any repairs, park the machine on hard, level ground and put blocks under the wheels to prevent the machine from moving. ¥ Before starting work, lower the forks to the ground. ¥ When leaving the operatorÕs seat, lower the forks to the ground, turn the engine OFF and remove the start key. ¥ Illuminate your work area adequately. Use a portable safety light for working. Make sure the bulb is enclosed by a wire cage when cheking the oil or battery electrolyte.

EX042

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USE HANDHOLDS AND STEPS 짜 Do not jump onto or down from the fork lift.

Especially, never jump onto or down from the travelling fork lift. 짜 Do not grasp an operating lever or steering wheel when getting on or off. 짜 When getting on or off, keep the body stable by grasping hands and stepping foot firmly. 짜 Always keep the handle, gripe and step clean, and wipe out oil or mud on them. Repair them if damaged, and tighten the loose bolts.

00 03 5

FX019

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CAUTIONS DURING OPERATION

6

AVOID HIGHÐPRESSURE FLUIDS ¥ The hydraulic line is always under high pressure. Never attempt to drain the oil or sevice other works before releasing the inner pressure. ¥ Escaping fluid under pressure can cause serious injury. Wear gloves and use thick paper or plywood for check. ¥ Do not bend or hit the high pressure pipes. ¥ Be careful not to twist the high pressure pipes for installing.

Damaged hoses or pipes are very dangerous.

Make sure to replace.

EX062

EX040

HANDLING OF HEAVY OBJECTS ¥ When raising heavy components, use a hoist or crane. ¥ Check of the wire rope, chains and hooks are free from damage. ¥ Always use lifting equipment which has ample capacity. Install the lifting equipment safely at the correct places. ¥ Operate slowly to prevent the component hitting any other part. Do not attempt another work at the same time. ¥ When disassembling or assembling the attachments, pay attention not to fall down. ¥ Before starting work under the machine, lower the forks to the ground. ¥ Do not work under the machine when it is not sufficiently supported. ¥ When tires are raised, support the machine with blocks.

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HANDLING OF ELECTRIC SYSTEM ¥ When welding on the machine or working on the electical system, ALWAYS turn the key switch OFF and remove the battery plug from the battery. ¥ When removing components, be careful not to damage the wiring. Damaged wiring may cause electrical fires. ¥ Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin and eat holes in clothing. If you spill acid on your clothes or skin, immediately flush with large quantities or water. ¥ When working on the battery, wear goggles or safety glasses. If splashed into the eyes, flush with water and get medical attention immediately. ¥ Keep sparks, lighted matches, and open flame away from the top of battery. Battery (hydrogen) gas can explode. ¥ Battery terminals touched by metal objects can cause short circuit and burn you. Keep tools away from the terminals.

Tighten the battery terminals to ensure good contact. ¥ When disassembling and assembling the battery, make sure that the battery terminals (+, Ð) are correctly connected. ¥ If water gets into the electrical system, abnormal operation or failure can result. Do not use water or steam on sensors, connectors and instruments in the cab.

00 03 7

EX032

EX030

EX031

EX041

EX034

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CAUTIONS DURING OPERATION ¥ Before removing the cover under pressure or spring force, release the pressure slowly. Until the pressure is released completely, keep 2 bolts in diagonal directions. ¥ Never put any loose objects near the rotating parts. ¥ Be careful not to get your fingers pinched in fan blade, fan belt or air conditioner belt. It can cause serious injury. ¥ The tire and wheel must be inflated by trained personnel only on designated working site. ¥ Use the tires under the specified conditions. It can burst by abnormal overheat or cut causing serious injury or death. ¥ Always keep the air pressure of tires proper.

Low air pressure may cause overheat.

EX023

EX035

Proper air pressure ➡ Refer to the section of ÒTiresÓ. ¥ When checking the air pressuer of tires, stand forwards tread instead of tire sides. ¥ Use long gauge to keep away body from the rim or wheel. ¥ If the tires are heated as installed to the wheel, flammable gases are emitted causing explosion.

The explosive power is so strong that it cannot bear comparison with burst of tires. Never work EX030 as followings as the tires are installed to the wheel. Ð Welding around rim Ð Welding or firing near wheel or tires ¥ When adding air to the tires, use safety guards as shown in the figure. ¥ Use only genuine tires. ¥ If the wheel or tire is handled improperly, it can burst causing serious injury. Contact to the specified A/S center.

EW0223

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CAUTIONS DURING CHECK

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¥ Never operate with wet or oily hands and feet. ¥ Do not operate the fork lift from any place other than the designated operatorÕs position.

Improper seating may cause serious injury. ¥ Never take any person on board.

Before sitting on the seat, make sure anyone is near around. ¥ Wear the seat belt before starting the machine.

Adjust the tension of belt properly.

FX020

FX001 FX002

¥ Before starting the machine, make warn by horning. ¥ Arrange another person on danger or poorÐsight places. ¥ Do not allow anyone to stand or walk under the elevated forks or load. Failure to comply can cause serious injury or death.

FX027

¥ Never use the forks to lift people.

FX028

¥ Read the Operation Manual carefully.

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MEASUREMENT CONVERSIONS

00 04 1

LENGTH

Unit

cm

m

km

in

ft

yd

mile

cm

1

0.01

0.00001

0.3937

0.03281

0.01094

0.000006

m

100

1

0.001

39.37

3.2808

1.0936

0.00062

km

100000

1000

1

39370.7

3280.8

1093.6

0.62137

in

2.54

0.0254

0.000025

1

0.08333

0.02777

0.000015

ft

30.48

0.3048

0.000304

12

1

0.3333

0.000189

yd

91.44

0.9144

0.000914

36

3

1

0.000568

mile

160930

1609.3

1.6093

63360

5280

1760

1

1mm=0.1cm, 1mm=0.001mm

AREA Unit

cm2

m2

km2

a

ft2

yd2

pyung

cm2

1

0.0001

Ð

0.000001

0.001076

0.000012

Ð

m2

10000

1

0.000001

0.01

10.764

1.1958

0.3025

km2

Ð

1000000

1

10000

1076400

1195800

302500

a

0.01

100

0.0001

1

1076.4

119.58

30.25

ft2

Ð

0.092903

Ð

0.000929

1

0.1111

0.00281

yd2

Ð

0.83613

Ð

0.008361

9

1

0.25293

pyung

33058

3.3058

0.000003

0.033058

35.583

3.9537

1

1ha=100a, 1mile2=259ha=2.59km2

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VOLUME Unit

cm3 = cc

m3

l

in3

ft3

yd3

cm3 = ml

1

0.000001

0.001

0.061024

0.000035

0.000001

m3

1000000

1

1000

61024

35.315

1.30796

l

1000

0.001

1

61.024

0.035315

0.001308

in3

16.387

0.000016

0.01638

1

0.000578

0.000021

ft3

28316.8

0.028317

28.317

1728

1

0.03714

yd3

764529.8

0.76453

764.53

46656

27

1

1gal(US)=3785.41 cm3=231 in3=0.83267gal(UK)

WEIGHT Unit

g

kg

t

oz

lb

g

1

0.001

0.000001

0.03527

0.0022

kg

1000

10

0.001

35.273

2.20459

t

1000000

1000

1

35273

2204.59

oz

28.3495

0.02835

0.000028

1

0.0625

lb

453.592

0.45359

0.000454

16

1

1 tonne(metric)=1.1023 ton(US)=0.9842ton(UK)

VOLUME Unit

kgf/cm2

bar

Pa=N/m2

kPa

lbf/in2

lbf/ft2

kgf/cm2

1

0.98067

98066.5

98.0665

14.2233

2048.16

bar

1.01972

1

100000

100

14.5037

2088.6

Pa=N/m2

0.00001

0.001

1

0.001

0.00015

0.02086

kPa

0.01020

0.01

1000

1

0.14504

20.886

lbf/in2

0.07032

0.0689

6894.76

6.89476

1

144

lbf/ft2

0.00047

0.00047

47.88028

0.04788

0.00694

1

kgf/cm2=735.56 Torr(mmHg)=0.96784atm

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Factor

Unit

Factor

Unit

Torque ´

0.8664

=

(lbáin)

newton meter (Nám)

´

0.74

=

lbfáft

´

1.36

=

Nám

newton meter (Nám)

´

0.102

=

kgfám

´

7.22

=

(lbfáft)

0.249

=

kPa

20

kgfácm

´

0.30

=

in. Hg

´

3.38

=

kPa

kilopascal (kPa)

´

0.145

=

psi

´

6.89

=

kPa

(bar)

´

14.5

=

psi

´

0.069

=

(bar)

(kgf/cm2)

´

14.22

=

psi

´

0.070

=

(kgf/cm2)

(newton/mm2)

´

145.04

=

psi

´

0.069

=

(bar)

megapascal (MPa)

´

145

=

psi

´

0.00689

=

MPa

PS (cv) ´

0.736

=

kW

kilowatt (kW)

´

1.34

=

HP

´

0.746

=

kW

kilowatt (kW)

´

0.948

=

Btu/s

´

1.055

=

kW

watt (W)

´

0.74

=

ftálb/s

´

1.36

=

kW

Energy (J = Nám)

160

=

140

1.36

320

´

280

kilowatt (kW)

0.948

=

Btu

´

1.055

=

kJ

joule (J)

´

0.239

=

calorie

´

4.19

=

J

360 400

Velocity and Acceleration ft/s2

´

0.305

=

m/s2

meter per sec (m/s)

´

3.28

=

ft/s

´

0.305

=

m/s

kilometer per hour (km/h)

´

0.62

=

mph

´

1.61

=

km/h

=

l/min

Horse Power/Torque TQ ´ R.P.M. 5252 = B.H.P.

480

BHP ´ 5252 R.P.M. = TQ (lbáft)

260

Temperature 520

¡F= (¡C ´ 1.8) + 32

¡C = (¡FÐ32) Ö 1.8

=

US gal/min´3.785

300

) NonÐSI Unit

0.264

560

Note : (

´

280

Flow Rate l/min (dm3/min)

240

=

220

3.28

440

´

200

´

180

kilojoule (kJ)

meter per sec2 (m/s2)

120

240

Power (W = J/s)

100

kilopascal (kPa)

80

in. H2O ´

60

=

200 212

4.0

160

´

120

kilopascal (kPa)

37

Pressure (Pa = N/m2)

0

=

98.6

10.2

80

´

40 32

newton meter (Nám)

Degree ¡C

SI

20

Conv

40

NonÐSI

0

Unit

Conv

Degree ¡F

SI

40

APPROXIMATE CONVERSIONS

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320

600

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STANDARD TIGHTENING TORQUE

4 The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of ÒDisassembly and AssemblyÓ.

METER TABLE Classification

4T, 5T

Bolt type

Bolt size

10T

10.9

Torque (kgfám)

Torque (kgfám)

M4

0.2 ± 0.02

0.4 ± 0.04

M5

0.3 ± 0.03

0.8 ± 0.08

M6

0.5 ± 0.05

1.4 ± 0.14

M8

1.2 ± 0.12

3.3 ± 0.3

M10

2.3 ± 0.23

6.5 ± 0.7

M12

4.0 ± 0.4

11.3 ± 1.1

M14

6.4 ± 0.6

17.9 ± 1.8

M16

9.5 ± 0.9

26.7 ± 2.7

M18

13.5 ± 1.4

38.0 ± 3.8

M20

18.6 ± 1.9

52.2 ± 5.2

M22

24.7 ± 2.5

69.4 ± 6.9

M24

32.1 ± 3.2

90.2 ± 9.0

M30

62.6 ± 6.3

176.1 ± 17.6

M36

108.2 ± 10.8

304.3 ± 30.4

M42

171.8 ± 17.2

483.2 ± 48.3

M45

211.3 ± 21.1

594.3 ± 50.4

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INCH TABLE

00 04

Classification

5

4T, 5T

10T

Torque (kgfám)

Torque (kgfám)

1/4

0.6 ± 0.06

1.7 ± 0.2

5/16

1.2 ± 0.12

3.0 ± 0.3

3/8

2.0 ± 0.20

5.6 ± 0.5

7/16

3.2 ± 0.32

8.9 ± 0.9

1/2

4.7 ± 0.47

13.4 ± 1.3

9/16

6.8 ± 0.68

19.0 ± 1.9

5/8

9.3 ± 0.93

26.1 ± 2.6

3/4

16.0 ± 1.60

45.1 ± 4.5

7/8

25.5 ± 2.55

71.6 ± 7.2

1

38.0 ± 3.80

106.9 ± 10.7

1Ð1/8

54.1 ± 5.41

152.2 ± 15.2

1Ð1/4

74.2 ± 7.42

208.9 ± 20.9

1Ð3/4

98.8 ± 9.88

277.8 ± 27.8

1Ð1/2

128.2 ± 12.82

360.7 ± 36.1

Bolt type

Bolt size

The torque in above table shall not be applied to the bolts with nylon packings and nonferrous metal washers, or the ones with specially designated torque and standard. ★ Newton meter : 1 Nám Å 0.1kgfám

TORQUE FOR SPLIT FLANGE BOLT The following torque shall be applied to the split flange bolts.

Diameter

Flat width

Torque

(mm)

(mm)

kgfám

Nám

10

14

6.7 ± 0.7

66.7 ± 6.8

12

17

11.5 ± 1

112 ± 9.8

16

22

28.5 ± 3

279 ± 29

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TORQUE FOR HYDRAULIC PLUG WITH OÐRING

6

Plug

OÐring

PF thread Thread

Plug Prat No.

Torque (kgfám)

1/8

9415Ð11011

1.1 ± 0.1

1/4

9415Ð11021

2.6 ± 0.2

3/8

9415Ð11031

4.6 ± 0.3

1/2

9415Ð11041

8.5 ± 0.4

3/4

9415Ð11051

19 ± 1.0

1

9415Ð11061

33 ± 2.0

TORQUE FOR SWIVEL NUT WITH OÐRING

Connector

OÐring

Swivel nut

Hose

Tube O.D.(inch)

Thread (in)

Torque (kgfám)

1/2

UN 13/16Ð16

9.5 ± 0.95

3/4

UN 1 3/16Ð12

18 ± 1.8

1

UN 1 7/16Ð12

21 ± 2.1

SPECIFICATIONS

¥ 01 Ð 01 GENERAL SPECIFICATIONS Ð Location of components Ð Dimension and weight Ð Performance Ð Tightening torque Ð Oil chart

01

S P E C I F I C A T I O N S GENERAL SPECIFICATIONS

LOCATION OF COMPONENTS

01

14

01

3

1 10 7

9

1 2 11 4

15

5 17

12 8 6

18

FX949

13

1 Head light 2. Turn signal lamp 3. Mast 4. Load backrest 5. Front hood 6. Front axle 7. Lift chain 8. Fork 9. Overhead guard

10.

11.

12.

13.

14.

15.

17.

18.

Lift cylinder OperatorÕs seat Battery Rear axle Steering wheel Battery cover stopper Stop, tail lamp and back lamp Drawbar pin

S P E C I F I C A T I O N S GENERAL SPECIFICATIONS

DIMENSION AND WEIGHT

01 M

01

L

C

G

E

B F

2

R

D A

FX966

PERFORMANCE Item Max. load

Basic

Tires

Motor

Battery

CEP15

CEP18

CEP20

CEP25

kg

1500

1750

2000

2500

Load center

mm

500

Max. lift

mm

3000

Free lift

mm

lift up speed Performance Fork (load/unload)

Overall

Unit

mm/s

100

105 320/450

280/400

Symbol

260/360

250/360

6/12

M/L

Tilt angle (F/B)

deg

Travelling speed (load/unload)

km/h

Min. turning radius

mm

Overall length

mm

Overall width

mm

1075

1150

B

Overall height

mm

2137

2196

C

Wheel base

mm

1250

1470

D

Wheel tread (F/R)

mm

893/910

960/980

F/E

10.1/12.5

10.6/12.8

10.6/13.7

1808

2066 3093

3049

10.2/13.1

3379

R 3445

Weight

kg

Front wheel

Ð

6.5´10Ð12PR

7.0´12Ð14PR

Rear wheel

Ð

5.0´8Ð10PR

6.0´9Ð10PR

Travelling

kw

5.0

6.0

Hydraulic

kw

Steering

kw AH/5h

3125

2910

3545

7.7

3920

8.5 0.4 450

500

580

A

S P E C I F I C A T I O N S GENERAL SPECIFICATIONS

TIGHTENING TORQUE

01

Specification Item

Unit CEP15

CEP18

CEP20

CEP25

3

16~20

Bolt, mount, drive axle

kgfám

Nut, driving wheel

kgfám

Nut, steering wheel

kgfám

8~10

Bolt, tight, steering axle

kgfám

8~10

Nut, tight, steering wheel

kgfám

5.3~6.4

Nut, tight, steering gearbox

kgfám

9~11

Nut, tight, pitman arm

kgfám

16~20

Nut, tight, drag link

kgfám

13.5~16.5

Nut, tight, tilt cylinder

kgfám

17.9 ± 1.8

Nut, tight, pump coupling

kgfám

4~5

Bolt, mount, mast

kgfám

26.7~2.7

8~10

01

28~34

S P E C I F I C A T I O N S GENERAL SPECIFICATIONS

á Recommended specification and oil filling capacity (Unit : liter)

01

Ambient temperature Division

01

Ð22 Ð30

Ð4 Ð20

14 Ð10

32 0

50 10

68 20

Filling capacity 86 30

104 122¡F 40 50¡C

CEP15/18

CEP20/25

23

29

8

8

2

2

4 ISO VG22 or VG15 Hydraulic oil

ISO VG32 ISO VG46

SAE 80WÐ90 Gear oil SAE 5WÐ30

Brake oil

SAE J1703

ASTM : American Society of Testing and Material SAE : Society Automotive Engineers API : American Petroleum Institute ISO : International Standardization Organization

ELECTRIC SYSTEM

¥ 10 Ð 01 GENERAL Ð Safety Ð Electric circuit Ð Control circuit Ð Illumination alarm system circuit Ð Arrangement of electric components Ð Electric wire harness diagram Ð Cable diagram Ð Main wire harness ¥ 10 Ð 02 BASIC THEORY Ð Theory Ð Symbol and function ¥ 10 Ð 03 COMPONENTS Ð Travel motor Ð Hydraulic motor Ð Control system Ð Instrument panel Ð Electric power steering system Ð Accelerator Ð DCÐDC converter Ð Fuse box Ð EPS controller Ð Battery

10

Ð Charger Ð Specification of main electric parts ¥ 10 Ð 04 FUNCTION OF CONTROLLER Ð Power control Ð Adjustment ¥ 10 Ð 05 DISASSEMBLY/ASSEMBLY Ð Electric motor (travel, hydraulic, steering) Ð Structure and Components Ð Disassembling procedures and cautions Ð Inspection Ð Assembling procedures Ð Disassembly/assembly Ð Inspecting/Correcting Contactor Ð Accelerator Ð Forward/reverse and turn signal switch Ð Main fuse Ð DCÐDC Converter Ð Instrument Panel Ð Battery

E L E C T R I C

S Y S T E M GENERAL

SAFETY CAUTIONS FOR CHARGING ¥ Battery generates Hydrogen gas and heats by chemical reactions while the battery is charged.

Pay attention to following cautions in order to prevent the gas explosion. ¥ Charge the battery in a wellÐventilated and clean area free of rain, moisture or dust. ¥ While charging, open and lock the battery hood. ¥ Before charging, if the electrolyte temperature of battery is 35¡C or above, keep the battery in a wellÐventilated and shaded place to cool down, and then start charging. ¥ In case the charger protective fuse is cut off, be sure to use the genuine parts. ¥ Battery may emits an explosive gas while the battery is charged. Do not charged near fire or flame. ¥ Keep the top surface of battery clean and dry, and tighten the battery caps securely. Dirty top surface of battery may shorten the life span of FX049 battery. ¥ If charger is used for long time with the voltage tap adjustment being wide, the charger may be damaged. Regularly conduct the tap adjustment of charging voltage. ¥ For the power supply to installation(building) side, use a wiring and outlet having a capacity more than maximum input current. Shortage in capacity may cause a fire. ¥ Plug in or out with holding the plug body. Never hold and pull the cable. Cable may be cut off. ¥ Loose plugÐinserting part, damaged contact terminal, or damaged power cord may cause a fire by heat generating. Make sure of checking.

Any trouble must be repaird or got a service in our Service Center. ¥ When charging, directly plug into the receptacle because high current flows upon charging.

Never use a jointed cable. ¥ When charging, do not plug out from the FX050 receptacle because high current flows while charging.

10 01 1

E L E C T R I C

S Y S T E M GENERAL

ELECTRIC CIRCUIT

10

10A

15A

01 B3

B5

B4

B6

3

B3

B4

HORN S/W1

D1

NC

NO

A

B2 B1 B5 B6

D3

5A

B5

B6

HORN S/W2 (OPT)

E L E C T R I C

S Y S T E M GENERAL

CONTROL CIRCUIT

10 01 5

D1

NC

NO

A

B2 B1 B5 B6

D3

5A

E L E C T R I C

S Y S T E M GENERAL

ILLUMINATION ALARM SYSTEM CIRCUIT

10 01 7

15A

10A

B3

B4

HORN S/W1

B3

B5

B4

B6

B5

B6

HORN S/W2 (OPT)

E L E C T R I C

S Y S T E M GENERAL

ARRANGEMENT OF ELECTRIC COMPONENTS

20

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

12 7 5

28 29

22

13

14

24

9 17

15 16 10 18

23 11

1

6

8

25

4

27

26

21

3

SCR Unit DC–DC converter EPS contactor EPS controller Panel ass’y Accelerator Fuse box Horn Buzzer Fowrard/Reverse switch Micro switch – Parking brake Brake stop switch Micro switch – Hydraulic Pedal ass’y Head lamp Turn signal lamp Combination lamp Battery Flash unit Horn relay Hydraulic motor Micro switch – Hydraulic (Option) Rear view mirror Key switch Travel contactor ass’y Hydraulic contactor ass’y Travel motor Beacon lamp Rear work lamp

10 01 9

E L E C T R I C

S Y S T E M GENERAL

ELECTRIC WIRE HARNESS DIAGRAM

10

3

01

COMBI LAMP LH/RH

HEAD LAMP & T/SIGNAL LAMP

11

2

First install the wires (#02) inside of overhead guard, assemble split housing and push it into the overhead guard, and then seal with item #06.

* As connecting item #04 and EPS motor Connect A1—A and A2—AA with bolt (M6), nut (M6), spring washer and plain washer, and then insulate with electric tapes.

4

Connect with EPS motor, and then arrange along the wire harness.

W/harness

Arrange the connections of w/harness—body on the top of hydraulic contactor.

After wiring, arrange them not to be interfered with frame or other parts.

Install the overhead guard wires(#02, 03), and then tie the remaining wires and the main wires(#01) to the support.

W/harness WIRING ARRANGEMENT

Lock the wires to the cables.

Tie them through inside of steering column.

1

When serveral kinds of ring terminal is connected at the same time, first connect the terminal with large current flow so that the heat generated from contact resistance can be reduced.

WIRING ARRANGEMENT IN COUNTERWEIGHT

When connecting 4 thick wires on the lower part of EPS contactor, lock them with screws according to the colors.

1.

2.

3.

4.

