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Service Manual Chassis & Mast FBC15K, FBC18K, FBC18KL A3BC1-10200-up A3BC1-20200-up A3BC1-30200-up A3BC2-40200-up

FBC20K, FBC25K A3BC2-10200-up A3BC2-20200-up A3BC2-30200-up A3BC2-40200-up A3BC2-80200-up

FBC25KE, FBC25KL, FBC30K A3BC3-10200-up A3BC3-20200-up A3BC3-30200-up A3BC3-40200-up A3BC3-80200-up

FBC30KL A3BC4-40200-up

99759-73110

TABLE OF CONTENTS Chapter 1: General Information Scope ................................................................................................................................ Truck Models Covered ...................................................................................................... Nameplate and Serial Number Locations ......................................................................... Dimensions ........................................................................................................................ Dimensions Chart .......................................................................................................... General Information (Standard Models) ............................................................................

1.1 1.1 1.2 1.3 1.4 1.5

2.2 2.2 2.3 2.3 2.3

Installation ......................................................................................................................... 2.4 Disassembly ...................................................................................................................... 2.5 Removing Front Wheel Hub .......................................................................................... 2.6 Inspection after Disassembly ............................................................................................ 2.7 Reassembly ....................................................................................................................... Axle Housing ................................................................................................................. Front Wheel Hub ........................................................................................................... Hub Bearing Preload ..................................................................................................... Installation and Setting Preload ................................................................................

2.8 2.8 2.8 2.9 2.9

Reduction Differential Description......................................................................................................................... 2.10 Disassembly ...................................................................................................................... 2.11 Inspection after Disassembly ............................................................................................ 2.12 Reduction Gear ............................................................................................................. 2.12 Differential...................................................................................................................... 2.12 Reassembly ....................................................................................................................... 2.13 Inspection and Adjustment ................................................................................................ Side Bearing Preload .................................................................................................... Reduction Gear Backlash.............................................................................................. Reduction Gear Face Runout........................................................................................ Tooth Contact ................................................................................................................ Tooth Contact Adjustment .............................................................................................

2.15 2.15 2.15 2.16 2.16 2.17 i

TABLE OF CONTENTS Chapter 3: Transfer Assembly Description......................................................................................................................... Disassembly ...................................................................................................................... Disassembly Sequence ..................................................................................................... Inspection after Disassembly .......................................................................................... Reassembly .......................................................................................................................

3.1 3.2 3.2 3.2 3.5

Chapter 4: Rear Axle Description......................................................................................................................... 4.1 Rear Wheels...................................................................................................................... 4.2 Removal ........................................................................................................................ 4.2 Installation ..................................................................................................................... 4.4 Rear Axle ........................................................................................................................... Removal ........................................................................................................................ Installation ..................................................................................................................... Disassembly .................................................................................................................. Inspection after Disassembly ........................................................................................ Reassembly...................................................................................................................

4.7 4.7 4.8 4.9 4.11 4.12

Inspection and Adjustment ................................................................................................ 4.17 Minimum Turning Radius Adjustment............................................................................ 4.17

Chapter 5: Brake System Description......................................................................................................................... 5.1 Automatic Adjusting Device........................................................................................... 5.1 General Information....................................................................................................... 5.1 Master Cylinder Disassembly .................................................................................................................. 5.2 Inspection after Disassembly ........................................................................................ 5.3 Reassembly................................................................................................................... 5.3 Service Brakes Disassembly (FBC15K - 18KL) ...................................................................................................... (FBC20K - 30KL) ...................................................................................................... Inspection after Disassembly ........................................................................................ Reassembly (FBC15K - 18KL) ...................................................................................................... (FBC20K - 30KL) ...................................................................................................... Wheel Cylinders Disassembly .................................................................................................................. Inspection after Disassembly ........................................................................................ Reassembly................................................................................................................... Inspection and Adjustment ............................................................................................ ii

5.4 5.5 5.7 5.8 5.9

5.12 5.13 5.13 5.14

TABLE OF CONTENTS Chapter 6: Steering System Steering System Description .................................................................................................................... 6.1 Steering System ...................................................................................................... 6.1 Oil Flow Sequence ............................................................................................... 6.1 General Information ............................................................................................. 6.1 Steering Gear Steering Wheel Removal.................................................................................................................... 6.2 Installation................................................................................................................. 6.2 Steering Gear ............................................................................................................... 6.3 Inspection after Removal .............................................................................................. 6.4 Disassembly.................................................................................................................. 6.5 Working Rules and Tips............................................................................................ 6.6 Suggestions .............................................................................................................. 6.6 Inspection after Disassembly.................................................................................... 6.6 Reassembly .................................................................................................................. 6.7 Suggestions ......................................................................................................... 6.8 Steer Pump Removal........................................................................................................................ 6.9 Installation.....................................................................................................................6.10 Disassembly..................................................................................................................6.11 Sequence..................................................................................................................6.11 Working Rules and Tips............................................................................................6.12 Suggestions ..............................................................................................................6.12 Inspection after Disassembly....................................................................................6.14 Reassembly ..................................................................................................................6.15 Sequence..................................................................................................................6.15 Suggestions ..............................................................................................................6.16 Inspection after Reassembly ....................................................................................6.18

Chapter 7: Hydraulic System Hydraulic System Description......................................................................................................................... Schematic ..................................................................................................................... Hydraulic Tank ............................................................................................................... Hydraulic Pump ............................................................................................................ Control Valve ................................................................................................................. Lift and Tilt Cylinders ..................................................................................................... Flow Regulator Valve..................................................................................................... Down Safety Valve ........................................................................................................

7.1 7.1 7.2 7.3 7.5 7.6 7.7 7.8

Removal and Installation Warning..................................................................................... 7.9

iii

TABLE OF CONTENTS Chapter 7: Hydraulic System, continued Hydraulic Pump Removal ............................................................................................................................ Installation ......................................................................................................................... Disassembly ...................................................................................................................... Working Rules and Tips ................................................................................................ Suggestions...................................................................................................................

7.10 7.11 7.12 7.13 7.14

Inspection after Disassembly ............................................................................................ Body .............................................................................................................................. Mounting Flange Face................................................................................................... Bushes and Balance Plate ............................................................................................ Gears.............................................................................................................................

7.16 7.16 7.16 7.16 7.16

Reassembly ....................................................................................................................... 7.17 Inspection after Reassembly ............................................................................................. 7.22 Control Valve Removal ............................................................................................................................ Installation ......................................................................................................................... Disassembly ...................................................................................................................... Suggestions....................................................................................................................... Reassembly .......................................................................................................................

7.23 7.24 7.25 7.27 7.27

Lift and Tilt Cylinders Removal Lift Cylinders.................................................................................................................. 7.28 Tilt Cylinders .................................................................................................................. 7.31 Disassembly Lift Cylinders.................................................................................................................. 7.33 Tilt Cylinders .................................................................................................................. Flow Regulator Valve..................................................................................................... Inspection after Disassembly ............................................................................................ Precautions for Reassembly .............................................................................................

7.34 7.35 7.36 7.36

Inspection and Adjustment Hydraulic Tank ................................................................................................................... 7.37 Control Valve ..................................................................................................................... 7.38 Lift and Tilt Cylinders ......................................................................................................... 7.40 Adjusting Method........................................................................................................... 7.41 Testing ........................................................................................................................... 7.42

TABLE OF CONTENTS Chapter 8: Mast and Forks Description.................................................................................................................. 8.1 Removal and Installation ............................................................................................ 8.2 Disassembly .............................................................................................................. 8.4 Inspection after Disassembly...................................................................................... 8.6 Reassembly ................................................................................................................ 8.7 Inspection and Adjustment ......................................................................................... 8.8 Forks....................................................................................................................... 8.8 Chain Tension Adjustment ...................................................................................... 8.9 Clearance Adjustment on Lift Bracket .................................................................... 8.10 Mast Clearance Adjustment.................................................................................... 8.13 Main Roller Shim Replacement .............................................................................. 8.15 Mast Strip Adjustment............................................................................................. 8.15 Tilt Angle Adjustment .............................................................................................. 8.16 Lift Cylinder Stroke Adjustment .............................................................................. 8.17 Bleeding Lift Cylinders............................................................................................ 8.17 Service Data ............................................................................................................... 8.19 Troubleshooting .......................................................................................................... 8.20

Chapter 9: Troubleshooting Section Front Axle and Reduction Differential ......................................................................... 9.1 Brake System ............................................................................................................. 9.2 Steering System ......................................................................................................... 9.4 Hydraulic System........................................................................................................ 9.6 Rear Axle .................................................................................................................... 9.8 Mast and Forks........................................................................................................... 9.9

TABLE OF CONTENTS Chapter 10: Maintenance Service Data Maintenance Service Data ................................................................................................ 10.1 Front Axle and Reduction Differential............................................................................ 10.1 Transfer Case ................................................................................................................ 10.3 Rear Axle ....................................................................................................................... 10.4 Brake System ................................................................................................................ 10.6 Steering System, ........................................................................................................... 10.11 Hydraulic System........................................................................................................... 10.13 Mast and Forks (Simplex Mast) .................................................................................... 10.16 Tightening Torques for Standard Bolts and Nuts .............................................................. 10.18 Fine Thread—With Spring Washer................................................................................ 10.18 Fine Thread—Without Spring Washer........................................................................... 10.19 Coarse Thread—With Spring Washer ........................................................................... 10.20 Coarse Thread—With Spring Washer ........................................................................... 10.21 Maintenance Chart ............................................................................................................ 10.22 Planned Replacement Parts.............................................................................................. 10.28 Lubrication Information ...................................................................................................... 10.29 Chart.............................................................................................................................. 10.29 Lubricant Specifications................................................................................................. 10.30 Recommended Brands of Lubrications ......................................................................... 10.30 Weight of Major Components (Approximate) .................................................................... 10.31 Special Service Tools ........................................................................................................ 10.32 Special Tool Illustrations ................................................................................................ 10.33 Inspection Guide................................................................................................................ 10.36

Chapter 1: General Information Scope......................................................................................................... 1.1 Truck Models Covered............................................................................... 1.1 Nameplate and Serial Number Locations.................................................. 1.2 Dimensions ................................................................................................ 1.3 Dimensions Chart ................................................................................... 1.4 General Information (Standard Models) .................................................... 1.5

GENERAL INFORMATION

Scope This service manual deals with all components or systems of the Mitsubishi Forklift Trucks, except for the electrical system, which is covered in a separate manual.

8609141A

Truck Models Covered This service manual furnishes service and maintenance information for the following trucks.

Truck Model

Serial Number

FBC15K, FBC18K, FBC18KL

A3BC1-10200-up A3BC1-20200-up A3BC1-30200-up A3BC2-40200-up

FBC20K, FBC25K

A3BC2-10200-up A3BC2-20200-up A3BC2-30200-up A3BC2-40200-up A3BC2-80200-up A3BC3-10200-up A3BC3-20200-up A3BC3-30200-up A3BC3-40200-up A3BC3-80200-up A3BC4-40200-up

FBC25KE, FBC25KL, FBC30K

FBC30KL

1.1

GENERAL INFORMATION

Nameplate and Serial Number Locations

Mast serial number

Power steering motor serial number

Chassis serial number

Traction motor serial number Hydraulic motor serial number

Nameplate 8609141

1.2

GENERAL INFORMATION

Dimensions

8609142

8609143

1.3

GENERAL INFORMATION

Dimensions Chart Ref#

Truck Model

FBC15K, FBC18K

FBC18KL

FBC20K, FBC25K

FBC25KE

FBC25KL

FBC30K

FBC30KL

Maximum Lift

3320 (130)

3340 (131)

3310 (130)

3215 (126)

Free Lift

115 (4.5)

130 (5.1)

135 (5.3)

Maximum Fork Spacing (outside to outside)

818 (32.0)

Fork Length

1070 (42)

Tilt Angle (forward/backward)

5°/6°

Overall Length

3050 (120)

3123 (122.8)

3152 (124)

3252 (127.9)

3325 (130.8)

Overall Width (outside of tires)

945 (37.2)

970 (38.2)

1054 (41.5)

1103 (43.4)

Overall Height (to top of mast, lowered)

2105 (83)

2110 (83.5)

Overall Height (to top of overhead guard)

2180 (85.8)

2207 (86.9)

Overall Height (to top of mast, extended)

4560 (180)

4570 (180)

4540 (179)

Tread (front)

793 (31.2)

818 (32.2)

875 (34.4)

900 (35.4)

Tread (rear)

826 (32.5)

897 (35.3)

Wheelbase

1170 (46.1)

1280 (50.4)

1380 (54.3)

Front Overhang

376 (14.8)

394 (15.5)

406 (15.9)

Rear Overhang

434 (17)

507 (19)

408 (16)

469 (18.4)

Underclearance (at center of wheelbase)

118 (4.6)

124 (4.9)

Unit: mm (in.)