Electric Electric Electric Electric

W/harness – Main W/harness – Accessory (LH) W/harness – Accessory (RH) W/harness – EPS motor

E L E C T R I C

S Y S T E M GENERAL

CABLE DIAGRAM

10 01 13

Hydraulic motor

Battery

Travel motor

E L E C T R I C

S Y S T E M GENERAL

MAIN WIRE HARNESS

231

223

150

700

50

50

15

200

116

50 900 50 50

0

232 220

235

226

908

016

224 213 906

CONTACTOR -DRIVE

500 50

915

112

120

126

121 920

914 116 114

115

518 L

118 119

122

124 123

FLASHER UNIT

218

100

219 125

813 811

136 135 134

124 119

122 B+

915

HYDOPT 1 017 020 514 S

919 125

113

921

236

901

133 132 131 130

50

100

50

50

50 117

022 925

823

200 200

222

412

111

901

200

50

522

50 50

0 20

50 513

CONTACTOR-HYD

225 223

824

KEY- 113 SW

GND 123 810 019 H B+

FLASHER UNIT

138

916

916

50

50

531

139 138 132

901

531 530 513 512

901

100 100

HYDS/W WIPER MOTOR 024

010A 021 022 023

300

126

821 917

916

530 139

HORN

HORN RELAY

PANEL

611

901 901

STOPS/W

901

200

923

900

134 K/SW

300

227

912

112 B+

023

50

228

512

133

020

100 100

050015

511

100

901

515 514

814

121

150

50

50

011 GND

50

903

018

DC-DC CONVERTER

011

901

511

615 136 919

616

HORN S/W-1

PARKING -S/W

131 901

901

250

250

100

50 118 OUT(12V)

930 010

225

227

50

010B 014 815

15

200

25 930

228

411

216

300

0

50 226

236

017 014 814

50

800

100

01

010C 019

919

813

215

910

0

25

126

918

817

229 902

235

812

217

50

823

816

EPSSENSOR

200

10

LAMP-OPT

LAMP-LH

518

822

916

824

900

50

600 50

821817

522

517

BACKBUZZER

50

224

901

412

021

909

902

911

018

SCR-UNIT

516

410

219

232

515

100

221

218

HORN S/W-2

815 120

909

50

215

50

216

913

616

222

910

30

217

150

930

822

411

200

350 135

930 615

111

909

931

816

905

909

115

214

611 231 229 516

903 213

200

114

410

517

904

909

221

220

130

200

127

214

50

100

930

310 311

930

117 015 016

050

ACCELERATOR-ASS’Y

902

MAIN-FUSE 930

CONTROL-EPS

50

915

100

50

100

50

CONTACTOREPS 127

50

915

150

DIRECTIONAL-S/W

310

311

811 812

LAMP-RH

HYDOPT 2

E L E C T R I C

S Y S T E M GENERAL

CAUTIONS FOR BATTERY ! Do not overĂ?discharge.

If battery is used until the equipment donÕt work any longer, the life span of battery is shorten. Charge immediately when the red lamp is blinking on the capacity gause.

! Prior to charing, read the specific gravity of electrolyte, and any accident may be prevented in advance because the abnormality of battery inside is detected according to the specific gravity difference between before and after charging.

! Charge in a rainproof, wellĂ?ventilated and safe place. ! Be careful of electrolyte not to be run out.

If the battery is charged, the water level of battery electrolyte (diluted sulfuric acid) goes down. Be sure to refill water upto the highest level.

Note) When refilling water into electrolyte, distilled water or purified water must be used.

! Before charging battery, make sure that plug or terminal is loose.

! Keep the battery clean.

Keep the top face of battery clean and dry.

Tighten the cover securely.

! Inflammable !

Any fire or flame must be kept away from battery. Explosive gas is produced from battery.

! Avoid overcharging.

Charge in accordance with the charger handling instruction.

! Do not plug out while charging.

In case of pluging out while charging, be sure to press the stop button, and when the charge lamp is off, pull the plug body out.

! Turn the start switch OFF while charging battery.

! Careful attention must be paid to the charging plug cord or battery cord not be damaged.

10 01 17

E L E C T R I C

S Y S T E M BASIC THEORY

THEORY MATERIAL AND ELECTRON (Corpuscle) Material

> Molecule >

(Elementary particle)

Atom

Atomic nucleus

Proton (+e) Neutron

10 02

Electron (Ðe)

Molecule is minimum unit which doesnÕt lose its nature, and consisted of many corpuscles.

Corpuscle is an atom consisted of elementary particles such as proton, neutron and electron.

Proton has (+) electric potential and forms atomic nucleus in the middle of atom by combinded with nertron. Electron has (Ð) electric potential and forms orbit around the atomic nucleus. Atom wants to keep the stabilization as taking same number of electrons as the number of protons in atomic nucleus.

1

Atom

Electron

MATERIAL AND ELECTRON The materials of copper or steel are called as conductor, and have Ôfree electronÕ. If outer force is applied to the free electrons, they are separated from the orbit and move into another atom.

If cathod and anode are connected to the both ends of conductor, the electronic balance will be broken so that the electron is stimulated to move. This is called as electromotive force or voltage, and indicated by V. Conductor

Movement of free electron

E L E C T R I C

S Y S T E M BASIC THEORY

If voltage is applied to one end of conductor and lots of electrons are moved, the atom will be unstable because the remaining proton (+) is more than electron (Ð).

In this way, the voltage on ends of conductor will be different. If the ends are connected together to compose ÒClosing circuitÓ, the electron will move to the sides where the electrons (Ð) are rare.

Therefore the electron move from (Ð) sides to (+) sides. This flow is called as Current, and marked by A.

10 02 2

The resistance is all the kinds of interference which disturb flow of electron in the conductor.

The kinds of conductor, length of conductor, and temperature, etc. will be included. It is marked by ½.

Now explain the relation of voltage, electric current and resistance by use of 2 water tanks.

Difference of Pipe The difference of water level between A water water level tank and B tank (water pressure), the water flow (Water A tank W pressure) from A tank to B tank, and the thickness of pipe at er are considered as follows : flo w ¥ Water pressure = Voltage ¥ Water flow = Electric current ¥ Thickness of pipe = Resistance B tank ¥ Voltage (V) : The difference of electric potential is called as voltage. The (+) electric potential is higher than (Ð) electric potential. ¥ Electric current (A) : If there is difference of electric potential, namely, voltage between two poles, the electricity flows. This flow is called as electric current. ¥ Resistance (½) : All the interferences which disturb the flowing of electric current caused by voltage are called as resistance.

RULE OF OHM If voltage is applied to closing curcuit, the electric current will flow. The current is in direct proportion to voltage and in inverse proportion to resistance.

Electric current =

Voltage Resistance

®I=

V R

ELECTRIC POWER Electric power is volume that the electricity works during unit time, and marked by P. The electric power is obtained by voltage multiplied electric current. (Unit : watt (W)) P = V ´ I

E L E C T R I C

S Y S T E M BASIC THEORY

3ÐPHASE ALTERNATING CURRENT (AC) ¥ 3Ðphase alternating current is composed of 3 single phase alternating current of which phases are different by 120¡C. 3Ðphase electric power is the sum of each single phase electric power, i.e. 3 times of single phase electric power. ¥ When transmiting electricity of 3Ðphase alternating current, 6 wires are required but gather eacb 3 wires (neutral wire). If the load is same for each 3-phase circuit, current will not flow to the neutral wire, so electricity can be transmitted by use of 3 wires. This is called 3Ðphase 3Ðwire type. Usually 220V, 380V and 440V are used for 3-phase alternating current.

02

PARALLELáSERIES CIRCUIT

3

VOLTAGE ¥ In series connection, the composing voltage is same as sum of voltage of each battery.

V1

V2

V3

V4

Composing voltage V0 = V1 + V2 + V3 + V4 ¥ The battery of 48V used for electric fork lift is composed by 24 batteries of 2V.

V0

CAPACITY ¥ In parallel connection, the voltage is same but the composing electric capacity is sum of capacity of each battery.

A1 A2

Composing electric capacity A0 = A1+A2+A3+A4

A3 A4 A0

RESISTANCE ¥ In seriesl connection, the composing resistance is the sum of resistance of each battery.

Composing resistance R0 = R1+R2+R3+R4

10

R1

R2

R3 R0

R4

E L E C T R I C

S Y S T E M BASIC THEORY

¥ In parallel connection, the composing resistance is reciprocal number for the sum of reciprocal numbers for each resistance.

Composing resistance R0 =

10

R1 R2

1 1 1 1 1 R1 + R2 + R3 + R4

R3 R4 R0

ALTERNATING CURRENT

02 4

The alternating current means voltage and electric current of which direction and capacity vary periodically. ¥ Frequency : Frequency of periodic variation per unit time. Marked by Hz. ¥ Period : The time required to complete the 1-time variation

ELECTRICITY OF ALTERNATING CURRENT Contrary to the direct current, the direction and capacity are varied for alternating current. It canÕt be obtained by only multipling electric current by voltage but the potential difference has an influence.

EFFECTIVE ELECTRICITY P (W) = V ´ I ´ COSq ¥ COSq (Inverse ratio) : It means the proportion of useful usage. For glow lamp and electric heater, it is 1, for electromotor, 0.5~0.8, and for fluorescent lamp, 0.6.

SUPERFICIAL ELECTRICITY S (V á A) = V ´ I Superficial electricity indicates the capacity how much current (A) can flow with how much voltage (V) to the alternating current instrument (transformer, generator, welding machine) or alternating current power source.

E L E C T R I C

S Y S T E M BASIC THEORY

SEMICONDUCTOR A material which has properties of conductor and insulator at the same time is semiconductor.

(The nature resistance of semiconductor is 10Ð5~102 ½ám)

PROPERTY OF SEMICONDUCTOR ¥ As connecting to the other metal or semiconductor, commutation or amplification can be performed. (Diode, transistor) ¥ Nature resistance is decreased or electric power is generated by lighting. (Photosensitive effect : Photo transistor, photovoltaic cell) ¥ Piezo effect : Electricity occurs by force. (press electric element) ¥ Hole effect : Conduction degree is changed by magnetic field ¥ Zee back effect : Electricity occurs by heat. (Temp. sensor) ¥ Never use above 80~150¡C.

ELECTRONIC ELEMENT RESISTANCE Made by insulated material such as carbon or nichrome wire. It distrubs the flow of electric current.

Symbol

Unit

Symbol

Unit

CONDENSER when electrode or steel piece composed by 2 conductors are filled with induced electricity, it will be condenser.

mF, pF

INDUCTOR It disturbs the changing of electric current in electric circuit.

Symbol

Unit mH

10 02 5

E L E C T R I C

S Y S T E M BASIC THEORY

SEMICONDUCTOR ELEMENT DIODE

10 02

In general, P type and N type semiconductors are connected. Each terminal is called as anode and cathode. If connected directly (Ò+Ó to anode, ÒÐÓ to cathode), the electric current will flow, and conndected reversely, the current will not flow.

K

A Anode

P type

N type

Cathode Anode Cathode Symbol

6

TRANSISTOR It is the typical TR or IC semiconductor. P type and N type are included, and connected in the order of PNP or NPN. 3 lead wires are specially welded, and each called emitter (E), base (B) and collector (C).

Emitter

P

N

P

Collector

Emitter

N

Base

E

P

N

Collector

Base

C

C

E

B

B

PNP type

NPN type

AMPLICATION OF TR When output signal is gained through collector as inputting little base current (input signal), it is called as amplication.

SWITCHING If electric current doesnÕt flow in the base, output will not be gained through collector, but if constant current is flows, output will be gained.

Therefore, switching the base ON/OFF, the current flowing to the emitter and collector will be ON/OFF.

E L E C T R I C

S Y S T E M BASIC THEORY

BIPOLAR TRANSISTOR (BJT) This is general type of transistor. When connecting (Ð) to (+) emitter of collector and flowing weak current between base and emitter, strong current will flow to collector and emitter.

IC C IB

VCC

B

E

VPB

10

IE

NPN type

FIELD EFFECT TRANSISTOR (FET) If general transistor is controlled by current applied to base, FET is power source control semiconductor of voltage control type which is controlled by voltage applied to gate.

After connecting (+) to drain terminal, (Ð) to souce terminal, current will not flow to drain or source if voltage isnÕt be applied to gate terminal. If (+) voltage is applied to gate terminal, strong current will flow between drain and source.

7 Gate

Source

Drain

N

N N type channel

Insulating film

FET Drain (D) VG (G) Gate (S) Source

Symbol

SEMICONDUCTOR ELEMENT This is a kind of power source control semiconductor, composed by PNPN joint 4 layer or more, and generally single direction 3-terminal SCR is used. Each terminal is called as anode (A), cathode (K) and gate (G). When connecting anode to Ò+Ó and cathod to (Ð), the current will not flow, but when flowing weak current to gate terminal, strong current will flow between anode and cathode.

In case of SCR, when turned on as voltage is applied to gate, it will keep conductance in spite of removing voltage of gate. To turn off the conductance, shut off the power source or apply the reverse voltage.

02

Cathode(K)

Gate

N P N P Anode(A)

SCR

K

G

ÒÐÓ

Ò+Ó

A Symbol

E L E C T R I C

S Y S T E M BASIC THEORY

ANALOGUE IC

10

This is comparator circuit. Power is supplied to ÔaÕ and ÔbÕ is earthed. When voltage is applied to input ÔdÕ, if larger voltage is applied to input ÔcÕ than ÔdÕ, output terminal ÔeÕ will flow voltage ÔaÕ. On the contrary, if smaller or same voltage is applied to input ÔcÕ, output terminal ÔeÕ will flow voltage of Vb(V).

In this case, the voltage applied to input ÔcÕ or ÔdÕ is called as reference voltage for fixed type, and variable voltage for varied type

02

a(Va)

Comparator

8

+

c

e

Ð Vd

Vc

d

b(Vb)

Vc>Vd : output (Va(V)) Vc<Vd : not output (Vb(V)) Operating codition of analogue IC

DIGITAL IC digital circuit, only 2 signals, high ÒHÓ and low ÒLÓ, are required. This signals are indicated by Ò1Ó for ÒHÓ, and Ò0Ó for ÒLÓ in number.

AND CIRCUIT In this circuit, when the switches A and B are ON at the same time, the output will be 1.

If any of them is OFF, the output will be 0.

Switch

Equivalent circuit

Logic circuit

+B

Output SWA

SWB

(1 : When the switch is closed

Input

A Input B

Output C

Truth table A

B

C

1

1

1

1

0

0

0

1

0

0

0

0

E L E C T R I C

S Y S T E M BASIC THEORY

OR CIRCUIT In this circuit, when either switch A or B is ON, the output will be 1.

If any of them is OFF, the output will be 1.

Switch

SWA

Equivalent circuit

Input

Logic circuit

A Output

Input

Output C

B

SWB

Truth table A

B

C

1

1

1

10

1

0

1

02

0

1

1

9

0

0

0

NOT CIRCUIT In this circuit, when the input is 1, the output will be 0. On the contrary, when the input is 0, the output will be 1.

Switch

Equivalent circuit

Logic circuit

Truth table

A

B

1

0

0

1

Output B

Input

When the switch is pressed, contact point is separated.

Input

Output

E L E C T R I C

S Y S T E M BASIC THEORY

SYMBOL AND FUNCTION ELECTRIC SYMBOL AND FUNCTION Symbol

Designation

Function

Thermistor

The resistance is changed according to the outside temp.

There are two types : Ð Thermistor with direct characteristics : When the temp. rises the resistance will be decreased. Ð Thermistor with inverse characteristics : When the temp. rises the resistance will be increased.

Diode

The current flows only one direction (marked by arrow).

The current canÕt flow in reverse direction against arrow.

This is also called as commutator used to change the alternating current into direct current.

10 02 10

Zener diode

Photo diode

Light emission diode

E B

E

Transistor

B C

A

A

Thyristor K

in

reverse

The current flows by lighting.

It is used for switching circuit generally.

If the current flows, light will be emitted.

It is usually used for pilot lamp.

NPN type in L.H, and PNP type in R.H. It is used for switching and amplification.

C

Photo transistor

G

It is usually used for voltage controller.

If current exceeding allowable limit flows direction, it will be conductive in an instant.

Namely, it is constantÐvoltage diode.

G

K

If lighted from outside, the current will flow.

It is a kind of photo sensitive element, and called as CDS.

It is similar to diode, but the element will be conductive only after the current flows to cathode.

It plays the same role of the relay.

E L E C T R I C

S Y S T E M BASIC THEORY

Symbol

Designation

Function

Piezo electric element

If power is applied, the current will flow.

Is is usually used for stress gauge, and also used for the ignition of electronic lighter or crystal oscillator of clock.

Battery

It means the power source, battery.

The long side is (+), and the short side is (Ă?).

10 02 11

Condenser

The current can be stored temporarily and discharged.

It restrains the spark on contact point.

Natural resistance, nichrome wire Resistor

Variable resistor

The resistance can be changed artificially.

It is like the volume of the radio.

It means the lamp.

Bulb

Double bulb

Winding coil

It means the lamp with double filament.

Tail light, head light

Solenoid, electromagnet, relay If the flow currents, it will be electromagnet for a while.

The same function as solenoid coil Magnetic

E L E C T R I C

S Y S T E M BASIC THEORY

Symbol

Designation

Function The same function as ignition coil

Transformer

10

This means the general switch.

Switch

02 12 Switch (Normal open)

It is not contatced at ordinary times, however contacts when pressing.

Horn switch, various kinds of switches

The wiring is not connected.

Disconnection

The wiring is connected with each other.

Connection

Earth to (Ă?) side.

Earth

E L E C T R I C

S Y S T E M COMPONENTS

TRAVEL MOTOR The travel motor in this machine is direct winding magnetized type magnetic draft motor. The starting torque is high and speed control is easy, so it is highly efficient for travel. High heatresisting insulated materal of F type (155ยกC) is used so that performance of the motor can be kept under high temperatrue caused by high speed rotation. Therefore, heat proof characteristcs is high compared to general motor with same output. The overheat is prevented by cooling fan inside of motor. The fan cover is installed ouside of cooling fan to prevent foreign materials from entering.

10 03 1

HYDRAULIC MOTOR The hydraulic motor is also direct winding magnetized type magnetic draft motor. It is adequate to lift, tilt and operate attachments.

The function or convenience is as same for travel motor.

E L E C T R I C

S Y S T E M COMPONENTS

CONTROL SYSTEM ¥ This system is consisted of travel control function by SCR chopper and hydraulic control function by contactor with large volume. It also performs protection for safety and self diagnostics.

10 03

¥ Specifications per function Ð Travel control function The traveling speed can be accelerated or decelerated by operator to keep optimum travelling condition according to machine condition. There are 4 modes : general travel mode, smooth travel as start mode, automatic torque increasing travel mode, bypass (high speed) travel mode

2 Ð Pluging brake Electric braking is applied as operating forward/reverse lever to change the travelling direction so that impact will be reduced and smoothly turned. Regeneration circuit works to regenerate the energy occured while pluging and charge the battery. Energy reduction, preventing overheat of motor and extending life of brush can be conducted. Ð Hydraulic control function Power is supplied to the hydraulic motor by use of contactor through input of hydraulic control switch. Structure is simple so trouble rarely occurs and maintenance is easy. Ð Self diagnostics The power will be shut off for safety if any trouble occurs in the internal contorl system.

After repairing, operation can be restarted.

E L E C T R I C

S Y S T E M COMPONENTS

INSTRUMENT PANEL Hour meter, battery indicator, etc. are arranged. When the fuses are cut by melting, it indicates the damaged fuse, and when parking brake is applied, it warns to the operator.

10 1

03

8

3

7

5 2 3

6 4

E L E C T R I C

S Y S T E M COMPONENTS

1. POWER CONTROL SWITCH It controls the max. current flowing to the travel motor. Turning it righthand, the mobile power and grade ability will be decreased but smooth acclerating will be accomplished. Turning it lefthand, the mobile power and grade ability will be increased. Turn the switch to ÒPÓ position on a slope, and turn it to ÒSÓ on an even ground. For smooth starting on an even ground, turn it to ÒSEÓ.

10 03

2. TRAVEL CIRCUIT WARNING LAMP It indicates that the fuse of travel circuit is blown. When the travel system doesnÕt work and this lamp turns ON, replace the fuse with specified capacity (275A).

4

3. HYDRAULIC CIRCUIT WARNING LAMP It indicates that the fuse of hydraulic circuit is blown. When the hydraulic system doesnÕt work and this lamp turns ON, replace the fuse with specified capacity (275A).

4. PARK WARNING LAMP It warns that the parking brake is applied.

5. HOUR METER It indicates the accumulated working hours of the machine. It is useful for control and plan of loading and unloading work, check of working efficiency, and periodic inspection.

6. VOLUMETER (BATTERY CHARGING INDICATER) It indicates the discharging condition of the battery. Turning the key switch to ÒONÓ, all the green lamps will light up if the battery is sufficiently charged. When the battery is discharged, the green lamps will be OFF from the left in order. If only the red lamp remains, recharge the battery immediately.

7. HEAD LIGHT/TAIL LIGHT SWITCH Turning the switch upwards, all the head lamp and tail light will light up. Turning it downwards, only the tail light will light up. The lights will be OFF when the switch is in neutral position.

8. OPTION SWITCH The options switches are provided for additional illuminations or alarm lamp. In addition, the option fuses are installed in fuse box.

E L E C T R I C

S Y S T E M COMPONENTS

ELECTRIC POWER STEERING SYSTEM (EPS) WHAT IS EPS? The general power steering system is operated by hydraulic power. However, the steering system adopted in this model is operated by electric power and composed of steering motor, controller, sensor and actuator.

CHARACTERISTICS OF EPS ¥ The steering motor is operated only the steering wheel is handled, so the energy can be saved. ¥ It works only while steered, so noise will be reduced greatly. ¥ The output of motor is increased or decreased in proprotion to the torque of steeling wheel, so the power output suitable for the work can be easlily obtained. ¥ As the intricate piece of pipes arenÕt be required for sutructural use and leakage doesnÕt occur, the system can be clean all the time.

WORKING PRINCIPLE ¥ When handling the steering wheel, the torque sensor detects the operating force and sends the singnals to the EPS controller. ¥ The controller decides the rotating speed and direction of EPS motor by the input signals, and supplies the motor with required current flow . ¥ The EPS motor will turn by current flow and the torque will be increased by the reduction gear of actuator, so the steering force will be delivered to the rear axle. In this way the steering can be performed.

10 03 5

E L E C T R I C

S Y S T E M COMPONENTS

ACCELERATOR FEATURES

10 03 6

It is no point of contact type. The slit plate is moved as interlocked with accelerator between 4 infrared rays luminous diodes and photo transistor.

In neutral condition, the slit shuts off the signal between infrared rays luminous diode and photo transistor. When the accelerator pedal is pressed, the slit will move so that the infrared rays can pass through the holes in the plate for the photo transistor to take the signals. The output can be subdivided as 16 steps in accordance with the change of pedal.

OPERATIONS The accelerator operates the forward/reverse contactor by micro switch and cam which is interlocked with pedal so that the power circuit can be connected.

When the pedal is operated fully, the bypass micro switch will work to operate the bypass contactor a few seconds later.

E L E C T R I C

S Y S T E M COMPONENTS

DCÐDC CONVERTER DCÐDC converter is used for accessary operated by 12V converted from main power of 48V. Warning system and the lights are used by 12V.

10 03 7

Under front foot rest (LH of the machine)

E L E C T R I C

S Y S T E M COMPONENTS

FUSE BOX The fuse box for electric accessory parts is arranged under the foot rest to perform maintain the blown fuses easily.

10 03 8

Under front footrest

E L E C T R I C

S Y S T E M COMPONENTS

EPS CONTROLLER Electric power steering (EPS) system is adpoted to eliminate the operatorÕs fatigue. EPS controller is connected to outer parts as followings.

10 6ÐPIN CONNECTOR

RH of the machine

03 9

E L E C T R I C

S Y S T E M COMPONENTS

BATTERY PRINCIPLE OF BATTERY PRINCIPLE OF BATTERY

10 03 10

The battery converts the electric energy to chemical energy and store. Storing the energy is called as charging, and using the energy by converting to electric one is called as discharge.

If the positive plate (lead peroxide) and the negative plate are insulated in thin sulphuric acid electrolyte by lead battery usually used for fork lift, electromotive force of approx. 2.13V will be generated. (+) Electrolyte + 2H2SO4 PbO2 Lead peroxide Suphuric acid

+

(Ð) Discharge (+) Electrolyte (Ð) ® + 2H2O + Pb Charge PbSO4 PbSO4 Lead Lead sulphuric Water Lead sulphuric

Ð Chemical change during discharge When both terminals of battery are loaded, discharge will begin. Sulphuric acid and active elements of positive, negative plates are reacting to form lead sulphuric. During discharging, sulphuric in electrolyte is consumed so that the density of electrolyte will be thiner. (Specific gravity is decreased.)