1.4

GENERAL INFORMATION

General Information (Standard Models) Truck Model Units

FBC15K

FBC18K

FBC18KL

meters

3.3

2095

2335

2595

2685

2870

2695

2865

3335

3502 (7721)

Standard Controller Standard Simplex Mast Size

Work Performance Traveling Performance

FBC25K

FBC25KE FBC25KL

FBC30K

FBC30KL

GE SX Controller

Without Service Weight

Battery

(4620)

(5140)

(5720)

(5920)

(6330)

(5940)

(6320)

(7353)

(standard axle)

With Max.

3298

3534

3797

4296

4482

4509

4681

5150

5317

Battery

(7270)

(7790)

(8370)

(9470)

(9880)

(9940)

(10320)

(11353)

(11722)

kg (lb)

Rated Capacity/

kg/mm

1500/500 1800/500

Load Center

(lb/in.)

(3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5000/24) (5000/24) (6000/24) (6500/29)

Maximum Fork Height

mm (in.)

Lift Speed

36V

m/sec.

.24 (48)

.23 (45)

.34 (67)

.31 (61)

.28 (56)

.26 (51)

.23 (45)

(Rated Load)

48V

(fph)

.34 (67)

.32 (64)

.47 (93)

.40 (78)

.38 (74)

.36 (70)

.31 (62)

1800/500 2000/500

2500/500 2500/500 2500/600

3320 (130)

Lowering Speed (rated load)

3340 (131)

.50 (99)

Tilt Angle (forward/backward)

degrees

Free Lift

mm (in.)

Travel Speed

36V

km/h

(Without Load)

48V

(mph)

3000/500 3500/500

3310 (130) 3215 (126)

.50 (98) 5° / 6°

115 (4.5)

130 (5.1)

12.9 (8.0) 14.3 (8.9) DNA

17.9 (11.1)

11.6 (7.2) 14.8 (9.2)

135 (5.3) 11.1 (6.9) 10.8 (6.7) 13.2 (8.2) 14.5 (9.0) 14.2 (8.8) 16.4 (10.2)

Minimum Turning

1790

1840

1890

1990

2045

Radius

(in.)

(70.5)

(72.5)

(74.5)

(78.5)

(80.5)

36V

60min.

8.2 (6.1)

9.6 (7.1)

8.3 (6.1)

Output

48V

HP(kW)

DNA

13.4 (10.0)

11.7 (8.7)

Transfer

Type

Traction Motor

Power Train

FBC20K

Gear

Ratio

Reduction

Type

Gear

Ratio

Differential

Spur 3.538

3.067 Bevel

4.571

5.0

Axle Housing

Banjo

Gear Type/

Gears

Straight Bevel/2

Number

Pinions

Straight Bevel/2

1.5

GENERAL INFORMATION Truck Model

Power Steering System

Units

FBC15K

FBC18K FBC18KL FBC20K

Type

FBC25K FBC25KE FBC25KL FBC30K FBC30KL

Dynamic Load Sense Inside

83°

54°

56°

Degrees

Turning Angle Outside Steering Wheel Diameter

mm (in.)

Cylinder Minimum Test Pressure

kgf/cm (psi) [kPa]

328 (13)

107 (1522) [10,500]

Type

163 (2320) [16,000]

Self-Adjusting Duo-Servo

Inside Drum mm (in.) Diameter

254 +0 0.13(10.00 +0 0.0051)

Service Brake Lining Thickness

mm (in.)

4.87 (0.19)

Master mm (in.) Cylinder ID

Traveling System

Brake System

Wheel Cylinder ID

1.6

22.22 (0.8748)

Type Park Brake

6 (0.24)

28.58 (1.1252)

Mechanical, Mounted on Front Wheels

Lever Operating Effort

kgf (lbf) [N]

25 to 30 (55 to 66) [245 to 294]

Front Wheels

Fixed Type

Rear Wheels

Center Pivot Type

Mounting

Wheel Alignment

Oscillation Angle Camber

3° Degrees 1°

GENERAL INFORMATION Truck Model Units

Hydraulic Pump

FBC15K

FBC18K FBC18KL FBC20K

Type

Gear

Make

Parker Hydraulics, Inc.

Model

1PX230

1SX250

1PX290

1SX250

Displacement cc (cu in.) 23.0 (1.403)/rev. 25.(1.526)

29(1.77)

25(1.526)

Make Control Valve

Hydraulic System

Husco International

Model

5000CC Sectional Valve

Relief

kgf /cm2

Pressure

(psi) [kPa]

Flow Regulator Valve

263 (3750) [25855]

Type

Variable

Regulated liter Flow Rate (cu.in.) / min

Lift Cylinders

ID Stroke

48(2929)

Stroke

79 (3.11) 1 (US gal.)

50 (1.97)

81 (3.19)

8 (4.8)

24 (6.3)

100 x 15 x 12 (3.94 x 0.59 x 0.47)

Outer

Mast and Forks

30 (7.9)

115 x 20 x 13 4.53 x 0.79 x 0.51)

115 x 21 x 13 (4.53 x 0.83 x 0.51)

mm (in.)

Side Rollers

Inner

100 x 17 x 12 (3.94 x 0.67 x 0.47)

115 x 20 x 13 (4.53 x 0.83 x 0.51)

Type

#6308 Ball Bearing

#6309 Ball Bearing

100 x 30 (3.94 x 1.18)

Type Diameter x Width

115 x 35 (4.53 x 1.58)

100 x 30 (3.94 x 1.18)

Lubricating type needle roller bearing mm (in.)

Lift Chains

42 x 36 (1.65 x 1.42) BL534

Forks (Lgth x Wdth x Thk) mm (in.)