The consumed quantity of sulphuric is in proportion to the electric discharge volume. So, the discharge volume can be obtained to measure the density (specific gravity) of electrolyte. Ð Chemical change during charge The lead sulphuric in positive, negative plates formed during discharge will be decomposed by flowing electric current to both terminals. Sulphuric acid is discharged to electrolyte, and the density will be thicker so that the specific gravity can recover original level. Positive plate is reconstructed to the plate before electric discharge so that electricity can be discharged agaom.

E L E C T R I C

S Y S T E M COMPONENTS

COMPOSITION OF BATTERY (CELL) The battery is composed of positive plate and negative plate which store electric energy, isolate plate which prevent shortÐcircuit of both plates, electrolyte, and case and cover.

10 03 11

RELATION BETWEEN ELECTROMOTIVE FORCE AND SPECIFIC GRAVITY Relation between electromotive force and specific gravity can be calculated as follows for each cell.

Electromotive force (E) = Specific gravity of electrolyte + 0.85

CAPACITY OF BATTERY The capacity means the discharge current volume of full charged battery which discharge to the specifed voltage with fixed electric current. The unit is Ampereáhour (AH).

¥ Relation of capacity and discharge current

110 100

Capacity (%)

Electric discharge rate indicates the ratio of discharge current per unit time.

Although the batteries have same capacity, the discharge current can be different according to electric discharge rate. The capacity is in inverse proportion to the discharge current. Because the supply of sulphuric acid to the plate will be late according to the late spreading of electrolyte while discharging electricity.

90 80 70 60 50 40 1

2

3

4

5

6

7

Electric discharge rate (HR)

8

9

10

E L E C T R I C

S Y S T E M COMPONENTS

★ Dischage Rate per Rate per Rate per Rate per Rate per

10 12

battery with = 400AH ´ = 400AH ´ = 400AH ´ = 400AH ´ = 400AH ´

capacity of 400AH/5HR 1/5H = 80A 0.93/5H = 93A 0.85/5H = 113A 0.75/5H = 150A 0.6/5H = 2400A

¥ Relation of capacity and temperature As the temperature of battery is low, the capacity will be decreased.

The followings are reasons. Ð The reaction of active element will be weakened as the spreading electrolyte is difficult. Ð Electric resistance is increased, but electromotive force is decreased. Ð Much loss (gas emission) during charge

Capacity per 5hr (%)

03

current of 5hr (5HR) 4hr (4HR) 3hr (3HR) 2hr (2HR) 1hr (1HR)

110 100 90 80 70 60 50 -20

-10

0

10

20

30

40

50

Battery temperature (¡C)

LIFE OF BATTERY AND DISCHARGE VOLUME The life of battery is indicated as used year or chargeádischarge frequency until the volume is decreased to 60~80% of rated volume.

¥ Life and discharge volume The life of battery is in inverse proportion to discharge volume. Take care of overdischarge.

Degree of discharge volume %

Chargeádischarge frequency (Cycle)

Used year as daily 1 time chargeádischarge

100 90 80 75 70 60 50

600 750 900 1000 1100 1300 1500

2.0 2.5 3.0 3.3 3.7 4.3 5.0

E L E C T R I C

S Y S T E M COMPONENTS

¥ Life and charge volume It is recommended to charge as 110~120% of discharge volume.

If overcharged, the battery temperature rises causing electric decomposition of water at the end of charging. The electrolyte is decreased by gas emission, so life will be highly shortened.

¥ Life and impurities in electrolyte If acetic acid, hydrochloric acid, glacial acetic acid, sulfurous acid or chlorine is contained in electrolyte, the plate will be corroded. Therefore the life will be highly shortened and the magnetic discharge volume will be increased.

The iron or manganese, which is easily oxidized, shorten the life of negative plate.

Therefore, use only distilled water to refill the electrolyte, and fasten the cap while cleaning to prevent foreign material from entering.

CONVERSION OF SPECIFIC GRAVITY ACCORDING TO TEMPERATURE The specific gravity of battery is in inverse proportion to temperature.

The increase or decrease per 1¡C is 0.0007.

Battery specific gravity at 25¡C = Measured specific gravity + 0.0007 (Present temp. Ð25) Example) Converted for 25¡C, if temperature of electrolyte is Ð5¡C and specific gravity is 1.280.

1.280 + 0.0007(Ð5Ð25) = 1.259

CAUTIONS FOR USE The main causes of troubles of battery are overcharge, overdischarge or lack of electrolyte.

Check the battery periodically as interval of 1~2 times in a week. ¥ If it is lowered to 42V or less (red zone) under noload condition, it is overdischarged.

Immediately charge. ¥ If daily usage is very short, reduce the charging hour or donÕt charge. ¥ During chargeádischarge or overdischarged, the moisture in electrolyte will evaporate. Check the electrolyte level 1~2 times in a week and fill the distilled water. ¥ Dirt or overflown electrolyte on the battery surface will cause leakage of electricity. Inspect periodically and clean with water if necessary. ¥ While charging or discharing, especially end of charging, the water in electrolyte will be decomposed into hydrogen and oxygen. The emitte gases are imflammable (explosive), so keep away from the fire.

10 03 13

E L E C T R I C

S Y S T E M COMPONENTS

TROUBLE DIAGNOSTICS FOR BATTERY

10 03 14

¥ Battery temperatrue is high during charge. Ð The electrolyte temperatrue rises 15~25¡C during charge.

1. When the temperature before charge was high 2. When the electrolyte is lack 3. In case of overcharge 4. In case of short circuit in battery ¥ Electrolyte is overflown during charge. Ð The electrolyte volume will be increased after charge.

1. When the electrolyte is more than specified volume 2. In case of overcharge ¥ Electrolyte is reduced rapidly. Ð The electrolyte naturely evaporate, so refill with distilled water per 1~2 times per week.

1. When the outside temperature is high 2. In case of overcharge 3. In case of short circuit in battery 4. When the case is broken ¥ After charge, the specific gravity will not increase. Ð The specific gravity varies with temperature, so compare with standard by converting to 25¡C. 1. When the outside temperature is high 2. In case of overcharge 3. When the charger is damaged 4. When electrolyte is more than specified value 5. When distilled water is refilled after charge 6. Sulphuric acid is lack in electrolyte ¥ Use life of battery is short. Ð When the volume is less than 80% of the capacity, the life is ended.

1. When the electrolyte is lack 2. When the life is ended 3. A lot of impurities in electrolyte 4. When some of the group battries are poor 5. When the fork lift itself is damaged.

E L E C T R I C

S Y S T E M COMPONENTS

CHARGER The charger is used to recharge the battery which is discharged by coverting the AC to DC.

STRUCTURE POWER PILOT LAMP (RED LED) When the power is supplied to charger and the battery plug is connected, magnet swithc will operate and this lamp will be ON. After charging, it will be OFF.

CHARGE PILOT LAMP (YELLOW LED) If charging proceeds 85% (58.5+0.5V), this lamp will be ON together with power pilot lamp.

CHARGE COMPLETION PILOT LAMP (GREEN LED) When the battery plug is connected, this lamp will be ON for a minitue and thel OFF. If charge is completed, it will be ON again.

OVERLOAD RELAY PILOT LAMP (WHITE LED) When temperature relay of magnet switch is operated by overload, this lamp will be ON and the charge stop. Reset by pushing the button of OCR, if no abnormality.

EMERGENCY STOP SWITCH (RED PUSH BUTTON AND SWITCH) If charge must be interrupted during charging, press this switch to stop all operation. When recharge is required, disconnect the plug and then connect again.

AMPERE METER (DC) It indicates the charge current flowing from charger to battery.

10 03 15

E L E C T R I C

S Y S T E M COMPONENTS

RADIATING FIN (HEAT SINK) It cools the heat generated by diode during commutating so that the diode can be protected.

DIODE

10 03 16

Change the alternating current into direct current by use of the characteristics that the current flows in one direction. 6 diodes are used to commutate the 3Ðphase alternating current.

DIVIDER It is a kind of sensor to measure the charge current. It supplis fine voltage to the ampere meter.

FUSE It is connected to charger output and will be blown to prevent diode or trans from burning when short circuit or the ploes of battery are confused.

DIODE PROTECTION CIRCUIT The diode as a kind of semiconductor will be easily broken by instant high voltage, so it must be protected by use of condenser.

TROUBLE DIAGNOSTICS CHARGER WILL NOT OPERATE AT ALL ¥ Power is not supplied. (Green lamp is ON.) ¥ The power source is not a kind of 3Ðphase power. ¥ 1 phase among 3 phases (R, S, T) is short. ¥ The coil of magnet switch is cut. ¥ The voltage of battery is less than 36V (48V). ¥ The connection between charger and battery is improper. ¥ Aux. trans is poor. (In case of 380, 440V) ¥ Fuse for output is blown.

GREEN LAMP WILL BE ON BUT NOT BE OPERATED ¥ Overload relay (OCR) is operated. (Overload LED is ON.) ¥ The contact of magnet switch is poor. ¥ Charger PC is improper. (Try to short the A point.)

E L E C T R I C

S Y S T E M COMPONENTS

CHARGE CANÕT BE COMPLETED ¥ The voltage for input is low. (Adjust tap.) ¥ Battery is poor. (Internal short circuit) ¥ Charger PCB is poor. (OFF when B contact point is short while yellow lamp ON (53.5V))

EXCESSIVE NOISE DURING CHARGE ¥ Diode is short. ¥ Battery is poor. (Internal short circuit) ¥ Iron core of trans is separated by vibration.

10 03 17

FUSE IS BLOWN ¥ Contact of fuse is poor. ¥ Over current is supplied. ¥ Terminal for output is short. ¥ Ò+Ó terminal and ÒÐÓ terminal for output are confused. ¥ Ò+Ó plug and ÒÐÓ plug for battery are confused.

CHARGER PCB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

DC (+) Earth Emergency stop switch Earth LED kit (+) PL.2 (YL) PL.1 (RL) PL.3 (GL) NC AC output AC input/output COM AC input

(A) : Circuit inspect function short pin (B) : Manual charge function short pin (C) : Work condition check function pilot lamp (LED 3f red) (D) : Overvoltage set voltage VR (E) : 85% charge set voltage VR

E L E C T R I C

S Y S T E M COMPONENTS

SPECIFICAITON OF CHARGER Classificatioon

10 03

Basic specification

18

Standard

Remarks

Charging type

SemiÐstatic voltage

Commutating type

3Ðphase electric wave commutating

Cooling type

Natural draft cooling

Charging hour

8 ± 2(H) AC 3Ðphase 60Hz

50Hz is

220V/330V/440V, respectively

option

Input power voltage Input allowable range

Input voltage ± 10%, Frequency ± 5%

Size (L´W´H)

460(mm)´460(mm)´680(mm)

Chainging begining voltage

DC 51 ± 2V

Electric

Charging ending voltage

DC 66 ± 2V

characteristics

Overvoltage set voltage

DC 66 ± 0.5V

Charging efficiency

More than 65%

SPECIFICAITON OF BATTERY Class.

Unit

Rated specification

Voltage

V

48

Volumme

Weight

Size

AH/5H

kg

L(mm)´W(mm)´H(mm)

CEP15, CEP18

450

CEP20

500

CEP25

580

CEP15, CEP18

766

CEP20

848

CEP25

891

CEP15, CEP18

970´664´470

CEP20

970´730´470

CEP25

970´730´470

Remarks

E L E C T R I C

S Y S T E M COMPONENTS

SPECIFICAITON OF MAIN ELECTRIC PARTS SPECIFICATION OF TRAVEL MOTOR Rated specifications Classification

Remarks CEP15

CEP18

CEP20

CEP25

10

Structure

D.C. direct winding type

Cooling type

Internal FAN

03

No. of poles

4

19

Rated output (kW)

5

6

Rated voltage

45V

Rated hour

1hr

Rated rpm

1500

1600 F

Insulation grade 70.3

Weight

74.3

SPECIFICATION OF HYDRAULIC MOTOR Rated specifications Classification

Remarks CEP15

CEP18

CEP20

Structure

D.C. direct winding type

Cooling type

Internal FAN

No. of poles

4

Rated output (kW)

7.5

8.5

Rated voltage Rated rpm

45V 1500

1700

Insulation grade Weight

CEP25

F 37.4

44.7

SPECIFICATION OF BUZZER AND HORN Classification

Specification

Remarks

Back up buzzer

12V

1EA

horn

12V

1EA

E L E C T R I C

S Y S T E M FUNCTION OF CONTROLLER

POWER CONTROL TRAVEL CONTROL Accoring the the tilt degree of accelerator, the power supplied to the travel motor will be controlled for operatorÕs convenience.

Ð SMOOTH STARTING When starting, abrupt impact will be reduced to achieve smooth starting.

10 04 1

Ð AUTOMATIC TORQUE INCREASE While travelling, keep the current limit high as 30% for a short time just before performing bypass so that the impact will be reduced.

Ð BYPASS TRAVEL When travelling, max. power is supplied to get high gradeability so that durability will be increased by reducing burden for controller.

Ð PLUGING BRAKE When changing directions abruptly (changing over forward/reverse lever abruptly), use electric brake function as required.

HYDRAULIC CONTROL ¥ Tilt operating

E L E C T R I C

S Y S T E M FUNCTION OF CONTROLLER

ADJUSTMENT START CURRENT ADJUSTMENT

10 04 2

Adjust the current supplied to the travel motor from the initial output of accelerator. (Usually the degree that tire will not slip as sudden start.)

Adjust as following procedures. Ð Restrict the machine.

(Keep the tooth end on the lock stopper (wall) and apply the parking brake.) Ð Disconnect the battery plug and turn the start switch OFF. Ð Remove the rear cover of machine. (Cover controller) Ð Install the ammeter (hook meter) to the right cable (AA) of SCR unit. Ð Turn the travel power switch to <P>. Ð Connect the battery plug, and turn the start switch to ON. Ð Push the forward/reverse lever to FORWARD. Ð Depress the accelerator pedal slowly until forward contactor is operated. (Confirm the chopper sound.) Ð Check the value of ammeter (hook meter) is <40 ± 10(A)>. If different, adjust the value by turning ST (VR5). (VR5 : Located on the control board) ★ Start current is related to the current limit. So adjust as repeating the following procedures ; a Adjusing start current ® b Adjusting current limit ® c Adjusting start current ® d Adjusting current limit

CURRENT LIMIT ADJUSTMENT It means the max. current which the controller can control while travelling, and the result is same as adjusting initial acceleration or fine operation.

Adjust as following procedures, and it is normally performed together with start current adjustment. Ð After adjusting start current, depress the accelerator pedal fully while depressing the brake. Ð Confirm that the value by ammeter (hook meter) is 330 ± 15(A) for CEP15/18 and 385 ± 15(A) for CEP20/25. Ð If different, adjust the value by turning CL (VRI). (If depressing accelerator pedal more than 4 seconds while brake is worked, the machine will be forced to bypass travel condtion causing impact to machine and damage to parts. Never depress the accelerator more than 3 seconds for current limit adjustment.) (VR1 : Located on the control board)

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

DISASSEMBLING/ASSEMBLING TRAVEL MOTOR ASSÕY ! Before disassembling electric motor assÕy, put wedge shape wooden blocks so that the machine will not move. ¥ Disassemble the front foot rest. ¥ Disconnect the cable connected to travel motor. ¥ Lift the motor by wire rope as it is strained, and loosen the tightening bolt to disassemble the motor. ¥ Assemble as reverse order of disassembly.

10 05

DISASSEMBLING/ASSEMBLING HYDRAULIC MOTOR ASSÕY ¥ Disassemble the left side cover. ¥ Disconnect the cable connected to hydraulic motor. ¥ Disconnect the hose connected to hydraulic pump. ¥ Loosen the mount bolt of frame and pull out it. ¥ Disassemble the hydraulic pump. ¥ Assemble as reverse order of disassembly.

1

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

ELECTRIC MOTOR (TRAVEL, HYDRAULIC, STEERING) REMOVAL TRAVEL MOTOR

10 05 2

! Before

disassembling electric motor assÕy, put block under the tires so that the machine will not move.

¥ Disassemble the brake bracket. ¥ Remove the lead wire from terminal.

drive

motor

1. Brake bracket 2. Lead wire

3. Tightening bolt 4. Motor assÕy

Removing drive motor

HYDRAULIC MOTOR ¥ Disassemble the left side cover. ¥ Disconnect the cable connected to hydraulic motor. ¥ Disconnect the hose connected to hydraulic pump. ¥ Loosen the mount bolt of frame and pull out it. ¥ Disassemble the hydraulic pump.

STEERING MOTOR ¥ Disassemble the right side cover. ¥ Disconnect the cable connected to motor.

1. Cable 2. Hydraulic hose 3. Nut, spring, washer, bolt,

washer, cushion rubber 4. Motor assÕy 5. Hydraulic pump

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

STRUCTURE AND COMPONENTS TRAVEL MOTOR 1.

2.

3.

4.

5.

6.

7.

8.

Yoke End cover (D) End cover (C) Brush, holder assÕy Spring Brush Field coil assÕy Field core

9.

10.

11.

12.

13.

14.

15.

Armature assÕy Fan Band cover (C) Terminal Band cover (D) Stud bolt Rubber cap

10 05 3

Travel motor structure

HYDRAULIC MOTOR 1.

2.

3.

4.

5.

6.

7.

8.

Yoke End cover (D) End cover (C) Brush, holder assÕy Spring Brush Diode Field coil assÕy

9.

10.

11.

12.

13.

14.

15.

Field core Armature assÕy Fan Band cover (C) Terminal Band cover (D) Bearing

Hydraulic motor structure

STEERING MOTOR 1.

2.

3.

4.

5.

6.

7.

Yoke Connector assÕy Lock washer bolt Armature assÕy Bearing End cover End cover assÕy

8.

9.

10.

11.

12.

13.

Brush hold assÕy Spring Brush Bolt Cover Diode

Steering motor structure

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

DISASSEMBLING PROCEDURES AND CAUTIONS TRAVEL AND HYDRAULIC MOTOR

10 05 4

¥ Disassemble the band cover. ¥ Remove the brush wire of brush holder. ¥ Remove the brush and diode (hydraulic motor). ¥ Disassemble the end cover (C). (Make a mark between end cover (C) and yoke, end cover (D) and yoke to assemble easily.) ¥ Disassemble the brush holder assÕy.

! Do not disassemble the brush holder assÕy any more. ¥ Disassemble the end cover (D). ¥ Disassemble the armature assÕy. ¥ Disconnect the wires of field coil.

! Be careful the wiring and do not damage the lead bar. ¥ Remove the field coil.

1. Nut, bolt, band cover 2a. Brush 2b. Brush 3. Bolt, spring washer 4. Bolt, spring washer, plain washer, brush holder 5a. Bearing.

5b. Bearing 6. Screw, end cover (D), stud bolt, bearing 7. Armature assÕy 8. Bolt, spring washer 9. Field coil, field core

Disassembling procedures for travel motor

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

10 05 5

1.

2a.

2b.

3.

Nut, bolt, band cover Brush Brush Bolt, spring washer, end cover (C) 4. Bolt, spring washer, brush holder assĂ&#x2022;y 5. Bolt, spring washer, washer, diode

6. Bearing 7. Bolt, spring wahser, end cover (D), bearing 8. Armature assĂ&#x2022;y 9. Bolt, spring washer 10. Field coil, field core

Disassembling procedures for hydraulic motor

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

INSPECTION ARMATURE ASSÕY Insepct the commutator surface for damage.

10 05 6

REPAIR ¥ Perform lathe turning for commutator.

! While performing lathe turning, set the center of commutator precisely.

Condition of commutator

¥ Perform undercutting. ¥ After undercutting, finish the surface with sand paper (#400). Clean with compressed air.

REPAIR LIMIT OF COMMUTATOR Unit : mm Travel motor Item

Hydraulic motor

Model Type

Std. dim.

Limit

Type

Std. dim.

Limit

CEP15

DT-1500-5AA

104

99

DTL-7.5PJ-1550C

90

85

CEP18

DT-1500-5AA

104

99

DTL-8.5HSF-1700

90

85

commutator CEP20

DT-1600-6AB

104

99

DTL-8.5HSF-1700

90

85

CEP25

DT-1600-6AB

104

99

DTL-8.5HSF-1700

90

85

O.D of

UNDERCUT DEPTH Unit: mm Travel and hydraulic motor

0.5~1.0

Steering motor

0.8~0.85

Repair limit and undercut depth

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

MEASURING FOR INSULATION

! Before measuring clean with compressed air.

MEASURING METHOD BY VOLTÐOHM METER ¥ Adjust the knob so that the measuring of voltÐohm meter is in k½ range. ¥ Contact the (+) terminal to (Ð) terminal of meter, and adjust the level of 0½. ¥ Contact the (+) terminal of meter to the commutator, (Ð) terminal to the armature shaft, and measure the insulating resistance power.

10 05 7

Measuring for insulation

MEASURING METHOD BY MEGA TESTER ¥ Contact the (+) terminal to the commutator to measure the insulating resistance power. ¥ Contact the (Ð) terminal to the armature shaft to measure the insulating resistance power.

ARMATURE SHAFT ¥ Confirm the armature shaft and serration or spline of coupling for wear or deformation. If heavily deformed or worn, replace it.

Travel and hydraulic motor

More than 0.5M½ (DC 500V)

Steering motor

More than 0.5M½ (DC 500V)

BRUSH, BRUSH HOLDER AND SPRING ¥ Measuring brush wearing If the wearing limit line is marked on brush, this line is wearing limit. If there isnÕt any mark, measure the brush height to compare with wearing limit dimension.

¥ Measure the clearance between brush and brush holder.

1. Carbon brush 2. Commutator

3. Brush holder 4. Spring

Wear limit and brush clearance

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

SPECIFICATION Item

Direction

Clearance

Width

0.3~0.55

Length (1 brush)

0.5~0.9

Length (2 brushes)

1~1.8

Clearance between brush and holder

10 05 8

CONFIRM THE CONTACT SURFACE OF BRUSH ¥ Repair or replace if the condition is poor.

1. Brush

2. Commutator Contact surface of brush

REPAIR ¥ Insert sand paper (#400) between commutator and brush. ¥ Rotate the commutator to repair the contact surface. ¥ After repairing, clean with compressed air.

MEASURING LOAD OF BRUSH SPRING Measurement

1. Brush 2. Commutator

3. Sand paper

Contact surface of brush

¥ Hang the spring on the spring scale, and pull the direction of arrows to measure the load.

Confirm the values for 4 springs are all the same.

! 1. In case of steering motor, measure for 2 springs.

2. If the spring and brush are rusted, replace them.

Measuring spring load

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

FIELD COIL MEASURE THE INSULATED RESISTANCE. Measurement Refer to ÔMeasuring armature assÕy.

for

insulationÕ

(P)

of

10 05 9 Measuring for insulation

DIODE MEASURING DIODE ¥ The diode is assembled inside of hydraulic motor. When measuring resistance, remove the diode or disconnect the lead wire.

1. Diode 2. Brush holder

3. Brush 4. Spring

Contacting face of brush

MEASURING PROCEDURES ¥ Adjust the knob so that the measuring of voltÐohm meter is in ´ 1½ range. ¥ Contact the terminal so that the needle of meter will point 0½. ¥ Judge the condition of diode as contacting the terminal alternately to anode (A) and cathode (K) of diode.

Criteria for judgement No.

+

Ð

Resistance

1

K

A

¥

2

A

K

10~100½

Inspection of diode

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

ASSEMBLING PROCEDURES ASSEMBLING FIELD COIL AND MEASURING INSULATION JOINT OF FIEL COIL AND FIELD CORE

10 05

0.9~1.1 kgám

! Assemble the field coil tightly. If loose, repair it.

10

1. Field core

REPAIR

2. Field coil

Connection of field core

¥ Remove the field core and field coil. ¥ Prepare the insulating sheet. (ex : Nomex) ¥ Insert the insulating sheet between field core and field core. ¥ Wind the insulating sheet and field coil with glass tape, and then connect to the field core.

MEASURING RESISTANCE

Field coil and field core

Insulating resistance : More than 0.5½ (DC 500V Mega test)

MEASUREMENT

Insert of insulating sheet

¥ Contact the (Ð) wire to the yoke, (+) to the field coil.

Connect the terminal of field coil by use of lead wire. Arrange the yoke and bolt of terminal so that the clearance between them is more than standard value.

Min. clearance

More than 3.2mm

Measuring insulation

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

ASSEMBLING BRUSH HOLDER When only the brush holder is replaced, set the center precisely.

TIGHTENING TERMINAL BOLT

10

0.9~1.1 kgám

05 11 1. Diode (Hydraulic motor) 2. Brush holder

INSPECTING MOTOR ASSÕY

3. Diode 4. Locker

Assembling brush holder

Check the abnormal noise of motor and commutating condition of brush.

CONNECTION OF MOTOR DRIVE MOTOR ¥ Connect the (+) terminal of battery to (A) of motor. ¥ Connect the (Ð) terminal of battery to (F) of motor. ¥ Connect the (AA) terminal to (FF) of motor.

HYDRAULIC MOTOR ¥ Connect the (+) terminal of battery to (A) of motor. ¥ Connect the (Ð) terminal of battery to (FF) of motor.

! Diode is assembled inside of motor. Be careful the wiring connection.

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

MEASURING INSULATION OF MOTOR ASSÕY MEASURE

10 05 12

¥ Contact the (Ð) terminal of mega tester to the stud bolt for mounting motor assÕy, (+) terminal to the lead wire.

! 1. In case of hydraulic motor, remove the diode or short out anode (A) and cathode (K).

2. While measuring, do not touch the terminal of lead wire.

Measuring insulation of electirc motor assÕy

TROUBLE DIAGNOSTICS Phenomenon

Cause

1. Abnormal noise

(1) (2) (3) (4)

2. Arc

(1) Commutating of brush is poor.

(2) Commutating surface is rough.

Repair, replace Repair, replace

(1) Poor adjustment of current limit or pluging current, or partial short of armature assÕy (2) Poor rotation

Adjust, replace

3. Heating

(1) Armature shaft and coupling spline are worn.

(2) Drive gear is improperlly adjusted or worn, or bearing is broken.

(3) Poor adjustment of current limit (4) Adverse operation

Replace Replace

4. Abnormal noise and excessive heating after mounting

Bearing is poor.

The center of armature shaft is not correct.

Cooling fan is loose.

Field core tightening bolt is loosened.

Countermeasure Replace Repair, replace Replace Retighten

Replace

Adjust Care

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

DISASSEMBLY / ASSEMBLY CONTROL UNIT ! Before disassembling control assÕy, turn the switch OFF and disconnect the battery plug. ¥ Remove the rear cover of counterweight. ¥ Remove the wires and cables from control assÕy. ¥ Loosen the lock nut of control assÕy to remove the assÕy. ¥ Assemble in reverse order of disassembly.

TRAVEL CONTACTOR ASSÕY ! Before disassembling contactor assÕy, turn the switch OFF and disconnect the battery plug. ¥ Remove the rear cover of counterweight. ¥ Remove the wires and cables from contactor. ¥ Loosen the lock nut of travel contactor assÕy to remove the assÕy. ¥ Assemble in reverse order of disassembly.

HYDRAULIC CONTACTOR UNIT

! Before disassembling contactor assÕy, turn the switch OFF and disconnect the battery plug. ¥ Loosen the lock bolt of left side cover. ¥ Remove the contactor cover. ¥ Remove the wires and cables from contactor. ¥ Loosen the lock nut of hydraulic contactor assÕy to remove the assÕy. ¥ Assemble in reverse order of disassembly.

STEERING CONTACTOR UNIT

! Before disassembling contactor assÕy, turn the switch OFF and disconnect the battery plug. ¥ Loosen the lock bolt of right side cover. ¥ Loosen the lock bolt of contactor (2~3 threads) to remove the cover. ¥ Remove the contactor wires. ¥ Remove the wires for steering filter. ¥ Disassemble the steering contactor assÕy. ¥ Assemble in reverse order of disassembly.

10 05 13

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

¥ CEP15/18 19(2) 25(2)

3 9 11

6

10

26

13

21 23

24 (2) 22 (2)

05

24 22 23 24 (4) (4)22 (4)

14

14 35 37 (2) 1 2

36

10 40 (4) 39 38 19(2) (4) (4) 25 (2) 27

43,44

27 (2) 4

5

30

45

7

46

8

19 (2)

25 (2)

42 26 26 17 18

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

13.

14.

17.

Base Heat sink Heat sink Heat sink SCR unit SCR unit Diode Diode Diode Insulating sheet Insulating sheet Coil Condenser Power board

49 48 41

47

18.

19.

21.

22.

23.

24.

25.

27.

30.

31.

32.

33.

34.

35.

33 (3) 32(3)

34 31(3)

Control board Cup Resistor Cross recess screw Plain washer Spring washer Bolt Bolt Sensor assÕy Nut Spring washer Plain washer Bar Transformer

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

Terminal plate Bolt Nut Spring washer Plain washer Case assÕy Case Cover Packing Name plate Cap Fan head screw Spring washer Plain washer

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

¥ CEP20/25 3

19(2) 25(2)

9

6

11 26

13

21 23 24 (2) 22 (2) 14

10

24 22 23 (4) 24 (4) 22 (4)

05 15

35 37 (2)

20 26 1

2 36 10 40 (4) 39 38 (4) (4) 19 (2) 25 (2) 8 43,44

27 27(2) 5

4 30

45

7

46

19(2)

42

25(2)

26 26 17 18

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

13.

14.

17.

Base Heat sink Heat sink Heat sink SCR unit SCR unit Diode Diode Diode Insulating sheet Insulating sheet Coil Condenser Power board

49 48 41

47

18.

19.

21.

22.

23.

24.

25.

27.

30.

31.

32.

33.

34.

35.

33 (3) 32(3)

34 31(3)

Control board Cup Resistor Cross recess screw Plain washer Spring washer Bolt Bolt Sensor assÕy Nut Spring washer Plain washer Bar Transformer

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

Terminal plate Bolt Nut Spring washer Plain washer Case assÕy Case Cover Packing Name plate Cap Fan head screw Spring washer Plain washer

Contactor hyd.

(L.H of machine)

Contactor dirve (Drive contactor)

Contactor EPS (R.H of machine)

Contactor drive (Inside of counterweight at rear of machine)

16

05

Contactor EPS (Steering contactor)

Contactor hyd.

(Hydraulic contactor)

E L E C T R I C S Y S T E M DISASSEMBLY/ASSEMBLY

10

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

COMPONENTS OF TRAVEL CONTACTOR ASSÕY 16 17

15

14

10

F-D

40A

05

F-D

17

7

6

9,18,19

3

2

8

4 6

5 13 11

11,12 10

1.

2.

3.

4.

5.

6.

7.

8.

9.

Base Contactor (FWD/REV) Contactor Bracket Terminal Fuse (275A) Fuse (40A) Cable Screw

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Nut Plain washer Spring washer Wire harness CableÐ5 CableÐ6 CableÐ7 CableÐ4 Plain washer Spring washer

1

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

COMPONENTS OF CONTACTOR ASSÃ&#x2022;Y (EPS & HYD & BYPASS)

Screw

10 05 18

Nut Contac-A

Contac-Com

Coil

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

COMPONENTS OF CONTACTOR ASSÃ&#x2022;Y (FWD / REV)

Screw Bolt

10

Contac-A

05 19

Contac-Com Bolt Contac-B

Coil

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

INSPECTING/CORRECTING CONTACTOR ! When

inspecting and correcting the control, disconnect the battery plug.

10 05 20

INSPECTING CONTACTOR (EVERY 50 HOURS) Ð If the contact point surface is not smooth, finish with sandpaper (#400). (Insert the sandpaper between contact points, adhere 2 contact points with hand, and pull out the sandpaper. Repeat this operation until the surface will be smooth. Ð If the surface is heavily damaged or melted, replace the relevant parts in accordance with the table.

Standard height

Limit

0.8 mm

Less than 0.4 mm

Hydraulic

1.5 ± 0.1 mm

Less than 0.8 mm

Bypass

1.0 ± 0.1 mm

Less than 0.5 mm

Steering E.P.S

0.7 ± 0.1 mm

Less than 0.3 mm

Forward/Reverse A

★ Contact point of contactor Contact name

Contact common

Contact A

Contact B

Contact part number 8023829 8023830 8023831 8023832 8023833 8023834 8023835 8023836 8023837

Forward/Reverse v

Using contactor Hydraulic Bypass v v

v v v v v v

Ð If more than 10 strands of ribon wire are cut, replace the wire.

INSPECTING SOLENOID Ð Check the both terminals of solenoid with multiÐtester and confirm the value.

Forward/Reverse Hydraulic Bypass Steering E.P.S

Steering E.P.S

77 ± 10%(½) 75 ± 10%(½) 78 ± 10%(½) 192 ± 10%(½)

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

INSPECTING CONTACT POINT GAP It means the gap between fixed contact point and driving contact point to keep the suction/separation voltage.

If it exceeds the standard height, move the fixed contact point with (Ð) screwdriver to adjust the height.

Contactor Forward / reverse Hydraulic Bypass Steering E.P.S

10

Standard height (C) 2.3 ± 0.1mm 5.1 ± 0.1mm 3.8 ± 0.1mm 2.4 ± 0.1mm

05 21

SEPARATION OF CONTACT POINT Ð Measure the separation of fixed contact point and drive contact point for suction in order to prevent contact point from damage by uneven melting as making the contact area of the points be maximum. Ð If exceeding standard value, move the fixed contact point to adjust.

SUCTION SEPARATION VOLTAGE The suction/separation voltage is magnetized voltage for coil authorization to achieve high efficient of contact point operating.

Contactor Forward / Reverse Hydraulic Bypass Steering E.P.S

Suction 27 (V) ± 15% 19.8 (V) ± 15% 29.8 (V) ± 15% 25.7 (V) ± 15%

Separation 8.4 (V) ± 15% 5.8 (V) ± 15% 8.2 (V) ± 15% 8.6 (V) ± 15%

MEASURING INSULATION RESISTANCE The following value must be satisfied to keep the safety against surge occuring in the system as contact operating.

Measuring portion Drive contact point and fixed contact point Drive contact point and coil terminal Drive contact point and switch board Fixed contact point and coil terminal Fixed contact point and switch board Coil terminal and switch board

Standard value

More than 5M½

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

ACCELERATOR STRUCTURE

10 05 22

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part name Bracket Link end Case Cam comp.

PCB comp.

Guide Wahser Bushing Micro switch Plate Screw lock Spring Nylon washer (C) Nylon washer (A) Plate comp. slit Cover (B) Packing (C) Nylon washer (B) Cover switch Bushing Support Roller Packing (B) Packing (E) Screw set (M5 ´ 15L) Screw set

QtÕy 1 1 1 1 1 2 1 2 2 2 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1

No. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Part name Washer Name plate Packing (A) Bolt (M6 ´ 35L) Nut Spacer Accel arm Spring Nut Bolt Split pin Screw Plain washer Spring washer Screw Split pin Plain washer Screw Spring washer Plain washer Screw Screw Screw Nut Bushing

QtÕy 1 1 1 1 1 1 1 1 1 1 1 4 8 8 4 1 2 1 4 4 1 1 1 2 1

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

DISASSEMBLING ACCELERATOR ! Before

disassembling the accelerator, turn the key switch to OFF and disconnect the battery plug.

¥ Diassemble the linkage from accelerator pedel of front footrest. ¥ Disasemble the front footrest. ¥ Disconnect the wiring of accelerator. ¥ Loosen the locking bolt and nut of accelerator to disassemble the accelerator. ¥ Assemble as reverse order of disassembly.

However, when assembling accelerator pedal and linkage after assembling front footrest, check the following items with accelerator pedal is depressed fully. Ð Confirm the accelerator pedal is contacted with stopper as pedal is depressed fully. If it isnÕt contacted, move the stopper to contact with pedal.

(Set the stopper higher as 0.5~1mm.) Ð If the stopper is contacted with pedal, press the linkage by hand to check clearance. If the clearance is more than 1mm, adjust it to be 0.5~1mm.

10 05 23

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

FORWARD/REVERSE AND TURN SIGNAL SWITCH FORWARD/REVERSE AND TURN SIGNAL SWITCH

1

10 05

SW & CONT. LVR POSITION

FWD

SW & LVR CONT. POSITION

NEU

24 REV

HORN

2

FX1079

1. Forward/Reverse switch

2. Turn signal switch

DISASSEMBLING FORWARD/REVERSE AND TURN SIGNAL SWITCH

! Before disassembling the forward/reverse and the turn signal switch, turn the key switch to OFF and disconnect the battery plug. ¥ Disasemble the front footrest. ¥ Disconnect the wiring of switch. ¥ Disassemble the forward/reverse switch and the turn signal switch, and disassemble the switch assÕy.

1.

2.

3.

4.

Forward/reverse switch Turn signal switch Switch wiring Bolt

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

MAIN FUSE Before disassembling the forward/reverse and the turn signal switch, turn the key switch to OFF and disconnect the battery plug. ¥ Disasemble the rear cover of counterweight. ¥ Disconnect the wires and cables. ¥ Loosen the lock nut of contactor assÕy, and disassemble the relevant fuse. ¥ Assemble as reverse order of disassembly.

10 05 25

Drive fuse EPS fuse

27

5A

F-D

Hydraulic fuse

A

40

40A

27

5A F-H

Contactor ass'y

Fuse

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

DCÐDC CONVERTER STRUCTURE 150

10 1 GND 2 KEY

05 26

1.

2.

3.

4.

4 12V 3 48V

GND InÐkey S/W Output (DC12V) Input (DC48V)

! Before disassembling the DCÐDC converter, turn the key switch to OFF and disconnect the battery plug. ¥ Disconnect the front footrest. ¥ Disassemble the front footrest. ¥ Disconnect the wires for DCÐDC converter. ¥ Loosen the DCÐDC converter lock bolt, and disassemble the DCÐDC converter. ¥ Assemble as reverse order of disassembly.

INSTRUMENT PANEL ! Before disassembling the instrument panel, turn the key switch to OFF and disconnect the battery plug. ¥ Disconnect the wires for instrument panel under dash panel. ¥ Loosen the instrument panel lock bolt, and disassemble the panel. ¥ Assemble as reverse order of disassembly.

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

BATTERY DISASSEMBLING BATTERY ! Before disassembling the battery, turn the key switch to OFF and disconnect the battery plug.

10

¥ Open the battery cover, and fix the cover with lock pin. ¥ Disassemble the battery by chain for removing battery.

05 27

1. Battery plug 2. Battery cover

3. Battery

1. Battery plug

2. Battery

1. Battery 2. Plug

3. Battery terminal

! When disassembling the battery, do not impact to the battery. If electrolyte spatters to the body, clean with plenty of water immediately.

Especially, it spatters to the eyes, clean with plenty of water immediately and go to a doctor.

INSPECTING BATTERY MEASURING ELECTROLYTE LEVEL Ð Disconnect the battery plug. Ð Open the battery cover, and fix the cover with lock pin. Ð Confirm the level gauge in the middle of each cell (24pcs) in battery. If the level is low, refill the distilled water until the cell reaches the normal level.

! When refilling the distilled water, be careful not to overflow.

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

MEASURING SPECIFIC GRAVITY

! Before measuring the specific gravity of battery, turn the key switch to OFF and disconnect the battery plug.

10 05

¥ Open the battery cell cover, and put the hydrometer in the electrolyte. Make the hydrometer float and measure the specific gravity by naked eyes. ¥ Keep level the hydrometer with eyes to measure the specific gravity.

28

OVERHAULING TERMINAL OF BATTERY PLUG

! When

disassembling the terminal of battery plug, one terminal must be connected to plug.

(If both terminals are disconnected, (+) and (Ð) are confused causing serious damage to the machine.)

Ð Disconnect the battery plug. Ð Press the spring in plug by driver, and pull the lead wire backwards to remove the contact point terminal. Ð Inspect the contact portion of terminal for melting or rough. If it s rough, grind the surface with sand paper. Ð After inspecting, assemble the terminals concering the disassembly direction. Ð After a terminal is inspected and reassembled, perform inspection as same way.

1. Lock bolt

2. Battery plug

1. Battery plug 2. Cable terminal

3. Cable terminal 4. Cable

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

TROUBLE DIAGNOSTICS Class

Trouble

Chaging signal lamp is ON, and the hour hand of timer is bwtween 0 and set time.

Check before working

Cause

Power is shut off during charging.

Countermeasue a Wait until the timer return to 0 and chaging signal lamp is OFF. b If waiting is impossible, turn the timer in CCW to cut off charging. In this case, working capacity will be reduced than a, so charge during break time.

c Replace the damaged parts or repair the charging circuit.

Charging circuir d The battery can be used, however the is damaged. working capacity will drop as 20% comparing with normal condition.

Power is shut off e Repeat above procedures a and b, and during charging. then use.

Chaging signal lamp is ON, and the hour hand of timer indicates set time.

f Replace the damaged parts or repair the charging circuit. g If the specific gravity of the battery is more Charging circuit tnan 1.25 (25ยกC), it can be used but working is damaged. capacity is reduced. h If the specific gravity of the battery is less than 1.21 (25ยกC), it canร t be used.

Discharge

Check during working

When lifting up the fork under no load, it will be less than 42V. (In case of 48V group battery)

Charging is impossible.

i Stop operating and charge the battery.

Battery level is j Set the timer to 1~2hour and charge during low comparing break time. with working k If the lever is low even after charing as capacity, or level above procedure j, prepare a spare battery. is lowered due to l Replace the battery used for a long time with long time work. a new one.

Voltmeter is defective, m Replace the voltmeter. or fork operating n Repair the damaged portions or replace the system is damaged. parts.

Parts are in abnormal.

Check the abnormal charge signal lamp, poor contact between AC plug and outlet, snapping of AC power fuse, abnormal connector of battery,and charging chircuit.

If damaged, repair.

10 05 29

E L E C T R I C

S Y S T E M DISASSEMBLY/ASSEMBLY

Class

Trouble A group battery is totally reduded remarkably than other group battery.

10

Specific gravity is low.

Check for general items

Voltage is low.

Loose cap

Fasten the cap.

Broken cover, roll threaded cap

Replace battery.

Internal short circuit

Replace the single battery.

A group battery is tatally low remakably than other group battery.

Lack chafge

Increase set time by timer, or adjust the transformer tap according to power supply.

Refill distilled water just after charging

Measure the specific gravity before next working.

A single battery is low remarkably.

Broken cover, roll threaded cap

Replace battery.

Battery is leaved as discharged.

After charging, circuit.

Internal short circuit

After equal charging, replace the single battery of which open circuit voltage is less than 2.00V/single battery.

Terminal voltage is low than other single battery.

Not refilled with The temp. for distilled water, single battery is internal short high. circuit

Electrolyte temp. is high.

Reduce set time by timer, or check the charging circuit.

Replace the single battery.

A single battery is reduced.

30

Overcharge

Countermeasue

Short circuiting battery.

Electrolyte is reduced.

05

Cause

Not refilled with distilled water, overcharge The temp. for a group battery is higher than other.

Overdischarge

the

the

cap,

cap,

broken

broken

check

for

single

single

open

Replace the single battery of which temperature is higher as 10ยกC than even value.

(Same for electrolyte reducing)

Stop working as voltmeter indicates 42V (in case of 48V group battery) or 21V (in case of 24V group battery) while the fork is lifted up under no load.

DRIVING AND STEERING SYSTEM

¥ 20 Ð 01 DRIVE AXLE Ð Removal Ð Disassembly

20

¥ 20 Ð 04 TIRES Ð Dimensions of wheel

Ð Inspection

Ð Removal/installation

Ð Assembly

Ð Trouble diagnostics

Ð Installation Ð Trouble Diagnostics ¥ 20 Ð 02 STEERING AXLE

¥ 20 Ð 05 STEERING GEARBOX Ð Structure ¥ 20 Ð 06 ACTUATOR

Ð Disassembly

Ð Structure

Ð Assembly

Ð Disassembly

Ð Trouble Diagnostics ¥ 20 Ð 03 BRAKE Ð Wheel brake Ð Mast cylinder and brake pedal Ð Parking brake Ð Trouble diagnostics

/assembly

DRIVING AND STEERING SYSTEM DRIVE AXLE

REMOVAL STRUCTURE

3 1

20

5

2

01 1

1.

2.

3.

4.

5.

6.

Mast assembly Battery Accelerator pedal Brake bracket Parking brake lever Drive axle

6

PROCEDURES DISASSEMBLING MAST ¥ Remove the mast in accordance with the disassembling procedures.

4 FX993

DRIVING AND STEERING SYSTEM DRIVE AXLE

DISASSEMBLING BATTERY ¥ Open the battery cover, and lock it. ¥ Take out the battery.

20 01 2

DISASSEMBLING ACCELERATOR PEDAL ¥ Remove the accelerator pedal and the accelerator arm, and disassemble from the foot pedal.

DISASSEMBLING ACCELERATOR PEDAL ¥ Disconnect the wires proceeding to the fuse. ¥ Disconnect the wires proceeding to the accelerator housing. ¥ Disconnect the wires of horn and reverse warning alarm. ¥ Remove the wires from micro switch mounted on brake mast cylinder. ¥ Disassemble the brake pipe. ¥ Loosen the lock bolt of brake bracket assÕy.

DRIVING AND STEERING SYSTEM DRIVE AXLE

DISASSEMBLING PARKING BRAKE LEVER ¥ Disconnect the wires proceeding to the micro switch.

20 01 3

¥ Disassemble the parking brake assÕy along with the wires.

DISASSEMBLING DRIVE AXLE ¥ Disassemble the brake pipe.

DRIVING AND STEERING SYSTEM DRIVE AXLE

짜 Disconnect the wires from motor yoke.

20 01 4

짜 Put a block under the axle housing and the motor. 짜 Raise the fork lift by hoist crane so that the drive axle is positioned on the block. 짜 Loosen the axle mount bolt. Raise the fork lift by hoist crane to move backwards and then lower down to the ground safely.

DRIVING AND STEERING SYSTEM DRIVE AXLE

DISASSEMBLY STRUCTURE

20 01 5

Components of driving system

1.

2.

3.

4.

drain plug, nut, lock washer, corn washer, drive shaft, oil seal bolt, lock washer, differential gear lock nut, lock washwer, wheel hub, brake drum, bearing, oil seal retainer, oil seal, bolt bolt, washer, brake assÃ&#x2022;y, axle housing

DRIVING AND STEERING SYSTEM DRIVE AXLE

20 01 6

Components of differential gear

5. lock pin, bolt, lock washer, bearing cap, bearing nut, bearing bolt, dirve gear, spring pin, pinion shaft, differential pinion, differential side gear, thrust washer, differential case 6. bolt, lock washer, adapter case, bolt, lock washer, bearing, helical pinion, ball plug 7. bearing, lock nut, helical gear, bolt, beraring case, shim, drive pinion, bearing

DRIVING AND STEERING SYSTEM DRIVE AXLE

PROCEDURES

DISASSEMBLING WHEEL HUB AND BRAKE DRUM ¥ Disassemble the lock nut of wheel hub.

20 01 7 ¥ Disassemlbe the wheel hub and brake drum.

DISASSEMBLING DIFFERENTIAL GEAR ¥ Make match marks on the bearing cap and the differential gear. Loosen the spring pin and the bolt. ¥ Remove the differential gear.

DISASSEMBLING DIFFERENTIAL GEAR

¥ Loosen the nut. ¥ Disassemble the helical gear. ¥ Loosen the bolts and remove the bearing cage.

(Along with the bevel pinion)

! Record the number of shims.

DRIVING AND STEERING SYSTEM DRIVE AXLE

INSPECTION DRIVE SHAFT LEVELNESS OF SHAFT (unit : mm)

20 01 8

Measuring point

Standard dimension

Allowable limit

Shaft

0.5

1.0

Flange

0.05

0.5

MEASUREMENT AND INSPECTION ¥ Support the both ends of shaft, and mount the dial gauge on the middle of shaft. ¥ Turn the shaft to measure max. value of deformation.

(1/2 of measured value on gauge) ¥ After correcting, inspect the crack on shaft by color checker.

SPLINE FLOAT (unit : mm) Standard dimension

Allowable limit

0.07~0.17

0.5

MEASUREMENT ¥ Mount the differential gear on the shaft, and measure the run-out by dial gauge.