1070x100x35 (36x4x1.3)

BL634

BL834

1070 x100 x40 (42 x 3.9 x 1.6)

1070 x 125 x 45 (42 x 5 x 1.8)

240 / 818 (9.4/32)

284 / 958 (11.2/37.7)

min/max

Voltage

36/48

Amp Hours (6 hr. rate)

Battery

80 (3.15)

Roller type CL

Diameter x Width

Compartment

Height-Center

Dimensions

Height-Edges

Weight (Min/Max)

1600 (62.99) 70 (2.75)

Mast

Fork Spacing (out to out)

55 (2.17)

1650 (64.96)

mm (in.)

63 (2.48)

Hydraulic Tank Capacity liter (Approx)

71(4332)

59 (3600)

45 (1.77)

Tilt Cylinders

Mast Dimensions (Flange Inside Width x THK x WEB THK) Main Rollers

FBC25K FBC25KE FBC25KL FBC30K FBC30KL

36/48

36V

900

1300

48V

700

800

1000

598 (23.6) 592 (23.3)

mm (in.)

Length

708 (27.9)

Width

906 (35.6)

1003 (39.5

750/1200 (1650/2650)

1000/1600 1315/1600 (2200/3550) (2900/3550)

kg (lb)

775 (30.5)

875 (34.4)

1400/1800 (3100/4000)

1.7

Chapter 2: Front Axle & Reduction Differential Front Axle Description.................................................................................................. 2.1 General Information ................................................................................ 2.1 Front Wheels .............................................................................................. 2.2 Removal .................................................................................................. 2.2 Method 1.............................................................................................. 2.3 Method 2.............................................................................................. 2.3 Method 3.............................................................................................. 2.3 Installation .................................................................................................. 2.4 Disassembly ............................................................................................... 2.5 Removing Front Wheel Hub.................................................................... 2.6 Inspection after Disassembly ..................................................................... 2.7 Reassembly................................................................................................ 2.8 Axle Housing ........................................................................................... 2.8 Front Wheel Hub ..................................................................................... 2.8 Hub Bearing Preload............................................................................... 2.9 Installation and Setting Preload........................................................... 2.9

Reduction Differential Description ................................................................................................. 2.10 Disassembly ............................................................................................... 2.11 Inspection after Disassembly ..................................................................... 2.12 Reduction Gear....................................................................................... 2.12 Differential ............................................................................................... 2.12 Reassembly................................................................................................ 2.13 Inspection and Adjustment ......................................................................... 2.15 Side Bearing Preload .............................................................................. 2.15 Reduction Gear Backlash ....................................................................... 2.15 Reduction Gear Face Runout ................................................................. 2.16 Tooth Contact.......................................................................................... 2.16 Tooth Contact Adjustment ....................................................................... 2.17

FRONT AXLE: DESCRIPTION

Front Axle Description

5 7

3 2

203658

1. Front wheel hub

5. Reduction pinion

2. Frame support

6. Reduction gear

3. Axle shaft

7. Differential case

4. Axle housing

8. Differential carrier

General Information The frame supports hold the front axle housing in such a manner as to allow a limited amount of rotary motion of the housing, the rotary sliding surfaces being lubricated with grease. The cushion tire is press-fitted to the outer ring of the wheel hub.

2.1

FRONT AXLE: REMOVAL & INSTALLATION

Removal Front Wheels

Suggestions 1. Park the truck on level floor with the parking brake applied, the direction lever in neutral, the forks lowered, and the key switch off.

WARNING

Be sure to use the same size and brand tire for replacement.

2. Prepare tools, jacks, and wheel blocks. 3. Block the rear wheels. 4. Loosen the wheel nuts about two turns.

Removal Sequence 2 Wheel nut

1 100902B

205952

1. Wheel Nuts 2. Front Wheel

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

5. Raise the front end of the truck. Use one of the methods shown.

WARNING

To prevent possible injury, do not replace the tire when the truck is loaded. Dismount the truck before raising the front tire. To prevent possible personal injury, raise the truck only until the tire just clears the ground. Do not put any portion of your body under the truck. Securely support the truck on blocks after raising it.

2.2

FRONT AXLE: REMOVAL & INSTALLATION Method 1

Method 3

Position the jack under the frame and raise the truck until the tire clears the floor.

Fasten a hoist to the mast and lift the front end of the truck as shown.

100828

Jack Capacities

202778A

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

FBC15K - 18KL

3000 kgf (6700 lbf)

FBC20K - 30KL

5000 kgf (12,000 lbf)

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

Method 2 Tilt the mast all the way back, place wood blocks under the mast, and tilt the mast forward.

7. Remove the wheel.

! CAUTION After raising the front end, securely support it by blocks.

NOTE Service Limit For Cushion Tires Replace the tire if the height of the solid rubber portion is 25.4 mm (1 in. or less). For tire replacement, consult your Forklift Truck Dealer.

200227

25.4 mm (1 inch)

100880

2.3

FRONT AXLE: REMOVAL & INSTALLATION Installation To install, reverse the removal sequence and do the following steps.

! CAUTION

2. Lower the truck until the tire touches the floor. Then tighten the wheel nuts in numbered sequence shown below, in two or three steps, to the specified torque. 1

Use the same size and brand of tire. 6

Make sure the clamping surfaces of the wheel nuts and counterbores in the rim are free of dirt.

1. Install the tire and tighten the wheel nuts. Tighten each nut until its tapered portion is in full-face contact with the counterbore in the rim.

4 5 2 205953

Tightening Torque For Wheel Nuts

Wheel Nut Counterbore

100835A

2.4

FBC15K - 18KL

FBC20K - 30KL

16 kgf•m

38.5 kgf•m

(116 lbf•ft)

(278 lbf•ft)

[157 N•m]

[378 N•m]

FRONT AXLE: DISASSEMBLY

Disassembly 6

205954

Sequence 1. Axle shaft 2. Lock nut, lock washer, oil seal, and tapered roller bearing (inner bearing) 3. Hub & drum assembly [Front wheel hub, brake drum, wheel bolts, drum nuts, and tapered roller bearing (outer bearing)]

4. Tapered roller bearing (outer bearing), oil seal, and oil deflector 5. Tapered roller bearing (inner bearing), and seal retainer 6. Brake assembly 7. Frame support and axle housing

Start By: 1. Remove the mast. (For replacement of the front axle housing and disassembly of the differential, refer to section, MAST AND FORKS.)