PINION SHAFT ¥ Check the abnormal wearing. (unit : mm) Standard dimension

Allowable limit

26.0

25.75

DRIVING AND STEERING SYSTEM DRIVE AXLE

THRUST WASHER 짜 Wearing test (unit : mm) Standard dimension

Allowable limit

1.5

1.2

! If heavily worn, the case will be damaged by rotating impact.

DIFFERENTIAL GEAR CASE 짜 Check the differential gear case for crack or damage.

GEAR 짜 Check the gear for wear, scar or scratch.

! When replacing, replace the pinion and the gear at the same time.

TAPER ROLLER BEARING 짜 Inspect the inner race and outer race of bearing carefully.

20 01 9

DRIVING AND STEERING SYSTEM DRIVE AXLE

AXLE HOUSING, CARRIAGE, ADAPTER ¥ Check the crack on welding parts of axle housing. ¥ Check the bearing mount portions for wear or damage. ¥ Check the crack on diffenertial gear housing.

20 01

WHEEL HUB, BRAKE DRUM, HUB BOLT, NUT

10 ¥ Check the crack of wheel hub and brake drum. ¥ Check the drum lock bolt for loosness.

9~13 kgfám ¥ Check the drum lock nut for loosness.

20~30 kgfám

! After tightening, lock them by punching on 4 places.

OIL SEAL ¥ Check the seal ring of oil seal for wear or damage.

DRIVING AND STEERING SYSTEM DRIVE AXLE

ASSEMBLY STRUCTURE

20 01 11

ASSEMBLING DIFFERENTIAL PREÐLOAD AND BACKLASH ASSEMBLY ¥ Assemble the drive gear.

Threebond 1374 or equivalent 10~14.5kgfám

GEAR

&

MEASURING

BEARING

DRIVING AND STEERING SYSTEM DRIVE AXLE

¥ Confirm the marks on the bearing cap and tighten the bolt temporarily. ¥ Fasten the bearing lock nuts.

MEASURING BEARING PREÐLOAD ¥ Measure the bearing preÐload. Ð PreÐload : 0.09~0.14 kgfám

! The pre-load, when the spring scale is mounted on the drive mount bolt head of differential gear, is 0.9~1.4kg.

20 01

¥ Adjust the bearing preÐload by tightening torque of bearing lock nut.

MEASURING BACKLASH

12 ¥ Backlash : 0.18~0.23mm ¥ Mount the dial gauge at right side of differential drive gear tooth surface. ¥ Rotate the differential gear forward/backward to measure the backlash ¥ When adjusting, loosen the bearing lock nut and then tighten until it will be adjusted.

! Confirm the bearing preÐload is within specified value.

MEASURING BACKLASH ASSEMBLY ¥ Install the helical gear and tighten the lock nut.

40~50kgf.m ¥ Tap the bevel pinion by copper hammer so that the bearings can seat in positions.

DRIVING AND STEERING SYSTEM DRIVE AXLE

MEASURING BEARING PREÐLOAD ¥ Measure the bearing pre-load. Ð PreÐload : 0.09~0.14 kgfám

! The preÐload, when the spring scale is mounted on the mount hole of bearing cage (fD 150mm), is 1.2~1.9kg. ¥ If the bearing pre-load is too low, disassemble the distance piece to shorten by grinding.

! Do not adjust the bearing preÐload by fastening the lock nut. ¥ After adjusting, make match marks on nut and bevel pinion, and then disassemble.

20 01 13

¥ Install the removed shim into the bearing cage, and fasten with 3 lock bolts.

7~10kgfám ¥ After assembling the bearing cage, assemble the helical gear by lock nut temporarily.

INSPECTING GEAR AND ASSEMBLING BEARING CAP INSPECTING GEAR ¥ Apply red-seal ink to the differential drive gear. ¥ Rotate the differential gear forward/backward to inspect the gear meshing trace. ¥ Adjust the gear mesh.

DRIVING AND STEERING SYSTEM DRIVE AXLE

ADJUSTING GEAR MESH

20 01 14

¥ Adjust gear mesh under noÐload condition. ¥ In case that the large end of hypoid gear is meshed as forward rotating and the small end of hypoid gear is meshed as reverse rotating. Ð Cause : The hypoid pinion is too close installed to the hypoid gear. Ð Correction : Add the shims to the bearing cage so that the hypoid pinion can be far away from the hypoid gear center. Ð Shim : 0.1, 0.15, 0.50mm ¥ In case that the small end of hypoid gear is meshed as forward rotating and the large end of hypoid gear is meshed as reverse rotating. Ð Cause : The hypoid pinion is too far from the hypoid gear. Ð Correction : Remove the shims from the bearing cage so that the hypoid pinion can be close to the hypoid gear center.

¥ After adjusting, insert the split pin and tighten the bearing pin with bolts. ¥ Insert the lock wires on both bolts. ¥ Bend the split pin. ! After bending the split pin, check for crack.

DRIVING AND STEERING SYSTEM DRIVE AXLE

ASSEMBLING HELICAL GEAR ¥ Disassemble the lock nut and helical gear. ¥ Tighten the lock bolt of bearing cage.

Threebond 1374 7~11kgfám ¥ Install the helical gear and fasten the lock nut.

Lock the nut in positions by punch.

20 ¥ Assemble the bearing. ¥ Assemble the bearing outer race to the adapter case.

ASSEMBLING ADAPTER CASE AND HELICAL PINION ¥ Arrange the differential carrier and adapter case.

Threebond 1215 (Adhesive face) ¥ Tighten the lock pin.

or

equivalent

01 15

DRIVING AND STEERING SYSTEM DRIVE AXLE

¥ Fasten the lock bolt of adapter case.

4~6kgfám

20

¥ Install the bowl plug to the helical pinion.

Threebond 1215 (Bowl plug)

01 16

¥ Assemble the helical pinion.

¥ Apply grease on the seal lip of oil seal, and assemble it to the bearing cover.

Threebond 1215 or equivalent (Outside of seal) ¥ Apply threebond 1215 between the cover and case, and tighten the lock bolt.

2~3kgfám

DRIVING AND STEERING SYSTEM DRIVE AXLE

ASSEMBLING DIFFERENTIAL CARRIER ASSÕY ¥ Assemble the differential carrier assÕy and the axle housing by lock bolts.

Threebond 1215 or equivalent (Mount face) 4~6kgfám

ASSEMBLING BRAKE ASSÕY

20

¥ Fasten the lock bolt of brake assÕy.

01

Threebond 1374 or equivalent (Lock bolt) 15~20kgf.m

ASSEMBLING WHEEL HUB AND MEASURING BEARING PREÐLOAD ¥ Install the oil seal to the wheel hub.

Threebond 1327 or equivalent (Outside of oil seal) ¥ Apply grease on seal lip of oil seal, and assemble it to the wheel hub.

Threebond 1104 or equivalent (Outside of oil seal) ¥ Fill grease in the wheel hub. ¥ Fasten the lock nut in the bearing side, and rotate it 1/4 turn. ¥ Tap the hub by copper hammer so that the bearing can seat in positions.

17

DRIVING AND STEERING SYSTEM DRIVE AXLE

MEASURING BEARING PREÐLOAD ¥ Measure the bearing pre-load.

Bearing preÐload : 0.4~0.7kgfám

! The preÐload, when the spring scale is mounted on the hub bolt, is 3.6~6.4 kg.

20 01 18

ADJUSTMENT ¥ Adjust the pre-load as fastening the lock nut in bearing side. ¥ After adjusting, loosen the lock nut. Insert the lock washer and then fasten the lock nut.

17~23kgfám ¥ Bend the lock washer to the both sides of lock nut.

ASSEMBLING DRIVE SHAFT ¥ Apply grease on the seal lip of oil seal, and assemble it .

Threebond 1104 or equivalent (Outside of oil seal) ¥ Apply threebond 1215 between the wheel cover and the drive shaft, and tighten the nut.

Threebond 1215 or equivalent (Between wheel hub and drive shaft) 7.5~11kgf.m

GEAR OIL ¥ Gear oil SAE 90 or equivalent

! Use the recommended gear oil only. ¥ Capacity : Approx. 5.5 l (Above the level plug)

DRIVING AND STEERING SYSTEM DRIVE AXLE

INSTALLATION INSTALLING DRIVE AXLE ¥ Tighten the mount bolt to the specified torque.

45~50kgfám M24 spanner

! Tighten the upmost lock bolt facing outwards.

20 01 19

CONNECTING BRAKE PIPE ¥ Connect the brake pipe, and bleed the air.

! Pay attention to the assembling direction.

DRIVING AND STEERING SYSTEM DRIVE AXLE

TROUBLE DIAGNOSTICS Symptom 1. Continuous abnormal sound while travelling

20 01 20

2. Sometimes abnormal sound while travelling

3. Abnormal noise while rotating

4. Heating of differential case

Abnormality and cause

Countermeasure

1. Wear of hypoid gear or poor gear mesh 2. Worn bearing of hypoid gear and poor adjustment 3. Looseness or damage of hub bearing 4. Poor mesh condition of the shafts of differential drive gear and hypoid gear and the ring gear 5. Lack gear oil

Adjust, Replace Adjust, Replace

1. The bearings of differential drive gear and hypoid gear are damaged.

2. The hub bearing is damaged.

3. Excessive backlash due to wearing of differential gear or thrust washer 4. Foreign materials are suck in the axle housing.

5. The lock bolt of carrier or drive shaft is loosened.

Replace

1. Excessive backlash due to wearing of differential gear or washer 2. The differential gear/pinion or pinion shaft is damaged.

Replace

1. Gear backlash is too little.

2. The bearing is damaged due to excessive preĂ?load.

Adjust Replace

Adjust, Replace Adjust

Refill

Replace Replace Inspect, Clean Tighten

Replace

5. Oil leakage from 1. Oil quantity is too much. axle housing 2. Oil seal is worn or damaged.

3. The tightening torque of axle housing lock bolt is excessive.

4. The plug is loosened.

5. The function of air bleeder is damaged.

Discharge Replace Adjust

6. Oil leakage from 1. Oil seal is worn or damaged. wheel hub 2. The rotation of wheel hub is poor because the bearing is worn or damaged.

Replace Replace

7. Oil leakage from 1. Wear or damage of the oil seal. carrier assĂ&#x2022;y

Replace

Adjust Clean, Replace

DRIVING AND STEERING SYSTEM STEERING AXLE

DISASSEMBLY REMOVAL DISASSEMBLING WHEEL ¥ Disassemble the tires and wheels.

! Keep the fork lift frame on a hard block.

20 02 1

DISASSEMBLING STEERING AXLE ¥ Disassemble the ball socket from the center arm.

¥ Use the hydraulic jack to handle the steering axle smoothly. ¥ Loosen the lock bolt of steering axle. ¥ Remove the steering axle by lowering the hydraulic jack.

! Record the number of shims assembled to the steering axle shaft.

DRIVING AND STEERING SYSTEM STEERING AXLE

STRUCTURE COMPONENTS AND DISASSEMBLING ORDER

20 02 2

1. Split pin, lock nut 2. Bolt, lock washer, set plate, center arm pin 3. Split pin, nut, tie rod comp (rod end assÃ&#x2022;y, lock nut, tie rod), center arm, bearing 4. Hub cap, split pin, nut, washer, bearing wheel hub, oil seal, bearing 5. Lock nut, set screw, king pin, needle bearing, axle comp, spacer shim, needle bearing, knuckle

DRIVING AND STEERING SYSTEM STEERING AXLE

INSPECTION CENTER ARM, ROD END, TIE ROD ¥ Inspect the welding portion of stud ball for crack. ★ Correcting procedures ¥ Select the proper welding rod. Use low hydrogenous welding rod only. ¥ While welding, keep there is no gap between center arm and stud ball. ¥ Check the taper of rod end is abnormally worn.

★ Inspect procedures ¥ Apply red sealÐink around taper of rod end. ¥ Insert the rod end to the center, and then pull out to check the contact condition. ★ Countermeasures ¥ Replace the center arm or the rod end if the contact face is poor. ¥ Check the levelness of tie rod.

CENTER ARM PIN (Unit : mm) Standard dimension

Allowable limit

32.0

31.8

20 02 3

DRIVING AND STEERING SYSTEM STEERING AXLE

KNUCKLE ¥ Inspect the connections for abnormal wear. ¥ For inspecting, refer to the inspection method for contact of rod end and center arm. ¥ Inspect for crack or damage.

20 02 4

KING PIN ¥ Inspect the bearing for sliding wear.

(Unit : mm) Standard dimension

Allowable limit

32.0

31.8

HUB AND HUB BOLT ¥ Inspect the hub for damage or crack. ¥ Check that the hub bolt is loosened or cracked.

KING PIN ¥ Inspect the axle for bending or crack.

DRIVING AND STEERING SYSTEM STEERING AXLE

KNUCKLE ¥ Inspect the grade of wearing.

(Unit : mm) Item

Standard dimension

Allowable limit

fD

50.0

50.3

! If the groove isnÕt seen, replace it with a new one.

OIL SEAL

20

¥ Check the seal lip and dust lip for damage or deformation.

02

! When assembling, replace all the rubber parts with new ones, as possible.

5

DRIVING AND STEERING SYSTEM STEERING AXLE

ASSEMBLY STRUCTURE AND ASSEMBLY

20 02 6

DRIVING AND STEERING SYSTEM STEERING AXLE

ASSEMBLING KNUCKLE ¥ Install the bearing to the axle.

Special tool 221Ð2001

¥ Install the knuckle to the axle, and measure and adjust the clearance.

Standard clearance

0.3mm

¥ Measuring procedures : Assemble the bearing, spacer and king pin temporarily. Install the removed shims and measure the clearance by gauge. ¥ Adjustment : Adjust the clearance by adding or removing the shims. Install the shims between spacer and bearing. After adjusting, insert the king pin and lock by set screw and lock nut.

ASSEMBLING TIE ROD ¥ Assemble the tie rod in accordance with the standard dimension (M).

(Unit: mm) Standard dimension

L.H.

R.H.

(M)

469

476

20 02 7

DRIVING AND STEERING SYSTEM STEERING AXLE

ASSEMBLING TIE ROD TO CENTER ARM ¥ Install the bearing to the center arm.

Special tool 221Ð2002 ¥ Connect the tie rod to the center arm by nut according to the standard torque.

10kgfám

20 02

¥ Assemble the center arm to the axle, and connect the rod end and the knuckle.

8

ASSEMBLING CENTER ARM Assembling rod end ¥ Tighten the nut according to the standard torque.

10kgfám

DRIVING AND STEERING SYSTEM STEERING AXLE

ASSEMBLING AND ADJUSTING HUB ¥ Apply grease to the seal lip of oil seal and adhesive to the outside of mounting face.

Threebond 1104 or equivalent ¥ Fill the grease into the portion marked with . ¥ Fasten the nut and then loosen 1/4 turn. ¥ Tap the bearing by copper hammer light so that it can be seated easily.

MEASURING BEARING PREÐLOAD ¥ Measure the bearing preÐload.

Bearing preÐload : 0.2~0.4kgfám

! The bearing pre-load, when the spring scale is mounted on the hub bolt, is 2.3~4.7kg.

ADJUSTMENT ¥ Adjust the nut as tightening. ¥ After adjusting, bend the split pin to lock the nut and then assemble the cap.

MEASURING/ADJUSTING TOWÐIN ¥ Measuring procedures Ð Assemble the tires. Ð Measure the center distance of tires for front tires and rear tires to compare the values. Ð Standard towÐin : 0mm ¥ Adjusting procedures Ð Put the center arm at middle position, and loosen the lock nut. Adjust the tie rod by turning to right side.

20 02 9

DRIVING AND STEERING SYSTEM STEERING AXLE

! After adjusting, confirm the center arm is at the middle position. ¥ Fasten the lock nut.

16~20kgf.m

20 02 10

INSPECTING AND ADJUSTING STEERING ANGLE ¥ Inspect the steering angle.

A : 76¡ B : 49¡

¥ Adjust the angle by turning the bolt and then tighten according to the standard torque.

M16 : 8~10kgfám

DRIVING AND STEERING SYSTEM STEERING AXLE

INSTALLATION MEASURING CLEARANCE OF AXLE IN LENGTHWISE ¥ Measuring method Ð Assemble the shims. Ð Install the steering axle and measure the clearance A. Standard clearance : 0.1~0.7mm

¥ Adjustment Ð Adjust the clearance by adding or removing the shims.

Shim : 0.5, 1.0, 2.3, 3.2mm Ð After adjusting the clearance, tighten according to the standard torque.

24~29.4kgfám

INSPECTING WHEEL BEARING ¥ Inspect the wheel bearing for abnormal sound. ¥ Inspecting method Ð Raise the wheel from the ground. Ð Inspect the wheels by turning in forward/backward. Ð Inspect for abnormal sound.

! If the wheel doesnÕt rotate smoothly or abnormal sound is heard, disassemble it.

20 02 11

DRIVING AND STEERING SYSTEM STEERING AXLE

TROUBLE DIAGNOSTICS Symptom

02 12

Countermeasure

Ð Tires are not assembled properly. Ð Bearing of king pin is damaged. Ð The air pressure of tires are low. Ð No lubricating oil in the steering axle and linkage Ð The linkage is stuck.

Adjust Replace Adjust Lubicating test

2. Steering wheel canÕt be returned easily.

Ð The parts of the steering linkage and the axle are not adjusted correctly. Ð Wheels are improperly assembled.

Inspect, Adjust

3. Wheels are turned to one side suddenly.

Ð The air pressure of wheel is improper. Ð The diameters of wheels (L.H/R.H) are different. Ð Wheels are improperly assembled. Ð Wheel bearinbg is worn or improperly adjusted

Adjust Adjust, Inspect Inspect, Adjust Adjust, Replace

4. Steering wheel is rattled.

Ð Clearance between king pin and king pin bearing is too wide. Ð Wheel bearing is worn or improperly adjusted Ð Hub nut is loosened. Ð Ball joint of tie rod is excessively worn. Ð Steering axle is improperly assembled. Ð The air pressure of wheel is improper. Ð Steeing system is poor.

Replace

Ð Air pressure is poor Ð Wheels are improperly assembled. Ð Wheel bearing pre-load is poor. Ð Different types of tires (L.H/R.H) are used.

Adjust Inspect, Adjust Adjust Replace

1. Steering is heavy.

20

Abnormality and cause

5. Wheels are abnormally worn.

Replace, Correct

Inspect, Adjust

Adjust, Replace Tighten Replace Adjust Adjust Inspect, Replace

DRIVING AND STEERING SYSTEM BRAKE

WHEEL BRAKE REMOVAL REMOVING BRAKE ASSEMBLY ¥ Remove the wheel and drive shaft.

20 03 1

¥ Remove the wheel hub and brake drum. Refer to the drive axle for removing procedures.

¥ Remove the brake assembly. Ð Remove the parking brake cable from the brake lever. Ð Remove the lock bolt of wheel brake assÕy.

DRIVING AND STEERING SYSTEM BRAKE

STRUCTURE

20 03 2

1.

2.

3.

4.

5.

6.

7.

8.

Packing plate Shoe guide plate Piston Cup Spring Boot Bleeder screw Bleeder cup

9.

10.

11.

12.

13.

14.

15.

16.

Connecting link Bolt, washer Shoe lining kit Adjuster assÃ&#x2022;y Asjust cable Cable guide Lever Spring

17. Spring 18. Shoe holddown spring 19. Cup 20. Pin 21. Return spring 22. Cover 23. Parking lever

24.

25.

26.

27.

28.

29.

Struct Spring Lock washer Retainer Parking cable Snap ring

DRIVING AND STEERING SYSTEM BRAKE

DISASSEMBLY DISASSEMBLING SHOE LINING ¥ Disassemble the return spring.

20 03 3

¥ Disassemble the shoe spring. ¥ After the shoe spring and the return spring is disassembled, the remaining parts can be disassembled.

DRIVING AND STEERING SYSTEM BRAKE

DISASSEMBLING WHEEL CYLINDER 짜 Loosen the cylinder lock bolt. 짜 Disassemble the inner parts.

20

1.

2.

3.

4.

5.

6.

7.

8.

Connecting link Boot Piston Piston cup Cylinder body Spring Bleeder screw Cap

03 4

INSPECTION BRAKE DRUM 짜 Inspect the inner face of brake drum for wear or scratch.

Diameter of brake drum inner side

Standard dimension

Allowable limit

310mm

312mm

! Correct the parts if it is within the limit, and replace if it exceeds the limit.

BACK PLATE 짜 Inspect the parts for deformation or damage.

DRIVING AND STEERING SYSTEM BRAKE

SHOE AND LINING ¥ Measure the thickness of lining. ¥ Replace if it is below allowable limit.

Allowable limit

1.5mm

¥ Inspect the lining for dirt or hardening. ¥ Inspect the shoe for crack or damage.

ADJUSTER Inspect the screw spiral portions for deformation or wearing.

20 03 5

WHEEL CYLINDER

! Before inspecting, clean the parts with solvent. After cleaning blow the compressed air. ¥ Cylinder body Inspect the inner surface of body and the bleeder mounting parts marked with * for damage or rust. ¥ Piston cup and boot Inspect the parts for aging or damage. ¥ Piston Measure the clearance between body and piston.

Clearance

! The

Less than 0.15mm

cylinder is very important part. If there is any abnormality, replace it.

When disassembling, also replace it.

DRIVING AND STEERING SYSTEM BRAKE

ASSEMBLY ASSEMBLING WHEEL CYLINDER ¥ Apply oil to the inner surface of cylinder, and assemble to the cylinder body. ¥ Install the wheel cylinder.

0.8~1.2kgfám

20 03 6

ASSEMBLING PARTS ¥ Before assembling, apply following parts. ¥ Grease filling portions

grease

to

the

Components 1

Anchor pin

2

Shoe

3

Shoe and lining

4

Adjusting socket

5

Adjusting screw

6

Automaic centralizer

7

Cable guide

8

Adjusting cable

¥ Cautions for grease filling Ð Apply the grease sufficiently to the anchor pin. Ð When appling grease to shoe rack, be careful not to smear on the lining. Ð Apply grease to the adjusting screw for smooth turning. Ð Apply grease thinly to the adjusting socket and adjusting portions and connecting portions of shoe and lining. Ð Apply grease thinly to the cable guide and adjusting cable.

DRIVING AND STEERING SYSTEM BRAKE

ASSEMBLING RETURN SPRING ¥ Install the return spring.

CHECK AUTOMATIC CENTRALIZING FUNCTION ¥ Inspecting procedures: When pulling the adjusting cable, the adjusting screw is turned one revolution, and when releaing the cable, it can be returned to original position. ¥ If not worked, inspect as followings. ¥ Insepcting point and countermeasures Ð Confirm the cable guide is locked in the lining hloe and shoe. Ð Confirm the spring is firmly attached to the adjusting lever. Ð Confirm the adjusting cable. Ð Replace the adjusting lever. Ð Replace the adjusting screw.

INSTALLING WHEEL BRAKE ¥ Tighten the bolts to the specified torque.

15~20kgfám Threebond 1374 or equivalent

ASSEMBLING WHEEL HUB ¥ Refer to the drive axle section.

20 03 7

DRIVING AND STEERING SYSTEM BRAKE

AIR BLEEDING ¥ Connect a end of vinyl hose to the bleeder and the other end to the container. ¥ Depress the pedal several times and keep depressing. ¥ Release the bleeder. After a little oil is drained, fasten the bleeder again. ¥ Continue the above operations until air is completely disapeared in the oil. ¥ Lock the screw after air bleeding.

20 03 8

0.6~0.9kgfám

! Use the specified brake oil. Do not mix the brake oil with other kinds of oil. ¥ Check the oil leakage.

! If the brake system isnÕt connected compeletely, do not perform air bleeding.

DRIVING AND STEERING SYSTEM BRAKE

MASTER CYLINDER AND BRAKE PEDAL DISASSEMBLY REMOVAL ¥ Remove the pin from pedal and disassemble the mast cylinder. ¥ Disassemble the brake pipe. ¥ Loosen the cylinder lock bolt. ¥ Disassemble the return spring of pedal and remove the pedal pin.

20 03 9

DISASSEMBLY ¥ Cylinder body ¥ Clevis, nut, rod ¥ Boot, ring ¥ First cup, piston, cup spacer, secondary cup, spring seat, spring, check valve, valve seat

INSEPECTION MASTER CYLINDER ¥ Before inspecting, clean with solvent, and then blow with compressed air. ¥ Cylinder body Inspect the inner surface of body and tube nut for damage or rust. ¥ Piston cup and boot Inspect for damage or breakage.

DRIVING AND STEERING SYSTEM BRAKE

¥ Measure the clearance between piston cylinder body and piston, and replace it if exceeds standard value.

Standard clearance : Less than 0.15mm ¥ Inspect other parts for damage or abnormality.

! Master cylinder is very important part. If there is any abnormality, replace immediately.

It is recommended to replace the inner sliding parts annually.

BRAKE PEDAL, BUSHING, PIN

20

¥ Pedal and pad Inspect the welding portions of pedal for crack, and pad for damage.

03 10

¥ Bushing : Inspect for wearing.

(Unit : mm)

D (f)

Standard dimension

Allowable limit

20.0

20.15

¥ Pin : Inspect for wearing.

(Unit : mm)

D (f)

Standard dimension

Allowable limit

20.0

19.9

DRIVING AND STEERING SYSTEM BRAKE

ASSEMBLY ASSEMBLING MASTER CYLINDER ¥ Apply brake oil to inner surface of body and then assemble the parts.

INSTALLING MASTER CYLINDER ¥ Tighten the master cylinder mount bolt.

18~22kgfám

ADJUSTING PEDAL HEIGHT ¥ Pedal height (a) Approx. 95mm ¥ Free stroke (b) Approx. 10~15mm ¥ Height as depressing the pedal (c) Approx. 50mm ¥ Adjust the pedal height by loosening or fastening the bolt. ¥ Adjust the free height by loosening or fastening the push rod.

20 03 11

DRIVING AND STEERING SYSTEM BRAKE

PARKING BRAKE DISASSEMBLY ¥ Disconnect the wires of micro switch. ¥ Remove the parking lever lock bolt. ¥ Disconnect the brake cable from parking lever.

ASSEMBLY

20 03 12

ASSEMBLING PARKING BRAKE LEVER AND ADJUSTING HANDLING FORCE

! Before adjuting lever tension, adjsust the clearance between brake drum and shoe precisely. ¥ Put the lever on neutral position (A), and connect the cable to brake lever. ¥ Install the bolts as upper bolt is above 15mm from lower bolt. ¥ Assemble the brake lever. ¥ Install the spring scale on the clip, and measure the handling force to draw the lever from (A) to (B).

Handling force 14~16kgfám ¥ Adjustment : Loosen the fan screw, and adjust the tension by turning the clip in CW or CCW. After adjusting operate the lever 2~3 times, and then check the handling force again.

DRIVING AND STEERING SYSTEM BRAKE

ADJUSTING MICRO SWITCH 짜 Put the lever on neutral position, release the lock bolt of micro switch. 짜 Pull the lever to (B), so that the micro switch is pressed about 3mm. 짜 Fasten the lock nut of micro switch. 짜 When the lever is in (B) after adjusting, confirm that the parking brake lamp on insturment panel is lighted on.

20 03 13

DRIVING AND STEERING SYSTEM BRAKE

TROUBLE DIAGNOSTICS Symptom

20 03 14

Abnormality and cause

Countermeasure

1. Operation of brake is poor.

Ð Oil leakage from cylinder piston cup Ð Lack of oil due to air mixing Ð Oil leakage from cylinder cup Ð Air mixing on brake pipe Ð Poor contact with drum due to lining wear Ð Oil is smeared to brake drum or lining. Ð Brake is improperly adjusted.

Replace Oil filling, Air bleeding Replace Air bleeding Inspect, Replace Clean, Replace Adjust

2. Abnormal sound is emitted as braking.

Ð Oil is smeard to lining. Ð Back plate is moved or lock bolt is released. Ð Brake shoe is moved or poor adjusted. Ð Lining is abnomally worn. Ð Wheel bearing is released. Ð Back plate anchor pin is moved or worn. Ð Shoe rack is worn.

Correct, Inspect, Correct, Replace Inspect, Replace Replace

Ð Air pressure of tires for L/H and R/H is different. Ð Brake is improperly adjusted. Ð Lining is spread or it doesnÕt contact with brake drum evenly. Ð Water or oil is smeared to lining. Ð Lining is worn. Ð Wheel cylinder is improperly operated. Ð Back plate is moved or improperly assembled. Ð Brake drum is excessively worn. Ð Brake pipe is blocked. Ð Wheel bearing is released.

Adjust

Ð Brake pedal is not operated. Ð Wheel cylinder is improperly operated. Ð Master cylinder is improperly operated or oil passage is blocked. Ð Retrun spring of brake is broken. Ð Brake is improperly adjusted or brake oil is leaked. Ð Parking brake isnÕt released or improperly adjusted. Ð Brake pipe is blocked. Ð Wheel bearing is improperly assembled.

Adjust Replace Insepct, Replace

3. Only one side braking is possible.

4. Braking force is heavy.

Replace Retighten Replace Retighten

Adjust Correct, Replace Clean Replace Replace Replace, Retighten Replace Clean, Replace Inspect, Adjust

Inspect, Replace Adjust Adjust Clean, Replace Adjust

DRIVING AND STEERING SYSTEM BRAKE

Symptom

Abnormality and cause

Countermeasure

5. Pedal stroke distance is too long.

Ð Brake is improperly adjusted. Ð Stem is mixed into the brake pipe. Ð Oil is leaked in the brake pipe due to leakage. Ð Brake pedal is improperly adjusted.

Adjust Air bleeding Correct, Oil refilling Adjust

6. Parking brake is poor.

Ð Parking brake cable is improperly installed. Ð Lining is worn. Ð Brake is improperly adjusted. Ð Brake lever is improperly adjusted.

Adjust Replace Adjust Adjust

20 03 15

DRIVING AND STEERING SYSTEM TIRES

DIMENSIONS OF WHEEL AIR PRESSURIZED TIRES CEP15/18 Classification

Standard

Front wheel

6.50´10´12PR

Rear wheel

5.00´8´10PR

CEP20/25

04

Classification

Standard

Front wheel

7.00´12´14PR

Rear wheel

6.00´9´10PR

REMOVAL/INSTALLATION FRONT WHEELS

20 1

DRIVING AND STEERING SYSTEM TIRES

REAR WHEELS

20 04 2

TROUBLE DIAGNOSTICS Symptom

Tires are excessively or abnormally worn.

Cause Ð Tire pressure is poor. Ð Wheels are poor. Ð Wheel is improperly assembled. Ð Wheel bearing is released.

Countermeasure Adjust Replace Adjust Retighten

DRIVING AND STEERING SYSTEM STEERING GEARBOX

STRUCTURE STRUCTURE OF STEERING SYSTEM

20 05 1

1.

2.

4.

5.

6.

7.

Pitman arm UÐbolt Steering wheel Steering gear box assÕy Drag link Actuator

DRIVING AND STEERING SYSTEM STEERING GEARBOX

REPLACING/ADJUSTING EACH PARTS INTERCHANGEABILITY OF MAIN PARTS ★ The number means part number.

20 05 2

CEP15/18

CEP20/25

Torque sensor assÕy

32911Ð00690

32911Ð00690

Controller assÕy

37720Ð00280

37720Ð00290

EPS motor assÕy

32911Ð02630

32911Ð02640

Actuator comp.

32911Ð02370

32911Ð02690

ALLOWABLE LIMIT FOR BRUSH OR EPS MOTOR The brush of EPS motor is worn to the allowable limit line, replace with a new one. ★ The brush of EPS motor is in 2 types.

(Interchangable)

ADJUSTMENT AS REPLACING TORQUE SENSOR Replace the torque sensor. If it is mounted chassis, confirm adjustment for the following items. (a) Adjust the length of torque sensor (At the middle of center shaft to lock nut) will be 220mm when the rear tires are in straight condition.

Tightening torque

16~20 kgfám

DRIVING AND STEERING SYSTEM STEERING GEARBOX

(b) Turn the steering wheel to the ends for both directions, and clamp with joint band so that the harness canÕt be caught or pulled when the pitman arm is moved forward/backward. (c) Clamp the 6P white connector of torque sensor to the harness of chassis with band as the recess is upwards. (To prevent water enter)

20 05 3

(d) If force is added to the steering wheel knob on max. stroke (end), confirm the handle will return to 5.5 ± 2.5 sec. (Check operation of overcurrent protective circuit) * If it doesnÕt work, relaease the lock nut and tighten the torque sensor (approx. 2~3mm) adjusted above procedure (a).

DRIVING AND STEERING SYSTEM STEERING GEARBOX

REPLACING/ADJUSTING EACH PARTS ADJUSTMENT WHEN REPLACING ACTUATOR In case that the actuator is replaced and mounted to chassis, adjust and confirm the following items. ¥ Adjust the length will be the set value in table when the rear tires are in straight condition.

L dimension

20

CEP15/18

182.5mm

CEP20/25

179.5mm

05 4

¥ Adjust the length will be the set value in table when the steering wheel is turned to the ends for both directions.

L dimension Max. retract

Max. extension

CEP15/18

83mm

281.5mm

CEP20/25

83.5mm

283.5mm

! The L dimension for max. extension shall not exceeds the above value. ¥ Apply Loctite #262 to thread and lock nut, and tighten the lock nut to the specified torque.

Tightening torque

16~25 kgfám

¥ Lap the rubber boot to sphere parts of lock nut, and wind the wires by 2 strands. ★ The wire shall not be interfered with other parts.

DRIVING AND STEERING SYSTEM STEERING GEARBOX

WIRING AND SYSTEM DIAGRAM

20 05 5

DRIVING AND STEERING SYSTEM STEERING GEARBOX

DISASSEMBLING ACTUATOR COMPONENTS AND DISASSEMBING PROCEDURE OF ACTUATOR

20 05 6

1.

2.

3.

4.

5.

6.

7.

Gear case Cover Plate Taper roller bearing Lock nut Ball screw Universal joint comp

8.

9.

10.

11.

12.

13.

14.

HOLD THE ACTUATOR ON VICE. ¥ Hold the actuator horizontally. ★ Remove the boot in advance.

Tube Idle gear Roller bearing Pinion gear Roller bearing Washer Disc spring

15.

16.

17.

18.

19.

20.

21.

Joint Bleeder plug Bolt, washer Packing (cover) Packing (motor) Motor Bolt, wahser

DRIVING AND STEERING SYSTEM STEERING GEARBOX

REMOVE THE MOTOR ¥ Disassemble the motor by removing the bolts (3 pcs). If it is stuck, tap lightly with plastic hammer.

Do not apply strong impact to the motor. ¥ Pull out the joint.

DETACH THE UNIVERSAL JOINT ¥ Release the lock nut on cover, and detach the universal joint as the tube is attached. ★ Mark the assembling position for the tube and cover, and the tube and universal joint.

REMOVE THE COVER. ¥ Remove the bolts (6pcs).

20 05 7

DRIVING AND STEERING SYSTEM STEERING GEARBOX

¥ Disassemble the cover 2. Ð When disassembling, be careful not to drop inner gear and bearing.

20 05

REMOVE IDLE GEAR 9, PINION GEAR 11 AND BALL SCREW 6. ¥ Remove the idle gear 9 and pinion gear 11.

8

¥ Remove the ball screw 8. Ð Do not operate the ball screw upto the end of stroke. Handle it in a level condition as possible.

AFTER DISASSEMBLING ¥ Remove the packing 18 on the mating face of cover 2 and gear case 1. ¥ Remove the packing 19 on the mating face of cover 2 and motor assÕy 20.

DRIVING AND STEERING SYSTEM STEERING GEARBOX

INSPECTION CLEAN ALL THE DISASSEMBLED PARTS WITH KEROSENE AND IF THERE IS ANY ABNORMALITY TAKE APPROPRIATE COUNTERMEASURES Countermeasure

Part name

Inspecting items

¥ Universal joint assÕy

¥ Wheel rotating direction, rotating condition (rattling) ¥ Bearing condition ¥ Damage of spider ¥ Spot on the bent track, not smooth

Replace

¥ Ball screw assÕy

¥ Nut is not smoothly turned. ¥ Thread portions are peel off. ¥ Gear tooth is damaged or abnormally stepped.

Clean Replace

¥ Bearing

¥ Bearing is not smoothly turned. ¥ Heavy rattling.

Replace

¥ Idle gear ¥ Pinion gear

¥ Gear section is damaged or abnormally stepped. ¥ Spline is damaged or abnormally worn.

Replace

¥ Gear case ¥ Cover

¥ Separation damage. ¥ Scratch on bearing pipe joint.

Replace Correct

¥ Boot

¥ Separation hardening.

Replace

¥ Disc spring

¥ Damage, no elasticity

Replace

¥ Joint

¥ Spline is damaged or abnormally worn.

Replace

PERFORM ASSEMBLY AS REVERSE ORDER OF DISASSEMBLY. REPLACE PACKINGS WITH NEW ONES. USE THE EQUIVALENT LUBRICATING OIL FOR INSIDE OF ACTUATOR.

! Fill the lubricating oil to the bearing. Do not change the direction of disc spring.

05 9

ASSEMBLY

¥ Install the bearing to gear case. Ð Install the taper roller bearing. Ð Install taper roller bearing, washer and roller bearing. Ð After assembling the bearing, press in arrow direction by hand to check it works smoothly.

20

DRIVING AND STEERING SYSTEM STEERING GEARBOX

¥ Hold the gear case on vise.

Assemble same way as disassembly. ¥ Assemble the ball screw.

! Fill the lubricating oil to ball screw warm and ball nut threads. ¥ Assemble the idle gear 9 and pinion gear 11.

Apply lubricating oil to gear tooth.

20 05 10

¥ Assemble the beraring to cover. Ð Assemble the plate 3. (The concave side faces axis) Ð Assemble the taper roller bearing 4. Ð Fill the lubricating oil to bearing.

! Be careful the direction of taper roller bearing.

Ð Assemble the lubricating oil.

bearings

10,

12

and

fill

! The outer diameter is same for the bearings. Be careful not to confuse them. ¥ Assemble the cover to gear case. Ð Install the packing 18 to gear case. (Use new packing.) Ð Assemble as checking the position of bearing of cover gear shaft attached to gear case. ¥ Install the bolts (6pcs).

Tightening torque

20~25 kgám

DRIVING AND STEERING SYSTEM STEERING GEARBOX

¥ Tube 8 (Assemble the pipe.) ★ Install the effectuve threads facing cover.

20 05 11

Ð Tighten the lock nut 5 to tube 8.

! Apply Loctite (#262) to more than 2 threads of tube, and then assemble the cover. Ð Check the blocking part of tube, and measure the torque of pinion gear 11. Tighten the torque tube with torque of 0.003~0.008kgám. Ð Tightnen the lock nut 5.

Tightening torque

20~25 kgám

Ð Check the tightening torque of pinion gear 11 again. ¥ Install the universal joint 7. Ð Tighten the lock nut 5 to tube 8. Ð Apply Loctite to more than 2 threads of tube.

! Never fail to apply Loctite.

DRIVING AND STEERING SYSTEM STEERING GEARBOX

Ð Tighten the universal joint.

Tighten the lock nut temporarily to the dimension in figure.

20 05 12

¥ Assemble the motor assÕy. Ð Install the packing 19 and joint 15. Ð Assemble the motor assÕy 20, and tighten with bolts (3pcs).

Tightening torque

1.9~3.1 kgám

¥ Adjust the phase of motor assÕy for mount hole of unversal joint. Ð Match the phase before disassembly because of mouting relation against machine body and perventing interference. Ð Tighten the lock nut firmly.

Tightening torque

20~25 kgám

Ð Lap the rubber boot to gear case and wind with 2 strands of wires. Ð Install the bleeder plug. (Use new parts.)

! After assembling, the bleeder plug must not face downwards.

Check the center arm and ball stud for abnormality.

DRIVING AND STEERING SYSTEM ACTUATOR

STRUCTURE

20 06 1

1.

2.

3.

4.

5.

6.

7.

8.

Gear box Cover Plate Bearing Lock nut Ball screw assÕy Universal joint Tube

9.

10.

11.

12.

13.

14.

15.

16.

Gear Bearing Gear Bearing Joint Bleeder plug Bolt Packing (cover)

17.

18.

19.

20.

21.

Motor assÕy Packing (motor) Bolt Boot 22. Clamp

DRIVING AND STEERING SYSTEM ACTUATOR

DISASSEMBLY/ASSEMBLY TROUBLE DIAGNOSTICS Part name

20

Universal joint

¥ Impact in axial and rotational direction ¥ Abnormal turning of bearing ¥ Damage or crack of spider ¥ Bending

Replace actuator

Boot

¥ Crack, hardening

Replace boot

¥ Malfuntion

Replace motor

¥ Brush length (less than 13mm)

Replace brush

06 2

Inspecting items

Motor assÕy

¥ Fill the grease to grease nipple priodically for universal joint. ¥ Never use the rubber packing and wire clamp again.

REPLACING MOTOR REMOVAL ¥ Hold the actuator on vice laterally.

! If holding vertically to disassemble the boot, the ball screw can turn by its own weight causing damage of ball tube.

DRIVING AND STEERING SYSTEM ACTUATOR

¥ Disassemble the motor by removing bolts (3 pcs).

! Be careful not to drop the motor. If it is stuck, tap the motor with plastic hammer.

Do not apply strong impact.

¥ Remove the packing from motor mounting face, and clean completely.

! Be careful not to miss motor joint while disassembling motor.

20 06 3

INSTALLATION ¥ Apply grease to inner tooth of motor joint, and assemble the motor by installing new packing on motor mounting face.

1.9~3.1kgfám

DRIVING AND STEERING SYSTEM ACTUATOR

REPLACING BOOT ¥ Loosen the wire clamp and remove connector. Disassemble the boot.

the

! Do not apply excessive force to actuator body when assembling or removing the connector. ¥ When assembling new boot, put the large outer diameter of boot facing actuator body.

20 06 4

¥ After confirming the assembling position of bleeder plug and ball joint, and then perform clamping. ¥ Wind the wire clamp 2 turns and twist 4~5 times so that the boot will not rotate circumferencial direction.

¥ After clamping, bend the wire so tht it cannot be interfered with boot and body.

HYDRAULIC SYSTEM

¥ 30 Ð 01 MAIN PUMP Ð Specifications and Structure Ð Disassembly/Assembly Ð Trouble Diagnostics Ð Operations ¥ 30 Ð 02 CONTROL VALVE Ð Control of Pressure Ð Trouble Diagnostics Ð disassembly Hydraulic Valve Ð Assembling Hydraulic Valve ¥ 30 Ð 03 HYDRAULIC CYLINDER Ð Disassembly / Assembly Ð Tilt cylinder ¥ 30 Ð 04 HYDRAULIC CIRCUIT DIAGRAM

30

H Y D R A U L I C

S Y S T E M MAIN PUMP

SPECIFICATIONS AND STRUCTURE

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Pump model

P315

Delivery quantity

17.8 cc/rev (1.09 cu.in/rev)

Max. pressure

246 kgf/cm2 (3500psi)

Max. rpm

3000 rpm

Shaft cover Bushing Gear housing Port cover Bushing Gear set Thrust plate Channel seal Square seal Dust seal Dowel pin Bolt Washer

30 01 1

H Y D R A U L I C

S Y S T E M MAIN PUMP

DISASSEMBLY/ASSEMBLY DISASSEMBLY ¥ Clean out the dirts from outside of pump. ¥ Mount the pump to the vice as the pump shaft cover (1) downwards.

! When mounting the pump to the vice, use wooden piece or copper plate to prevent damage ¥ Before disassembling, make match marks on the shaft cover, gear housing and port cover. ¥ When removing the port cover (4), pull out upwards. If it is difficult, use plastic hammer. ¥ Remove the square seal (9) and the channel seal (8). ¥ Remove the thrust plate (7) and the gear set (6).

! Remove the gear set at a time, and keep them mesh. Otherwise, make a match mark

30 01 2

on the gear side. ¥ Disassemble the gear houshing (3) from the shaft cover (1). ¥ Remove the dust seal (10) from the shaft cover.

! Pay attention not to damage the mounting face of dust seal.

ASSEMBLY ¥ Check all the parts for breakage and wear. If necessary, replace them.

! Before assembling, lubricate them. ¥ Install a new dust seal (10) to the shaft cover (1).

! When installing seal, use proper tool. Make sure that the seal lip towards pump. ¥ Install the square seal to the gear housing. ¥ Install the channel seal to the thrust plate. ¥ Assemble the thrust plate with seal to the shaft cover.

! Do not force excessively. Keep the thrust plate level and assemble the gear housing.

Make the groove of thrust plate toward discharge direction of gear housing. ¥ Assemble the gear set.

! Make sure the match mark on gear side. ¥ Install the seal to the thrust plate as it towards the port cover. ¥ Tighten the port cover with bolts and fasten firmly.

H Y D R A U L I C

S Y S T E M MAIN PUMP

INSPECTION AND JUDGEMENT Clean the parts completely and inspect to judge if it can be used again. The followings are inspection standards.

GEAR HOUSING Check the portion where the housing contacts to the gear while its rotating. If the contact portion is worn lightly and the depth is less than 0.18mm, it can be used again.

The contact trace within half of inner diameter of gear hole will be proper. Inspect the gear housing if there is any circumferential damage cauing pressure loss or malfunction. Pay attention so the seal will not be caught in.

GEAR Check the tooth face of gear for stepped part or dint. Especially, the bearing mount part will be free from scratch or impact. This face must be smooth and lustrous.

If the dimension of fd is less than 23.887mm, replace the gear set. If the shaft seal mount part is abnormally damaged or scratched, replace the gear.

THRUST PLATE The surface of thrust plate is coated with gray teflon.

Under normal condition, light trace by gear contact will be appeared. If the contact is uniform, it can be admitted. However, if the total thickness is less than 4.984mm, replace the thrust plate.

30 01 3

H Y D R A U L I C

S Y S T E M MAIN PUMP

If the dowel pin is damaged, replace it.

If the gear housing or port cover assembled part is loose, replace the relevant parts.

SEAL Replace all the seal with new ones.

30 01 4

BUSHING When replacing the gear set, bushing at the same time.

Replace the bushing as set.

replace

the

H Y D R A U L I C

S Y S T E M MAIN PUMP

TROUBLE DIAGNOSTICS Symptom

The oil is not dischared from the pump.

The pressure is low.

Abnormality and cause

Countermeasure

The rotating direction of pump is improper.

Ð Correct the rotating direction. Ð Check the drive for pump shaft driving.

The coupling or shaft is cut.

Replace the relevant parts.

The oil suction port is clogged.

Remove the foreign materials on suction strainer and filter.

The oil viscosity is too high.

Replace oil with proper viscosity.

The air is mixed through suction port.

Check the air mixed position and retighten.

30

The relief valve spring is broken or it is stuck as open condition.

Replace the relief valve.

01

The inner part of pump is broken.

Repair the pump.

The set value of relief valve is low.

Adjust the relief pressure.

The oil inside of pump is leaked.

Replace the worn parts of pump.

The suction port is partially clogged.

Check the suction strainer suction port, and correct.

Cavitation is formed by air mixed through the suction port.

Check the air mixed position and retighten.

The pump driving speed is too high or to low.

Drive the pump in normal speed.

The alignment of pump drive shaft is poor.

Check the shaft seal or bearing, replace the worn parts, and align the driving shaft.

Oil is leaked from shaft seal.

Check the worn parts, and replace the worn parts and shaft seal.

Oil is leaked from pump housing.

Check the OÐring and OÐring groove, and replace, if necessary.

5

and

Noise

External leakage

H Y D R A U L I C

S Y S T E M MAIN PUMP

OPERATIONS After repairing, refill the hydraulic oil. This helps the pump operate easily and prevents worn.

When the pump rotates at the speed of more than 600rpm, it must discharge normally.

After operating, perform air bleeding. In this time, release the fitting in discharge section to bleed the air.