3. Support the front end of the truck at both sides with blocks or stands to keep the truck in a horizontal position.

2. Jack up the truck.

4. Remove the front wheels.

NOTE It is not necessary to remove the axle housing or drain the oil for removal of the shaft only.

2.5

FRONT AXLE: DISASSEMBLY Suggestions Removing the Lock Nut

Removing Bearings

Use a lock nut wrench (Special Tool).

The inner race of the tapered roller bearing remains in the axle housing when the hub is drawn out. Remove this race together with the seal retainer with a bearing puller.

Tool Lock Nut Wrench

FBC15K - 18KL FBC20K - 30KL 91268-00800

03703-59001

Special Tool

203651

200232

Removing Front Wheel Hub Use a wheel hub puller (Special Tool). Tool

FBC15K - 18KL FBC20K - 30KL

Wheel Hub Puller 64309-40100 (Puller seat) (64309-10601)

MH061017

NOTE It is not necessary to remove the oil seal from the hub or to disassemble the oil deflector unless the seal is defective.

Special Tool

200233

2.6

FRONT AXLE: DISASSEMBLY

Inspection after Disassembly Axle Shafts Looseness of Mating Splines

Runout

Mount the differential bevel gear on the splined end of the shaft and set a dial indicator as shown below. Turn the bevel gear and read the indicator.

Set a dial indicator at the middle part of the axle shaft. Turn the shaft and read the indicator to find runout.

Runout of shaft

200235

Free movement (looseness of splines)

0.07 to 0.17 (0.0028 to 0.0067)

0.5 (0.020)

Unit: mm (in.) A = Assembly Standard B = Repair or Service Limit

Axle Housing 1. Check the surfaces of axle housing in contact with the mast bearing for damage. 2. Check the entire axle housing for distortion, dents, and other defects, paying particular attention to the welds to see if any weld is cracked.

Oil Seals and Retainers 1. Check the outer surface of the oil seal retainer for wear or damage.

Face runout of flange

Runout of axle shaft (1/2 of dial indicator reading

200236

FBC15K -18KL

FBC20K 30KL

0.5 (0.020) maximum

1.0 (0.039) maximum

1.0 (0.039)

2.0 (0.079)

Unit: mm (in.) A = Assembly Standard B = Repair or Service Limit

Set a dial indicator against the flange of the axle shaft as shown. Turn the shaft and read the indicator to find face runout. Face runout of axle shaft flange

0.05 (0.0020)

0.5 (0.020)

Unit: mm (in.) A = Assembly Standard B = Repair or Service Limit

2. Check the outer and inner oil seals for wear and damage.

2.7

FRONT AXLE: REASSEMBLY

Reassembly To reassemble, reverse the steps of the disassembly sequence and do the following steps.

2. Install the inner race and oil seal retainer of the wheel hub bearing with an installer (Special Tool).

Axle Housing 1. Install the O-ring in the outer groove (of the two grooves in the bore of each frame support). Special tool

2. Apply grease to the surfaces A of the support and axle housing. O-ring

Frame support A

203569

Tool

FBC15K - 18KL

FBC20K30KL

Installer

64309-12300

91468-00300

200237

3. Apply retaining compound to the flange surfaces of the axle shafts.

Front Wheel Hub 1. Fill the front wheel hub, especially the roller holder and oil seal lip groove, with grease.

NOTE Be careful not to apply grease to the brake drum.

200238

2.8

FRONT AXLE: REASSEMBLY Hub Bearing Preload

Installation and Setting Preload

Tighten the inner nut to produce the required preload. Tighten the outer nut to the specified torque and check the preload. Be sure that the preload noted after tightening the outer nut meets the specification. This step is for new bearings. Where the bearings removed in disassembly are reused, try to produce the preload at the lower side of the range.

1. Fill the hub with the recommended grease as listed in the service manual.

Preload for hub bearing

5 to 50 kgf•cm (0.4 to 3.6 lbf•ft) [0.5 to 4.9 N•m]

Tightening torque for lock nuts

20 kgf•m (145 lbf•ft) [196 N•m]

2. Pack the inner and outer bearing with the recommended grease. 3. Install the inner bearing to the back side of the hub. 4. Install the inner seal. 5. Clean the lining surface of the drum. 6. Install the hub onto the axle. 7. Install the outer bearing, grease seal and preload nut. 8. If the bearings are being reused, try to produce the lower side of the applied force in tangential direction. 9. For new bearings, tighten the preload nut to 14 kgf•m (101 lbf•ft) [137 N•m]. Slowly rotate the hub slightly more than 3 turns, back the nut off 80°, and set the applied force in tangential direction.

Inner nut

Outer nut 200468

10. For models with an outer lock nut, torque the nut to 20 kgf•cm (145 lbf•ft) [196 N•m]. After torquing the lock nut, check the force applied in tangential direction again to insure the preload did not change.

Bar

Spring balancer

101653

2.9

REDUCTION DIFFERENTIAL: DESCRIPTION

Reduction Differential Description 3

5 2

1 200240

Sequence 1. Lock plates 2. Side bearing nuts 3. Differential carrier assembly (lock washers, side bearing caps, and differential carrier)

Start By: Remove the differential carrier from the transmission case.

2.10

4. Reduction gear and differential gear assembly (spring pins, pinion shafts, differential pinions, differential bevel gear, washers, and differential case) 5. Tapered roller bearings

REDUCTION DIFFERENTIAL: DISASSEMBLY

Disassembly Suggestions

Removing Bearing Inner Races

1. Before removing the differential carrier from the transmission case, measure the gear backlash to aid in obtaining correct backlash at the time of reassembly.

Use a bearing puller to remove the inner races from the differential case.

Backlash between reduction gear 0.15 to 0.25 and pinion (0.0059 to 0.0098) Unit: mm (in.)

200242

200247

2. Put a mark across the bearing cap, adjusting screw and carrier on each side. The caps are not interchangeable.

200241

2.11

REDUCTION DIFFERENTIAL: DISASSEMBLY

Inspection after Disassembly Reduction Gear

Differential

Check the teeth for wear, pitting, flaking, or chipping. Minor flaws on the tooth surface can be repaired by grinding with an oil stone or a hand grinder. Check the teeth for contact. If the gear is badly damaged and requires replacement, replace the pinion too. Reduction gear and pinion are a matched set and must be changed at the same time.