30 01 6

H Y D R A U L I C

S Y S T E M CONTROL VALVE

CONTROL OF PRESSURE ! Observe the following. Ð Park the fork lift on even ground. Ð Apply the parking brake. Ð Put wooden block in front of / behind the wheels not to move.

SPECIFICATIONS

30

Main relief pressure Model

BK16

1

CEP15 160 CEP18 CEP20 185 CEP25

02

H Y D R A U L I C

S Y S T E M CONTROL VALVE

CONTROL ! Open the hydraulic tank cap slowly to release the pressure. Operate the control lever several times to remove the remaining pressure in hydraulic pressure. ¥ Disaaemble the measuring plug of vavle inlet fitting (PT 1/8²). ¥ Install the pressure gauge. ¥ Pull the tilt lever to check the main relief pressure, and adjust, if necessary.

! Do not relief for a long time.

Do not raise the pressure above the specified value.

30 02

¥ Release the lock nut and turn the regulating screw to adjust the relief pressure of main control valve. Turning CW, the pressure will rise, and CCW, it will drop.

2

¥ Confirm the pressure, and adjust again, if necessary.

! Do not raise the pressure above the specified value.

H Y D R A U L I C

S Y S T E M CONTROL VALVE

TROUBLE DIAGNOSTICS Symptom

¥ The spool is leaked at one side. ¥ The spool will not return to neutral.

¥ The hydraulic system will not work or rattle.

¥ It will not be released.

(High pressure)

¥ The pressure is not obtained.

¥ The fork will drop just as the spool turns neutral to operation position.

Abnormality and cause

Countermeasure

The OÐring in valve body is damaged.

Replace the OÐring.

The spring is broken.

Replace the spring.

The spool is bent.

Replace the spool.

Foreign materials are sucked.

Clean the valve.

Arrangement of working linkage is poor.

Check and correct the working linkage.

Assembling torque of valve body is poor.

Tighten to the specified torque.

Set value of relief valve is abnormal or the valve is stuck.

Repair, clean and adjust.

Foreign materials on relief valve seat

Disassemble, assemble.

Inside of valve body is cracked.

Replace the valve.

The spool does not work to the end.

Check the condition of spool.

Foreign materials are sucked in relief valve orifice.

Check and clean the orifice.

The relief valve is poor assembled.

Reassemble.

Internal leakage between the spool and the body.

Replace the valve.

Central alignment of spool is poor.

Check the spring.

Foreign materials are sucked in check valve seat.

Disassemble and clean.

The check valve seat is damaged.

Replace.

30 02

clean

3

and

H Y D R A U L I C

S Y S T E M CONTROL VALVE

DISASSEMBLING HYDRAULIC VALVE The hydraulic control valve assembly is consist of sub assembling parts and parts written as below. The disassembly is limited to necessary sub assembling parts and parts.

30

Hydraulic control valve

IN/OUTLET

Ð Main relief valve

AUX. ASSÕY

Ð Load check

TILT ASSÕY

Ð Tilt lock valve Ð Load check

LIFT ASSÕY

Ð Load check

02 4

END COVER

Above composition diagram is for three serial valve. ¥ For four serial valve, an aux. assembly is added. ¥ Two serial valve is consist of lift assembly and tilt assembly.

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method

Picture

1. Hold the nut in B side with the wrench for socket wrench and disassemble the nut and washer in A side.

2. Disassemble each section from the stud bolt and put them on the work bench in order. At this time, put the OĂ?ring which is between the joining surfaces of sections beside the disassembled section.

30 02 5

DISASSEMBLING MAIN RELIEF VALVE 3. Disassemble the in/outlet section.

main

relief

from

NOTE : To prevent the joining surface of section from being damaged, disassemble on the vice with aluminum or brass attached.

DISASSEMBLING LIFT MAIN SPOOL 4. Mount the section assembly to the vice and disassemble the socket bolt of spool cap. (2 places) NOTE : To prevent the joining surface of section from being damaged, disassemble on the vice with aluminum or brass attached.

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method 5. Disassemble the spool cap.

Put the parts disassembled on clean work bench in order.

6. Disassemble the main spool assembly from the section body slowly.

30 02 6

! While disassembling, if the spool does not come out easily push in again and turn slowly to disassemble. If you apply excessive force while disassembling the body can be damaged.

Note ÂĽ The body and the main spool are assembled in a pair so that they are not interchangeable. ÂĽ Be careful not to mix the body with the main spool.

(It is recommended to attach tags to distinguish.)

7. Mount the section to the vice in the opposite direction and disassemble the socket bolt. (2 places)

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method

Picture

8. Disassemble the retainer plate, backup ring and OĂ?ring.

Put the parts disassembled on clean work bench in order.

9. Mount the spool assembly disassembled in previous section 6 to the vice by using the jig.

10. Loosen the retainer bolt and disassemble the spring retainer, shim spring, retainer plate, backup ring and OĂ?ring.

Put the parts disassembled on clean work bench in order.

! Be

careful when disassembling retainer bolt in above section 10 because the parts can be sprung out by spring force.

NOTE : For disassembling method of load check, refer to section 25 and 26.

DISASSEMBLING TILT MAIN SPOOL 11. Mount the section assembly to the vice and disassemble the socket bolt of spool cap. (2 places) NOTE : To prevent the joining surface of section from being damaged, disassemble on the vice with aluminum or brass attached.

30 02 7

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method 12. Disassemble the spool cap.

Put the parts disassembled on clean work bench in order.

13. Disassemble the main spool assembly from the section body slowly.

30 02 8

! 짜 While disassembling, if the spool does not come out easily push in again and turn slowly to disassemble. 짜 If you apply excessive force while disassembling the body can be damaged.

Note 짜 The body and the main spool are assembled in a pair so that they are not interchangeable. 짜 Be careful not to mix the body with the main spool. (It is recommended to attach tags to distinguish.)

14. Mount the section to the vice in the opposite direction and disassemble the socket bolt. (2 places)

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method

Picture

15. Disassemble the retainer place, backup ring and OÐring.

Put the parts disassembled on clean work bench in order.

16. Mount the spool assembly disassembled in previous section 13 to the vice by using the jig.

17. Loosen the retainer bolt and disassemble the spring retainer, shim spring, retainer plate, backup ring and OÐring. Disassemble the tilt lock spool and spring in the spool too.

Put the parts disassembled on clean work bench in order.

! ¥ Be careful when disassembling the retainer bolt in section 17 because the parts can be sprung out by spring force. ¥ Only the tilt section of shim out of the parts disassembled in section 17 is different. Therefore, put it separately.

NOTE : For disassembling method of load check, refer to section 25 and 26.

DISASSEMBLING AUX. MAIN SPOOL 18. Mount the section assembly to the vice and disassemble the socket bolt of spool cap. (2 places) NOTE : To prevent the joining surface of section from being damaged, disassemble on the vice with aluminum or brass attached.

30 02 9

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method 19. Disassemble the spool cap. Put the parts disassembled on clean work bench in order.

20. Disassemble the main spool assembly from the section body slowly.

30 02 10

! 짜 While disassembling, if the spool does not come out easily push in again and turn slowly to disassemble. 짜 If you apply excessive force while disassembling the body can be damaged.

NOTE : 짜 The body and the main spool are assembled in a pair so that they are not interchangeable. 짜 Be careful not to mix the body with the main spool. (It is recommended to attach tags to distinguish.)

21. Mount the section to the vice in the opposite direction and disassemble the socket bolt. (2 places)

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method

Picture

22. Disassemble the retainer plate, backup ring and OĂ?ring. Put the parts disassembled on clean work bench in order.

23. Mount the spool assembly disassembled in previous section 20 to the vice by using jig.

24. Loosen the retainer bolt and disassemble the spring retainer, shim spring, retainer plate, backup ring and O-ring. Put the parts disassembled on clean work bench in order.

! Be careful when disassembling the retainer bolt in above section 24 because the parts can be sprung out by spring force.

NOTE : For disassembling method of load check, refer to section 25 and 26.

DISASSEMBLING LOAD CHECK Disassembling methods of lift, tilt and aux. assembly are all same.

25. Mount the section to the vice and disconnect the plug in upside of the body with socket for socket wrench.

30 02 11

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Disassembling method 26. Disassemble the plug, spring and check poppet. Put the parts disassembled on clean work bench in order.

! Disassembled check poppet and body keep good seating condition during the working period. Therefore, be careful not to be mixed.

30 02 12

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

ASSEMBLING HYDRAULIC VALVE The hydraulic control valve assembly is consist of sub assembling parts and parts written as below. The assembly is limited to necessary sub assembling parts and parts.

Hydraulic control valve

IN/OUTLET

Ð Main relief valve

AUX. ASSÕY

Ð Load check

TILT ASSÕY

Ð Tilt lock valve Ð Load check

30 02

LIFT ASSÕY

END COVER

Above composition diagram is for three serial valve. ¥ For four serial valve, aux. assembly is added. ¥ Two serial valve is consist of lift assembly and tilt assembly.

Ð Load check

13

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method

ASSEMBLING LOAD CHECK Assembling methods of lift, tilt and aux. assembly are all same.

1. Arrange the check poppet, spring and plug in order for assembling.

! Inspect that the condition of OÐring assembled to the plug is good with naked eyes. If damaged, replace it.

30 02 14

2. Mount the body and the section to the vice and put the check poppet first into the upper hole, assemble the spring and finally tighten the plug with following torque by using the socket for socket wrench as the arranged order in section 1.

Tightening torque

8.1~8.9 kgfám

Tool

Socket hex. 27mm

! When assembling the plug, assemble with your hand about 3 to 5 threads and then tighten with a tool.

ASSEMBLING LIFT MAIN SPOOL 3. To assemble, arrange the OÐring, backÐup ring, retainer plate, spring retainer, spring, shim, spring retainer and retainer bolt in order.

! Inspect that the condition of OÐring assembled to the retainer bolt is good with naked eyes.

If it is damaged, replace it.

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method

Picture

4. Mount the lift spool to the vice by using the jig. Assemble the parts arranged in the order of above section 3. Apply loctite on the retainer bolt a little and tighten with following torque by using the socket wrench.

Tightening torque

1.4 ± 0.14 kgfám

Tool

Socket wrench 5mm

Loctite No.

TL277 or equivalent

5. To assemble, arrange the OÐring, backÐup ring, retainer plate, spring washer and socket bolt in order.

30 02 15

6. Mount the body to the vice and assemble the parts arranged in the order of above section 5. Tighten the socket bolt with following torque by using the socket wrench. (2 places) Tightening torque

1.4 ± 0.14 kgfám

Tool

Socket wrench 5mm

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method 7. Assemble the lift spool assembly assembled in the previous section 4 to the body.

! ¥ At this time, assemble it smoothly. ¥ If you apply excessive force while assembling, the body can be damaged.

30 02 16

8. After mount the body to the vice, apply grease on the return spring part of the spool assembly, put on the spool cap and tighten the socket bolt with following torque by using the socket wrench. (2 places) Tightening torque

0.9 ± 0.1 kgfám

Tool

Socket wrench 5mm

ASSEMBLING TILT MAIN SPOOL 9. To assemble, arrange the tilt lock spool, spring, OÐring, backup ring, retainer plate, spring retainer, spring, shim, spring retainer and retainer bolt in order.

! Inspect that the condition of OÐring assembled to the retainer bolt is good with naked eyes. If it is damaged, replace it.

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method

Picture

10. Mount the tilt spool to the vice by using the jig. In the order of above section 9, first put the tilt lock spool and spring into spring, second assemble other parts in order, and apply loctite on the retainer bolt a little, finally tighten it with following torque by using the socket wrench.

Tightening torque

1.4 ± 0.14 kgfám

Tool

Socket wrench 6mm

Loctite No.

TL277 or equivalent

11. To assemble, arrange the O-ring, backup ring, retainer place, spring washer and socket bolt in order.

30 02 17

12. Mount the body to the vice and assemble the parts arranged in the order of above section 11. Tighten the socket bolt with following torque by using the socket wrench. (2 places) NOTE : The assembling position is the spool hole in the opposite side of the gauge port.

Tightening torque

1.4 ± 0.14 kgfám

Tool

Socket wrench 5mm

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method 13. Mount the body to the vice in the opposite direction and assemble the tilt spool assembly assembled in previous section to the body.

! At this time, assemble it smoothly.

If you apply excessive force while assembling, the body can be damaged.

30 02 18

14. After mount the body to the vice, apply grease on the return spring part of the spool assembly, put on the spool cap and tighten the socket bolt with following torque by using the socket wrench. (2 places) Tightening torque

0.9 ± 1.0 kgfám

Tool

Socket wrench 5mm

ASSEMBLING AUX. MAIN SPOOL 15. To assemble, arrange the OÐring, backup ring, retainer plate, spring retainer, spring, shim, spring retainer and retainer bolt in order.

! Inspect that the condition of OÐring assembled to the retainer bolt is good with naked eyes. If it is damaged, replace it.

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method

Picture

16. Mount the aux. spool to the vice by using the jig. Assemble the parts arranged in the order of above section 15. Apply loctite on the retainer bolt a little and tighten it with following torque by using the socket wrench.

Tightening torque

1.4 ± 0.14 kgfám

Tool

Socket wrench 5mm

Loctite No.

TL277 or equivalent

17. To assemble, arrange the OÐring, backup ring, retainer place, spring washer and socket bolt in order.

30 02 19

18. Mount the body to the vice and assemble the parts arranged in the order of above section 17. Tighten the socket bolt with following torque by using the socket wrench. (2 places) NOTE : The assembling position is the left side spool hole when you see the OÐring groove of the body joining surface in the front.

Tightening torque

1.4 ± 0.14 kgfám

Tool

Socket wrench 5mm

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method 19. Assemble the aux. spool assembly assembled in previous section 16 to the body.

! At this time, assemble it smoothly.

If you apply excessive force while assembling, the body can be damaged.

30 02 20

20. After mount the body to the vice, apply grease on the return spring part of the spool assembly, put on the spool cap and tighten the socket bolt with following torque by using the socket wrench. (2 places) Tightening torque

0.9 ± 0.1 kgfám

Tool

Socket wrench 5mm

ASSEMBLING MAIN RELIEF VALVE 21. Assemble the main relief valve to inlet/outlet section with following torque.

Tightening torque

5.0~6.0 kgfám

Tool

Long socket HEX.24

Picture

H Y D R A U L I C

S Y S T E M CONTROL VALVE

Assembling method

Picture

ASSEMBLING ASSEMBLY 22. Assemble the OÐring to the joining surface of each section, arrange the section in the order of in/outlet, aux, tilt, lift. and end cover and assemble the stud bolt.

! When assembling the stud bolt, be careful that the OÐring of body joining surface does not come out. ¥ The two serial valve has no aux. valve.

23. Assemble the nut and spring washer with following torque.

! ¥Tighten it in the diagonal direction. ¥ Divide the tightening torque into two types as 1st and 2nd.

Tightening 1st torque Tool

3.0~3.5 kgfám

2nd 4.0~4.5 kgfám Socket hex. 17mm(2EA)

30 02 21

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

DISASSEMBLY/ASSEMBLY LIFT CYLINDER DISASSEMBLY Clean the outside of cylinder before disassembling.

Push the cylinder rod to drain the hydraulic oil. Be careful not to suck foreign materials while cylinder disassembling or assembling. ¥ Mount the cylinder on the vice.

Do not force excessively.

30 03 1

¥ Disassemble wrench.

the

cylinder

gland

by

hook

¥ After removing the gland, pull out the piston rod from the cylinder.

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

¥ Remove the piston packing and wear ring from the piston rod.

¥ Take out the retaining ring from the gland, and disassemble the dust wiper dry bushing, rod packing, OÐring and backÐup ring.

30 03 2

INSPECTION ¥ Clean all the disassembled parts with cleaning oil, and arrange them on a clean place. ¥ Check the piston rod for damage or scratch. Correct the slight scar by oil stone. ¥ Check the cylinder tube. ¥ If there is deep scar or heavily damaged, replace it. Inspect the thread portion of gland. ¥ Lubricate all the parts with hydrailic oil.

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

ASSEMBLY ¥ Assemble new retaining ring, dust wiper, bushing and rod packing to the gland. Install new backÐup ring and OÐring.

¥ Install new piston packing and wear ring to the piston rod.

30 03 3

¥ Apply hydraulic oil to the piston rod and assemble it to the cylinder tube.

¥ Apply hydraulic oil to the gland, and assemble it to the cylinder tube by hook wernch.

Be careful not to damage the seal when tightening the gland.

30 ± 3kfgám (216 ± 22lbfáft)

! After assembling the cylinder, check the working condition and oil leakage.

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

TILT CYLINDER

DISASSEMBLY Clean the outside of cylinder before disassembling.

Push the cylinder piston to drain the hydraulic oil.

Be careful not to suck foreign materials while cylinder disassembling or assembling. ¥ Mount the cylinder on the vice.

Do not force excessively.

30 03 4

¥ Disassemble the gland by hook wrench.

¥ After removing the gland, pull out the rod assÕy from the tube.

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

¥ Disassemble the piston and nut from the rod assÕy.

Remove the piston packing and wear ring from the piston.

¥ Take out the retaining ring from the gland, and disassemble the dust wiper, bushing and rod packing.

30 03 5

INSPECTION ¥ Clean all the disassembled parts with cleaning oil, and arrange them on a clean place. ¥ Check the rod for damage. Correct the slight scar on the plated face by oil stone. ¥ Inspect the inside of tube. If heavily damaged, replace it. ¥ Lubricate all the parts with hydrailic oil.

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

ASSEMBLY ¥ Assemble new retaining ring, dust wiper, bushing and rod packing to the gland. Install new back-up ring and OÐring.

¥ Install new piston packing and wear ring to the piston, and assemlbe it to the rod by nut.

30

63 ± 6.3kgfám

03 6

¥ Apply hydraulic oil to the piston rod and assemble it to the tube.

¥ Apply hydraulic oil to the gland, and assemble it to the tube by hook wernch.

Be careful not to damage the seal.

46 ± 7kfgám

H Y D R A U L I C

S Y S T E M HYDRAULIC CYLINDER

Â¥ After assembling the cylinder, check working condition and oil leakage.

the

30 03 7

H Y D R A U L I C

S Y S T E M HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM

LIFT CYL. TILT CYL.

FLOW LIMITING FLOW REGULATOR

RETURN LINE

MAIN VALVE

30 04

CHECK PORT PT 1/8"

1

AIR BREATHER

P315 GEAR PUMP

RETURN FILTER

STRAINER

HYD TANK

ATTACHMENTS

¥ 40 Ð 01 MAST Ð General Ð Maintenance ¥ 40 Ð 02 OTHER ACCESSARIES Ð Carriage Ð Cylinder racking Ð Lift chain Ð Fork ¥ 40 Ð 03 COUNTERWEIGHT Ð Maintaining counterweight

40

A T T A C H M E N T S MAST

GENERAL CAUTIONS ! When inspecting or maintaining the mast, carriage or fork, observe the following items. ¥ Do not put the hand in the mast. ¥ If the fork is lifted, never pass or stand under the fork. ¥ When using supports to prevent rail or carriage from falling, use wooden blocks so that the ends arenÕt be damaged. ¥ Confirm the capacity of chain and hook are acceptable and the condition is fine. ¥ Before starting the maintenance, know thoroughly the inspecting and control procedures.

If not, accident may be occured.

INSPECTIONS BY NAKED EYES Perform inspections by naked eyes daily. Detail inspection for mast assÕy must be performed by every 500hours at minimum.

40

MAST Inspect Inspect Inspect Inspect

the roller clearance and wear. the mast for arranging condition and smooth operation. loose bolt of mast mounting bracket and trunnion. the oil leakage of hydraulic hose or interference with mast.

CARRIAGE Inspect the roller clearance.

Inspect the fork bar for excessive wear or damage and smooth operation.

CHAIN Check the tension.

Check the lubricating condition.

Inspect for corrosion, bending or crack.

Inspect the chain mouting parts for wear or damage.

CYLINDERÐLIFT, TILT Check the oil leakage from seal.

Inspect the cylinder rod for scratch or scar.

Confirm the racking of cylinder. (The stroke for lift cylinder and tilt cylinder is different.)

01 1

A T T A C H M E N T S MAST

MAINTENANCE REMOVAL / INSTALLATION OF MAST REMOVAL

40 01

¥ Park the fork lift on even ground and align the drive wheel and steering wheel. ¥ Apply the parking brake and detach the fork. ¥ Tilt the mast forward fully. ¥ Support drive wheel and steering wheel with wooden blocks not to move, and turn off the start switch. ¥ Put an oil container under mast rail. ¥ Disassemble the hose between MCV and flow control valve. ¥ Lock the center of outer rail with overhead crane. ¥ Disassemble the bolt and tilt cylinder lock pin.

If appropriate tension isnÕt applied to overhead crane, the mast can be fall down just when the tilt cylinder lock pin is removed. Take special attention to the safety. ¥ Remove the bolt of trunnion bracket on the mast lower mounting part. ¥ Lift the mast with overhead crane to move forwards slowly.

2

REMOVAL ¥ Work as reverse order of removal for installing mast. ¥ When assembling the hose, take care of the direction of oil flow control valve and limit valve.

! If

the limiting valve is improperly installed, the hose will be damaged causing abrupt falling of carriage. Serious accident or death can be occured.

Bracket

Bolt

A T T A C H M E N T S MAST

TRUNNION BUSHING Inspect the following items for trunnion bushing. ¥ Check the trunnion cap bolt for missing, broken, bent ¥ Raise the mast 305~610mm from the ground and tilt ¥ Measure the clearance between trunnion cap and axle ¥ The clearance must be within 0.75 mm. ¥ If the clearance is excessive, replace the bushing or

or loose. If damaged, replace the parts. forwards fully. mount bushing face by clearance gauge. cap.

FLOW LIMIT VALVE Flow limit valve is installed to one lift cylinder so as to slow down the lowering speed of cylinder when the flow control valve or hydraulic hose is borken.

With normal lowering speed of cylinder, the pressure for cylinder inside and hydraulic pressure are almost same, so the flow limit valve will not operate but the flow control valve will control the lowering speed.

If the flow control valve is defective or the hoses burst, the pressure of cylinder and valve outlet will be different. The pressure inside of valve pushes the plunger so the outlet port, which decreases the lowering speed, will become smaller.

! When assembling, the arrow on valve must face opposite direction of cylinder mounting portions. If not, the valve will not operate.

40 01 3

1.

2.

3.

4.

5.

6.

OÐring Nipple Nipple stopper Body Spring Plunger

A T T A C H M E N T S MAST

FLOW REGULATOR VALVE Flow regulator valve is installed to master assĂ&#x2022;y. It controls the returned oil flow from lift cylinder so as to control the lowering speed of cylinder. If the lift cylinder is lowered, the check valve inside of flow regulator valve will close so that all the returned oil will flow through variable orifice to regulator the lowering speed of cylinder.

! When assembling, the arrow on valve must face the cylinder.

1.

2.

3.

4.

Housing Tee Valve OĂ?ring

40 01 4

Limit valve

A T T A C H M E N T S MAST

INSPECTING MAST AND CARRIAGE SHIM ¥ Park the fork lift where the fork can be lifted to max. height. ¥ Make the steering wheel parallel with chassis, apply the parking brake, and then put wooden blocks around the front and rear wheels.

Tilt vertically (0¡), and lower down the fork from the max. lift height as 50mm. Turn the start switch OFF. ¥ Prepare 0.5mm clearance gauge and CÐtype clamp.

Press the bearing. Insert block to the portions pressed by clamp so that the force will be supplied evenly without deformation of rail face or damage of bearing. ¥ Tighten the clamp with specifed torque.

27kgfám ¥ Fit the clearance gauge (0.5mm) between the oppostie side rail face locked by CÐtype clamp and the bearing surface. ¥ If the clearance gauge isnÕt available, use the standard shim (0.5mm). ¥ The inspection of shim for 3Ðstage mast is same as that for 2Ðstage mast. Only inspecting portion is added.

! The clearance between rail and roller will be measued for the shortest portion. If the clearance gauge (0.5mm) can pass but the one (1mm) canÕt, shim needs not to be adjusted.

40 01 5

A T T A C H M E N T S MAST

INSPECTING AND ADJUSTING CARRIAGE SIDE ROLLER CLEARANCE Upper and lower bearing of carriage can be inspected and adjusted, but the center bearing canÕt. After inspecting upper and lower bearing of carriage, disassemble the carriage to inspect center bearing and side roller. ¥ Remove the carriage. ¥ Inspect and adjust the shim clearance of upper and lower bearing of carriage as same for mast. The number of shims for right and left will be the same as possible. ¥ Adjust the shims of center and side roller by square ruler. ¥ When contacting the square ruler to the bearing, take the most protruded portion of each bearing to be standard line. Center and side roller bearing will be contacted perpendicularly with the square ruler.

ADJUSTING STANDARD MAST SHIM

40 01

! This procedure must be performed only the trained personnel.

DISASSEMBLY

6 Disassemble some parts to adjust the rail roller clearance. ¥ Remove the carriage from the mast.

A T T A C H M E N T S MAST

¥ Put the driving wheel on the block so that the mast end is 153~203mm from the ground. ¥ Apply the parking brake, and put blocks around the steering wheel. ¥ Make the mast vertical.

¥ Remove the lock bolt of lift cylinder rod, and remove the U-clamp locking outer rail and lift cylinder, bolt and cushion.

In this case, remvoe the safety lock necessary to hold the cylinder. ¥ Raise the inner rail by overhead crane. ¥ Remove the hoses and fittings to diassemble the lift cylinder. ¥ Remove the lift cylinder. ¥ Lower the overhead crane slowly. The outer upper roller and the inner lower roller will be seen.

! When disassembling lift cylinder, record the number of shims assembled to cylinder rod end. ¥ Remove the wooden blocks under inner rail, and lower slowly.

Then, outer rail and inner rail roller will be seen. ¥ Replace the bearing and adjust the shim, if necessary.

! Make the number of shims be same, as possible.

40 01 7

A T T A C H M E N T S MAST

INSERTING SHIM ¥ Disassemble the roller by tapping lightly. ¥ After measuring the clearance, if even number of shims are required, insert same number of shims between roller and rail for both sides. ¥ If odd number of shims are required, insert even number of shims to one side and odd number of shims to the other side. For example, if 3 shims are required, insert 2 shims to left side roller and 1 shim to right. ¥ If the bearing doesnÕt work smoothly, check and replace the roller. ¥ After inserting the shim, assemble the roller by roller tightly.

ASSEMBLING ¥ After adjusting shim, lift up the inner rail by overhead crane. ¥ After installing the lift cylinder and locating the lower part in position, assemble the lift cylinder rod to inner rail upper tieÐbar. ¥ Insert the shims to lift cylinder, and assemble together with tieÐbar.

40 01 8

! Use the disassembled shims only. ¥ Assemble the cylinder calmp bracket, rubber cushion bolt and UÐclamp bolt.

1~2kgfám (7~14lbfáft) ¥ Assemble the hydraulic hose and sheave. ¥ Assemble the lift chain. ¥ Assemble the carriage. ¥ Adjust the length of chain. ¥ Check the hydraulic oil level, and refill if necessary. ¥ Operate the mast up/down to confirm the interference.

Tightening torque for lock nut of lift cylinder rod end 26.7kgfám (193lbfáft)

A T T A C H M E N T S MAST

ADJUSTING SHIM OF TRIPLE STAGE MAST

! The shims of 3Ðstage mast must be adjusted trained personnel in the room with overhead crane. Some parts such as cylinder will be disassembled unlike 2Ðstage mast.

DISASSEMBLY ¥ Disassemble the carriage from mast. ¥ Remove the hoses connected to lift cylinder.

Put an oil container under the cylinder to prevent pollution of ground. ¥ Tie the hose end to outer rail or cawl to minimize the oil loss. Take care to prevent interference when other rail is raised or lowered. ¥ Remove the bolt of hose sheave, and disassemble the hose sheave. ¥ Tie the hose to prevent damage of inner or inter rail as raising or lowring. ¥ Remove the bent hosd of lift cylinder and tie around overhead guard. ¥ Remove the chains at left and right of lift cylinder. After supproting wooden blocks so that the outer, inner and inter rails are level with the ground, remove the pin and split pin of chain anchor, and then disassemble the chain. ¥ Tie the rail and cylinder by band or rope to prevent cylinder from falling aside even if the lift cylinder mounting bolt is disassembled. ¥ Remove the bolts tightened to lift cylinder and inter rail top tie bar. ¥ Lift up the inner and inter rail with overhead crane. ¥ Remove the lift cylinder. Support the wooden blocks under inter and inner rail to use the overhead crane. Remove the cylinder. The number of shims for left and right end of disassembled cylinder rod must be same.

40 01 9

A T T A C H M E N T S MAST

TRIPLE MAST CHECKING MAST AND CARRIAGE SHIM The procedure for checking the mast and carriage rail roller clearance is the same as that described for the standard mast.

40 01 10

A T T A C H M E N T S MAST

¥ Remove the wooden blocks under the inner and inter rail and lower down the rails to the ground with overhead crane. ¥ The upper bearing of outer rail and lower bearing of inter rail will be seen. ¥ Install the shims in accordance with the section of inspecting the shim for mast and carriage.

The number of shims for left and right will be the same as possible.

¥ Lift up the inter rail with overhead crane. ¥ The bearings of inter rail and inner rail will be seen. ¥ Install the shims in accordance with the section of inspecting the shim for mast and carriage.

The number of shims for left and right will be the same as possible. ¥ The asjustment for shim of triple stage mast is completed.

REASSEMBLY ¥ After adjusting the shim, lift up the inner and inter rail with overhead crane. ¥ Install the lift cylinder. Insert the shims to right and left of cylinder rod end as their disassembled positions. Tight the bolt of tie bar and cylinder.

Tighten bolt of tie bar : 26.7kgfám (193lbfáft) ¥ Assemble the chain and hose. (Assemble the carriage in accordance with the section of adjusting shim of carriage.) ¥ Adjust the chain length in accordance with the section of adjusting length of lift chain. ¥ If all the hoses are disassembled, assemble in accordance with the section of limit valve.

If the limit valve is abnormally assembled, hose can burst causing serious injury or death. ¥ Check the condition of hydraulic oil. Refill the oil as it is leaked. ¥ Lift up and lower down the fork to check interference.

40 01 11

A T T A C H M E N T S OTHER ACCESSARIES

CARRIAGE The cariages of standard mast and full free lift, 3Ðstage mast are very similar. The only difference is that the carriage of full free lift 3Ðstage mast is operated by lift cylinder installed at center.

REMOVAL ¥ Apply the parking brake and put the turn signal lever to neutral, and ¥ Tilt the mast vertical (0¡) to the ground. (Figure 1) ¥ Lift up the carriage 153~203 mm from the ground and put solid pallet under the fork. ¥ Lower the carriage fully until the fork is located on the pallet, and lock with 2 CÐclamps. ¥ In case of standard mast, lower the lift cylinder fully until the chain tension is completely eliminated. In case of full free lift 3Ðstage mast, lower until the chain tension for 1st cylinder is eliminated. Turn the start switch OFF. ¥ Remove the split pin from chain anchor on carriage rear side (standard mast), or remove the split pin from 1st cylinder to pull out the sheave and put it on the carriage. (full free lifr 3Ðstage mast) ¥ Lift up the inner rail until the carriage upper roller is seen. (Figure 2) ¥ Turn the start switch ON, release the parking brake, and then move the fork lift backwards slowly. (Figure 2)

40 02 1

A T T A C H M E N T S OTHER ACCESSARIES

Figure 1

Figure 2

INSTALL

40 02 2

¥ Confirm that the carriage is locked on the pallet firmly. ¥ Move the fork lift forwards slowly to align the carriage center. ¥ Lift up the inner rail until the carriage upper roller is seen. ¥ Tilt the mast so that the angle will be same as carriage assÕy. ¥ Stop the machine where the carriage bearing can be inserted into the inner rail when the inner rail is lowered, and apply the parking brake. ¥ Lower the inner rail slowly by operating the lever. ¥ Turn the start switch OFF, and support the steering wheel with wooden blocks. ¥ Install the lift chain. Use the split pin as a new one. ¥ Operate the fork up/down to check interference.

CYLINDER RACKING INSTALL Cylinder racking is occured when the lift and tilt cylinder storke is different from lift and tilt cylinder. ¥ Lift cylinder racking Ð It is occured when the rail reaches max. lift up position, one cylinder will stop and the other will operate continuly, so it is impacted. ¥ Tilt cylinder racking Ð It is occured when reaching utmost front or back tilt position, one cylinder will stop and the other will operate continuly, so it is twisted.

A T T A C H M E N T S OTHER ACCESSARIES

CONTROL LIFT CYLINDER ¥ Lift up the fork as 100mm from the ground with load. ¥ Check the tension of both chains, and control if necessary. ¥ Lower the carriage as the fork bottom is 13mm from the ground. Control the chain anchor so that the carriage can be lifted.

Tightening torque of lock nut : CEP15/18 : 11.3 ± 1.1 kgfám, CEP20/25 : 26.7 ± 2.7 kgfám ¥ Raise the lift cylinder to max. lift height, and check both cylinder rods stop at the same time. ¥ If racking is occured after controlling the chain, disassemlbe the lift cylinder rod, which stop working first, from the tie bar and add shims. ¥ After adjusting the shims, check again. ¥ Tigtening torque of lock bolt for lift cylinder rod end : CEP15/25 : 11.3 ± 1.1 kgfám

TILT CYLINDER ¥ Tilt the cylinder utmost front or back, and check both cylinder rods start and stop operating at the same time. ¥ If racking is occured, adjust the cylinder of which stroke is long. ¥ Loosen the clamp bolt of rod end yoke, and turn the cylinder rod to reduce the stroke. ¥ Fasten the clamp bolt after racking is eliminated.

CEP15/25 : 17.9 ± 1.8 kgfám

40 02 3

LIFT CHAIN Lift chain is very important component in the mast assÕy. Periodic inspection and maintenance are indispensable to delivery the lift force of hydraulic cylinder to the carriage (fork) safely and efficiently. To lengthen the life of chain, use the proper lubricating oil and adjust percisely.

LUBRICATING CHAIN Inspec the chain every 250 hours, and lubricate with jet lubricant or engine oil SAE20. If working condition is adverse, perform every 50 hours. To improve the durability of chain, the lubricant must be immersed in joint bewteen links. Lubricating of the outer surface prevents corrosion. (Figure 1)

A T T A C H M E N T S OTHER ACCESSARIES

CHAIN FAILURES ¥ If excessive force is applied to the chain without sufficient lubricating, pin can be come out or link can be broken. (Figure 2)

Figure 2

¥ The link can be cracked or broken by fatigue more than rated value. (Figure 3) ¥ Insufficient or improper lubrication causes breakage of rotating parts by stuck.

40 02 4

WEAR

Figure 3

If the chain is lengthen more than 3% against initial length, replace it. When replacing chain, replace all the chains used for lift device at the same time.

CORROSION The lift chain must be rustproof while operating and keeping. Rust on the chain causes crack so the rated capacity will be reduced.

CRACK The crack on chain may be occured by overloaded usage or impact, however in most cases it is caused by fatigue. Replace the cracked chain. When replacing chain, replace all the chains used for lift device at the same time.

STUCK The lift chain connection must be freely rotated. Stuck joint is caused by bent or rust of pin or plate. Never cut the worn chain, replace the whole chain.

A T T A C H M E N T S OTHER ACCESSARIES

CHAIN ANCHOR/CLEVIS BOLT Check the wear and damage of chain anchor. If the achror is worn or clevis pin and anchor threads are borken, replace the anchor assÕy.

CLEAN Use the exclusive cleaner for chain. Do not use steam.

INSPECTING CHAIN TENSION ¥ Put the mast vertical (0¡) with the ground. ¥ Rasie the fork 153mm from the ground with load. ¥ Move the chain to check the chain tension. ¥ If a chain tension is weak, lower the carriage and adjust the chain tension on both sides to be same. ¥ Check the chain tension again. ¥ Chain anchor lock nut CEP15/18 : 11.3 ± 1.1 kgfám CEP20/25 : 26.7 ± 2.7 kgfám

40 02 5

ADJSUTING LIFT CHAIN LENGTH STANDARD The chains are assembled from the middle tie bar of outer rail to the carriage for standard mast.

Two chains are assembled to mounting portions of 1st cylinder of full free lift 3Ðstage mast (middle of inner rail). ¥ Inspect the tire air pressure. ¥ Lift the rated load so as to apply max. lifting force to the chain. ¥ Put the mast vertical. ¥ Lower the carriage and inner rail completely. ¥ Adjust the carriage chain so that the fork bottom is 13mm from the ground. ¥ Check the chain tension again. ¥ Tighten the anchor lock nut.

CEP15/18 : 11.3 ± 1.1 kgfám CEP20/25 : 26.7 ± 2.7 kgfám

A T T A C H M E N T S OTHER ACCESSARIES

FULL TREE LIFT 3ÐSTAGE MAST There are 4 chains for full free lift, 3Ðstage mast. One set connects lower part of inner rail with top tie bar of outer rail, and the other connects mounting part of 1st cylinder with carriage. ¥ Check the air pressure of tires. ¥ Lift rated load so as to apply max. tention to the chain. ¥ Tilt the mast vertical (0¡) with the ground. ¥ Lower the inner and middle rails completely. ¥ Adjust the rear chain so that the inner rail is above 3.1mm from middle rail. ¥ Check the chain tension. ¥ Put the fork 13mm from the ground, and adjust the carriage chain. ¥ Check the chain tension again.

40 02 6

A T T A C H M E N T S OTHER ACCESSARIES

FORK REMOVAL / INSTALLATION ¥ Loosen the fork latch and push the fork to the notch of lower carriage fork bar.

¥ If rasing the fork end, the lower fork hanger will be disassembled from the lower carriage fork bar. ¥ Put an wooden block under the fork.

40 02 7

¥ If pressing the tip end of fork, upper fork hanger will be disassembled from the upper carriage fork bar.

! The fork may fall aside because it isnÕt supported by carriage while disassembling.

Perform as same procedures to disassemble the other fork. Assemble the fork as reverse order of disassembly.

A T T A C H M E N T S COUNTERWEIGHT

MAINTAINING COUNTERWEIGHT MAINTAINING COUNTERWEIGHT The counterweight must be mounted on the machine safely.

It is very big and heavy, so take care to handle. When lowering down the counterweight to the ground, take care not to fall down.

! After removing the counterweight, the fork lift will be unstable. Never operate or handle the fork lift which the counterweight is removed from. If not, serious injury or death will be caused.

REMOVING COUNTERWEIGHT Remove the counterweight by use of overhead crane and hoist or overhead crane and other fork lift.

Before removing, perform as followings. ¥ Park the fork lift on an even ground. ¥ Lower the fork or attachment fully. ¥ Keep the control lever in neutral, and turn the start key to ÒOFFÓ. ¥ Lock the parking brake. ¥ Disconnect the battery power plug. ¥ Put support block under the drive wheel.

40 03 FX997

1

A T T A C H M E N T S COUNTERWEIGHT

REQUIRED TOOL ¥ Support block for wheel ¥ Lift chain and hook ¥ Torque wrench (0~138.4 kgám) ¥ Overhead hoist (enough capacity)

! Check the condition of tools and instruments.

Confirm the capacity is acceptable and the tools confoms to OSHA standards.

! Improperly installed counterweight may move or fall down suddenly.

Before removing the mount bolt, confirm the counterweight is safe.

Never remove the support block while the counterweight is mounted on the fork lift.

If the fork lift is improperly operated, serious injury or death will be caused.

! Use the hook with latch so that the hook will not slip from the chain.

40 03 2

FX998

A T T A C H M E N T S COUNTERWEIGHT

ÂĽ Using hoist or overhead guard Park the fork lift in place under the hoist.

Apply the parking brake, and support the drive wheel with blocks.

FX997

Install the chain and hook or long stick to the hoist hook.

40

FX999

03 3

Insert the chain hook to the overhead guard locking hole on the counterweight. Raise the hoist so the counterweight is suspended by chain.

FX994

A T T A C H M E N T S COUNTERWEIGHT

Remove the counterweight mounting bolt.

FX996

Lift up the counterweight from the fork lift.

Disassemble the counterweight from the fork lift.

Refer to inspecting method for counterweight.

Take care not to damage on controllers on both sides.

40

Move the counterweight to the designated place. Use flatform or pallet to keep. The cpacity of the flatform or pallet must be adequate to keep and support the counterweight temporarily or permanently. It can be easily moved.

03

FX996

4

Lower the counterweight to the flatform or ground carefully.

At this time, the convex portion of the counterweight must face upwards.

FX1002

A T T A C H M E N T S COUNTERWEIGHT

Remove the chain or hook.

When the counterweight is kept for a long time, remove the eye bolt.

FX1000

! If the convex portions faces ground to inspect or maintain the counterweight, support the both ends with blocks to prevent rocking or falling aside.

ÂĽ Using other fork lift instead of hoist Confirm the fork lift is capable to raise the counterweight.

! When using the fork lift instead of hoist, work with other person. One operates the fork lift, and the other watches out the counterweight.

Confirm the parking brake is applied and the drive wheels are supported by blocks.

40 03 5

FX997

A T T A C H M E N T S COUNTERWEIGHT

Install the chain and hook or long stick to the fork. Wind around the fork bar with chain so that the hoist chain will not slip off from the fork end.

FX1003

Insert the chain hook to the overhead guard locking hole on the counterweight. Lift up the fork so the counterweight is suspended by chain.

FX1003

40 03 6

Remove the bolts and nuts of counterweight.

Before removing the bolts, confirm the counterweight is raised and same force is applied to both chains.

FX994

A T T A C H M E N T S COUNTERWEIGHT

Raise the carefully.

counterweight

from

the

fork

lift

! Keep away from the counterweight when moving.

Confirm the tightening of chain and hook.

Never go through or stand under the raised fork.

FX994

Move the fork lift slowly so that the counterweight will not swing.

Refer to the inspection chapter for keeping the counterweight.

FX1002

40 03

INSPECTING COUNTERWEIGHT If the counterweight is removed from fork lift, overhaul the counterweight.

Inspect the damage or crack on the surface, especially inner surfae.

Inspect the bolt hole for boring and casting condition.

Inspect the mount bolt for worn or damage.

7

A T T A C H M E N T S COUNTERWEIGHT

Inspect the counterweight while removed from the fork lift and suspended by hoist. Take care to safety when lowering the counterweight to the ground or suspended by hoist.

Never go through or stnad under the raised fork.

FX1004

INSTALLING COUNTERWEIGHT Apply the parking brake and support the drive wheels with blocks.

FX997

40 03 8

Insert the chain hook to the overhead guard locking hole on the counterweight. Confirm the hook is properly insertd or latch is locked. Lift up the fork or hoist so the counterweight is suspended by chain.

FX1005

A T T A C H M E N T S COUNTERWEIGHT

Inspect the counterweight while removed from the fork lift and suspended by hoist. Take care to safety when lowering the counterweight to the ground or suspended by hoist.

Never go through or stnad under the raised fork.

FX1004

Raise the counterweight to match the mount hole.

! Install the mount bolt taking care not to be damaged. Do not use damaged or improper mount bolt.

If it is worn or damaged, replace with a new one.

FX1006

! Use the original bolts and nuts when installing the counterweight. Tighten them with

40 03

specified torque. If not, serious injury or death will be caused.

9

Install the counterweight mount bolts and nuts.

Fasten them tightly so that the counterweight takes in place. Use shims to fit the counterweight.

After tightening the bolts, confrim the arraging condition of the counterweight.

FX996

A T T A C H M E N T S COUNTERWEIGHT

Tighten the counterweight mounting bolt with specified torque.

Tightening torque : 45~50 kgám Lower the hoist and loosen the chain and hook.

Remove the blocks supporting the drive wheels.

! Damaged machine will cause accidient.

All the tools and instruments must be in normal condition. The capacity will meet the requisities and the instruments will conform to OSHA approval. Using damaged tools may cause serious injury or death.

LIFTING AND SUPPORTING Perform the following procedures. ¥ Park the fork lift on an even solid ground such as concrete without scar. ¥ Put the mast vertical with ground and lower the fork or attachments to the ground completely. ¥ Keep the control lever in neutral, and turn the start key to OFF. ¥ Apply the parking brake.

RASING DRIVE WHEEL FROM GROUND

40 03 10

Use the mast to raise the drive wheel from the ground. ¥ Start the engine, and tilt the mast backwards fully. If necessary, raise the mast a little and turn the start swith OFF.

P

R METER

0000 H 1/10

E

FX1076

A T T A C H M E N T S COUNTERWEIGHT ¥ Put support blocks with 100 ´ 100mm under the mast rail.

Place steel plate with 6.4mm in thickness on each blocks.

Steel plate Support block

FX1007

¥ Turn the start switch ON and tilt forwards fully.

Release tilt control lever, and check the clearance between the wheels and ground.

P

R METER

0000 H 1/10

E

FX1077

40 03

¥ Turn the start switch OFF.

11

FX1008

¥ Confirm the fork lift is in safe place. Make sure the support blocks are under the mast rail properly. ¥ Perfrom the revers order in above procedures and remove the support blocks.

Steel plate Support block

FX1009

A T T A C H M E N T S COUNTERWEIGHT

RAISING THE REARSIDE OF FORK LIFT ¥ Park the fork lift slowly.

Confrim the fork lift is safe.

! Improperly assembled counterweight may move or fall suddenly.

Do not lift or support by use of counterweight.

If not serious injury or death may be caused.

Perform the following procedures. Ð Park the fork lift on an even solid ground such as concrete without scar. Ð Put the mast vertical with ground and lower the fork or attachments to the ground completely. Ð Keep the control lever in neutral, and turn the start key to OFF. Ð Apply the parking brake. Ð Support the drive wheel with blocks.

40 03 12

FX997

¥ Prepare the jack under rear of fork lift frame.

Never put the jack under the counterweight.

Put the jack under frame center such as front or rear of mount on steering side, or under the center of steering axle. In this way, you can raise the rear side of fork lift.

FX1011

A T T A C H M E N T S COUNTERWEIGHT

¥ Raise the fork lift to repair the fork lift. ¥ Push the support block under both sides of the frame to support the machine.

To acquire the most safe condition, push the support block as near to steering wheels as possible. To keep the level, support the fork lift with blocks of same number at both sides.

At the point of length, the length of blocks must suit for the width of fork lift.

FX1010

¥ Lower the fork lift to the support block, and remove the jack.

Before maintaining, confirm the stability of fork lift. ¥ Lower the fork lift as reverse order of above procedures. Ð Put the jack under the fork lift frame. Ð Lift up the fork lift using jack. Ð Remove the support blocks. Ð Lower the fork lift on the ground. Ð Remove the jack. Ð Remove the blocks supporting the drive wheels.

40

RAISING THE WHOLE FORK LIFT

03

¥ Park the fork lift safely.

To perform following procedures: Ð Park the fork lift on an even solid ground such as concrete without scar. Ð Put the mast vertical with ground and lower the fork or attachments to the ground completely. Ð Keep the control lever in neutral, and turn the start key to OFF. Ð Apply the parking brake. Ð Inspect the condition and capacity of the tool.

13

A T T A C H M E N T S COUNTERWEIGHT

¥ Put the jack under the side of frame in center of fork lift.

! Confirm that the jack is located under the side of frame of fork lift precisely.

FX1012

¥ First, raise the fork lift on one side. Raise the fork lift upto available height within 120mm.

FX1013

40 03 14

¥ Put the support blocks as near to the front and rear wheels as possible around the jack so that the fork lift can keep the level. Lower the fork lift on the suppoort block, and perform same procedures for the other side with jack.

Keep the level by use of support blocks with same size.

Before maintaining, confirm the set condition of support blocks. ¥ When maintaining the parts besides of drive wheel or steering wheel, arrange wheel cradles to all the wheels for safety. ¥ Lower the fork lift as reverse order of lifting.

Lower the one side of fork lift slowly and remove the support blocks.

Confirm the condition under the fork lift is clear.

FX1014

FX1015