1. Check the differential cases for damage. Check in particular the seat formed of each case for carrying the side bearing inner race to see whether the seat surface is galled or not. 2. Check the sliding surfaces of the thrust washers and gears for wear or damage. 3. Check the teeth of the differential pinions and bevel gears for wear, pitting, chipping, or galling. 4. Check the fit of each pinion on the spider. Fit of differential pinions on spider

0.02 to 0.07 (0.0008 to 0.0028)

0.35 (0.0138)

Unit: mm (in.) A = Assembly Standard B = Repair or service limit

2.12

REDUCTION DIFFERENTIAL: REASSEMBLY

Reassembly 4

200243

Sequence 1. Tapered roller bearings

3. Spring pin

2. Differential gear assembly [differential case, thrust washers, bevel gears, pinions, and pinion shaft]

4. Reduction gear 5. Differential carrier assembly [carrier, side bearing caps, side bearing nuts, and lock washers]

2.13

REDUCTION DIFFERENTIAL: REASSEMBLY Suggestions Reassembling Differential Pinions

Reassembling Differential Case

The thrust washers of the differential gears are to be used for adjusting the backlash between the differential gears and pinions. Measure the backlash and, if it exceeds the limit, replace the thrust washers.

After putting the case assembly in place on the carrier, install the bearing caps tentatively by making the cap bolts snug tight. The caps are to be secured tight after the bearing preload has been adjusted.

Backlash between differential gears and pinions

0.18 to 0.23 (0.0071 to 0.0091)

0.5 (0.020)

Unit: mm (in.) A = Assembly Standard B = Repair or service limit

Installing Bearing Caps Be sure to know which are the left and right caps and to put each cap in place correctly. Tightening torque for bearing cap bolts

12.8 kgf•m (93 lbf•ft) [126 N•m]

200244 200241

Installing Reduction Gear Apply LOCTITE No. 271 to the bolts for holding the reduction gear to the case. Be sure to tighten these bolts evenly so as not to strain the gear. Tightening torque for reduction gear bolts

2.14

12.0 kgf•m (87 lbf•ft) [118 N•m]

REDUCTION DIFFERENTIAL: REASSEMBLY

Inspection and Adjustment Side Bearing Preload

Reduction Gear Backlash

Tie a wire on the reduction gear tooth and hook a spring scale to the wire. Tighten the side bearing nuts while reading the spring scale until the specified preload is obtained.

Adjust the backlash between the reduction gear and pinion after installing the differential carrier assembly to the transmission case. To measure the backlash, set a dial indicator with its spindle pointing squarely to the tooth face of the reduction gear. With the pinion held, move the gear back and forth to read the indicator. Adjust the backlash using the left and right side bearing nuts and pinion shims.

NOTE Before measuring the preload, tap the back of the reduction gear with a copper hammer while rotating the gear to center between bearing.

0.15 to 0.25 (0.0059 to 0.0098)

Backlash between reduction gear and pinion

Unit: mm (in.)

Preload for differential case side bearings

Min.

15 to 30 kgf (1.1 to 2.2 lbf) [1.5 to 2.9 N]

Max.

1.32 to 2.5 kgf•cm (2.9 to 5.5 lbf•ft) [13 to 25 N•m]

As force applied to reduction gear in tangential direction.

200247

Backlash Increase Decrease Decrease Increase 200246

Increase Backlash

Decrease 200248

2.15

REDUCTION DIFFERENTIAL: INSPECTION Reduction Gear Face Runout

Tooth Contact

Using a dial indicator, check the reduction gear for face runout at the maximum radius position in back of the gear. If the runout exceeds the limit, check the reduction gear bolts for tightness; retighten if necessary. Check the tapered roller bearings for condition. Readjust or replace them if necessary.

Check the gear reduction tooth contact. To check, apply a thin coat of bluing to several gear teeth on both drive and coast sides. Press forward on the reduction pinion and rotate the reduction gear back and forth until a contact pattern is noted on both concave and convex faces of the gear teeth. To adjust the tooth contact, refer to the chart.

Face runout of reduction gear

0.05 (0.0020) maximum

Unit: mm (in.) A = Assembly Standard B = Repair or Service Limit

200250

200249

2.16

REDUCTION DIFFERENTIAL: INSPECTION Tooth Contact Adjustment (FBC15K - 18KL) Tooth Contact

Adjustment

Extends from toe to middle portion, covering not less than 50% of tooth length.

Correct tooth contact

Short contact at toe of tooth.

1. Move gear away from pinion.

203669-1

2. Move pinion toward gear by increasing shim thickness to secure correct backlash.

2 203669-2A

203669-2

1. Move gear toward pinion.

Short contact at heel of tooth.

2. Move pinion away from gear by decreasing shim thickness to secure correct backlash.

3 203669-3A

203669-3

1. Move pinion toward gear by increasing shim thickness.

Heavy contact on face or upper portion of tooth.

2. Move gear away from pinion to secure correct backlash. 203670-4A

203669-4

1. Move pinion away from gear by decreasing shim thickness.

Heavy contact on flank or lower portion of tooth.

5 203669-5

2. Move gear toward pinion to secure correct backlash. 203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

2.17

REDUCTION DIFFERENTIAL: INSPECTION Tooth Contact Adjustment (FBC20K - 30KL) Tooth Contact

Adjustment

Extends from toe to middle portion, covering not less than 50% of tooth length.

Correct tooth contact

203670-1

1. Move pinion toward gear by increasing shim thickness.

Short contact at toe of tooth.

2. Move gear away from pinion to secure correct backlash.

2 203670-2A

203670-2

1. Move pinion away from gear by decreasing shim thickness.

Short contact at heel of tooth.

2. Move gear toward pinion to secure correct backlash.

3 203670-3A

203670-3

1. Move pinion toward gear by increasing shim thickness.

Heavy contact on face or upper portion of tooth.

2. Move gear away from pinion to secure correct backlash. 203670-4A

203670-4

1. Move pinion away from gear by decreasing shim thickness.

Heavy contact on flank or lower portion of tooth.

5 203670-5

2. Move gear toward pinion to secure correct backlash. 203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

2.18

Chapter 3: Transfer Assembly Description ...............................................................................................3.1 Disassembly.............................................................................................3.2 Disassembly Sequence ...........................................................................3.2 Inspection after Disassembly .................................................................3.2 Reassembly .............................................................................................3.5

TRANSFER ASSEMBLY

Front axle center

Description 1

Traction motor

7 5

209002

Main component 1 2 3 4 5

Transfer case Transfer cover Input gear (13T) Output gear (48T) Bevel gear set

6 7 8 9

Taper roller bearing Lock nut Ball bearing Plug (standard) or pulse generator (option)

The transfer assemblies of all the 1 ton, 2 ton, and 3 ton class trucks share completely identical components except the different bevel gear sets as shown below. No. of teeth on bevel pinion

No. of teeth on bevel gear

1 ton class trucks

2 and 3 ton class trucks

3.1

TRANSFER ASSEMBLY Disassembly Start by:

(3) Remove the traction motor, reduction and differential assembly and transfer assembly as one unit, from the front axle housing.

(1) Remove the drain plug on the front axle housing to let the oil drain out. (2) Disconnect the connectors of the traction motor harnesses and pulse generator harness.

(4) Separate the three assemblies removed in step (3) from each other.

Liquid gasket

14 17 Plug (standard) or Pluse generator (option)

Staked 7

4 6

9 13

12 209002A

Disassembly sequence 1 Bolt 2 Transfer cover 3 Side cover with pulse generator, or plug 4 Nut 5 Shim Remove parts 6 and 8 as a unit. 6 Bevel pinion shaft 7 Shim 8 Bearing cone 9 Bearing cone

3.2

10 Output gear 11 Spacer 12 Bearing cup 13 Bearing cup 14 Snap ring Remove parts 15 to 17 as a unit. 15 Input gear 16 Ball bearing 17 Ball bearing 18 Transfer case

TRANSFER ASSEMBLY Suggestions for Disassembly 1. Remove the bevel pinion shaft 6 as follows:

(1) Using a chisel, cut the staked portion of the nut 4, taking care not to damage the bevel pinion shaft. (2) Hold the input gear 15 with the special tool to prevent the bevel pinion 6 from rotating, then remove the nut 4 and shims 5.

Shaft locking bar fixing bolt

Shaft locking bar Special tool

Special tool needed Staked

Transfer bearing tool

97E67 - 00100

(3) Using the bevel pinion puller (special tool), pull the bevel pinion 6 out of the bearing cone 9 (See the drawing on the right). Special tool needed Bevel pinion puller

4 5 9 8

12 209003

91268 - 00300

(4) If the bearing cone 8 needs to be removed, use a bearing puller and a press to pull it from the bevel pinion 6. (5) If the bearing cups 12 and 13 need to be removed, use a bearing cup puller to pull them out of the transfer case 18.

NOTE (1) The taper roller bearing cup and cone are an exclusive pair. If either the cup or cone of a pair is faulty, replace them as a set.

205829

(2) The removed shims should be kept together until they are reinstalled. (This only applies when the bevel pinion and/or taper roller bearing are/is reused.) (3) The bevel pinion and bevel gear are an exclusive pair. If either of them is defective, replace them as a set. 205830

3.3

TRANSFER ASSEMBLY 2. Remove the input gear as follows:

(1) Remove the snap ring 14. (2) Using a sliding hammer, pull the input gear 15, complete with the ball bearings out of the case 18. (3) If the ball bearings 16 and 17 need to be removed, use a puller to pull them out. Do not attempt to tap them out.

M14 × 1.5 18 Thread

14 15 Rod of sliding hammer

16 209004

Inspection after disassembly (1) Check the output gear 10 and the input gear 15 for damaged/worn teeth and worn splines. (2) Check the bearings for wear or damage. Make sure that they rotate freely without making noise. (3) Check the transfer case for cracks or other damage. (4) Check the bevel pinion and the bevel gear for incorrect tooth contact, damage and wear.

3.4

TRANSFER ASSEMBLY Reassembly Follow the disassembly sequence in reverse. 2

5 17

13 10

Staked

9 15

209002B

Reassembly sequence 1 Transfer case Assemble the parts 2 to 4 first, then install the assembly into the case 1. 2 Input gear 3 Ball bearing 4 Ball bearing 5 Snap ring Press-fit the parts 6 and 7 into the case 1. 6 Bearing cup 7 Bearing cup Assemble the parts 8, 9 and 10. 8 Bevel pinion shaft 9 Shim 10 Bearing cone

11 12 13 14 15 16 17 18 19

Spacer Output gear Bearing cone Shim Nut Side cover with pulse generator (option) Liquid gasket Transfer cover Bolt

3.5

TRANSFER ASSEMBLY Suggestions for Reassembly CAUTION Axle center

Ball bearings and taper roller bearings can be fitted onto shafts more easily when they are warmed in hot oil. However, do not increase the oil temperature above 120 °C (250 °F).

Mark “b” is indicated here.

1. Install the input gear 2 as follows:

(1) Press-fit the ball bearings 3 and 4 into the input gear 2. Force the assembly into the transfer case 1. (2) Install the snap ring 5. 2. Sub-assemble the bevel pinion shaft 8 as follows:

(1) Place shim stock 9 and bearing cone 10 on the bevel pinion 8, then install these into place using a press. The thickness C of shims 9 can be calculated using the following equation.

Mark “a” is indicated here. 209005

C = 1.8 + a/100 - b (unit: mm) a: Machining error in the differential carrier dimension A b: Machining error in the bevel pinion dimension B The machining error “a” is stamped on the top surface of the differential carrier. (No stamping is present if the error is within ± 0.05 mm.) The machining error “b” is marked on the end surface of the bevel pinion using electric marking pen. No mark is present if the error “b” is ± 0.

NOTE When installing shim stock 9, be sure to locate the 1.0 mm (0.04 in.) thick shim closest to the bevel

1.0 mm (0.04 in.) thick shim C

Standard shim stock thickness 1.8 mm (0.071 in.) 209006

3.6

TRANSFER ASSEMBLY (2) While inserting the bevel pinion shaft subassembly into the case, install the spacer 11, output gear 12, bearing cone 13, and shim stock 14. Reuse the originally installed shim stock 14. Preload adjustment of taper roller bearing

Attach spring scale hook here to measure the tangential force.

Special tool 8

(3) Hold the input gear 2 to prevent the bevel pinion shaft 8 from rotating. Special tool needed 14

Transfer bearing tool

97E67 - 00100 15

(4) Install a new nut 15 on the bevel pinion shaft 8. Tighten and loosen the nut several times, each time after rotating the shaft a little, so that the bearing cups and cones settle completely on each other. Finally, tighten the nut to the torque shown below. Do not give the bearings too much preload.

Tightening torque of nut 15

11 209007

294 ± 20 N·m (30.0 ± 2.0 kgf·m) [217 ± 14.5 lbf·ft]

(5) With the special tool installed on the input gear 2, measure the preload of the taper roller bearing on the bevel pinion gear shaft 8. The preload is measured in terms of the tangential force required to start the input gear 2 rotating. The measurement should meet the following specified value.

Tangential force required to start input gear 2 rotating

13 12

(1) Stake the nut completely against the bottom of the groove on the bevel pinion. (2) The staked portion should have a flat of φ 4 mm (φ 0.16 in.) or more.

54 to 81 N (5.5 to 8.3 kgf) [12.1 to 18.26 lbf]

(6) Adjust the preload as required by increasing or decreasing the thickness of the shim stock 14. The greater the shim stock thickness, the smaller the preload. The smaller the shim stock thickness, the greater the preload. Repeat the steps (4) and (5) until the specified preload is obtained. (7) After the specified preload is obtained, lock the nut 15 on the bevel pinion shaft 8 by staking to prevent it from loosening. (See the drawing shown on the right)

Staking tool needed

A screwdriver is not appropriate for staking.

R φ 4 to 6 mm (φ 0.16 to 0.24 in.)

209008

3.7

TRANSFER ASSEMBLY 3. Bolts to be tightened to special torques

Supply liquid gasket onto the face of flange. 4 2

1 5 209009

Tightening torque

3.8

N·m

kgf·m

lbf·ft

33 ± 2

3.4 ± 0.2

24.6 ± 1.4

Cover-to-traction motor

Side cover

39.2 ± 3.9

4.0 ± 0.4

29.0 ± 2.9

Plug or pulse generator 54.0 ± 4.9

5.5 ± 0.5

39.7 ± 3.6

Case-to-cover

39.2 ± 3.9

4.0 ± 0.4

29.0 ± 2.9

Lock nut

294 ± 20

30.0 ± 2.0 217 ± 14.5

Chapter 4: Rear Axle Description ................................................................................................. 4.1 Rear Wheels .............................................................................................. 4.2 Removal .................................................................................................. 4.2 Installation ............................................................................................... 4.4 Rear Axle.................................................................................................... Removal .................................................................................................. Installation ............................................................................................... Disassembly............................................................................................ Inspection after Disassembly .................................................................. Reassembly ............................................................................................

4.7 4.7 4.8 4.9 4.11 4.12

Inspection and Adjustment ......................................................................... 4.17 Minimum Turning Radius Adjustment ..................................................... 4.17

REAR AXLE: DESCRIPTION

Rear Axle Description

2 1

7 3 6 B

8609001

1. Rear axle

5. Tie rods

2. Steering cylinder

6. Wheel rims

3. Steer knuckles

7. Shims

4. King pins

The truck is steered by the rear wheels. The rear axle is connected to the frame by its center pivot shaft. Because of the center pivoting feature, the rear axle can oscillate up to 3° in each direction.

4.1

REAR WHEELS: REMOVAL & INSTALLATION

Rear Wheels Removal

Suggestions 1. Park the truck on level floor with the parking brake applied, the direction lever in neutral, the forks lowered, and the key switch off.

! CAUTION Use the same size and brand of tire for replacement.

2. Prepare the tools, parts, jack, and wheel blocks. Tools Needed: Spring scale, bearing installer, and puller.

10 7 A

Parts Needed: Lock washer 3; oil seal 7; cap 1 (when required); bearings 5, 8, 9, and 10 (when required); wheel assembly 6.

A 9 5 4 3

3. Cap 1 is press-fitted to the rim. Pry it off using a chisel and hammer as shown. Discard the removed cap. Use a new cap when installing a replacement wheel.

207030

Removal Sequence 1. Cap 2. Outer nut 3. Lock washer 4. Inner nut

203614

5. Inner race bearing

4. Bend down lock washer 3.

6. Wheel assembly

5. Loosen nut 2.

7. Oil seal

6. Raise the wheels.

8. Outer race bearing 9. Outer race bearing 10. Inner race bearing

Hoist Capacities FBC15/18KL FBC20/30KL

4.2

3000 kgf (6700 lbf) 5000 kgf (12,000 lbf)

REAR WHEELS: REMOVAL & INSTALLATION

Steering Cylinder *: Parts contained in seal kit 12 * 14 13 * *

▲

11 *

▲

9 8

16 * ▲

7 ▲

▲

•▲

• ▲

5 ▲

▲

•

* 15

▲

4 207168

1 2 3 4 5 6 7 8 9

Cylinder tube Piston rod Cylinder head Cylinder head Pivot joint Snap ring Tie rod Nut Spring washer

10 11 12 13 14 15 16 17

Stopper ring Wiper U-seal O-ring O-ring Guide ring Piston seal Bushing

Double-action cylinder is used.

4.3

REAR WHEELS: REMOVAL & INSTALLATION Suggestions, continued 7. Block the front wheels. 8. Fasten a hoist to the counterweight and lift the rear end of the truck. 9. Place the wood blocks under the side frames to support the truck (with the left and right rear wheels slightly clearing the floor).

Inspection 1. Oil seal Check the oil seal of the rim for excessive wear or damage. 2. Tires Check the height of the solid rubber portion and, if worn down to 25.4 mm (1 in.), replace the tire. NOTE Replace all tires if one tire is damaged. If new and used tires are mixed, rapid tire wear will result.

Blocks

100393B

Installation To install, follow the reverse the removal sequence: 1. Using a puller, install bearings (outer) 8 and 9 to the new wheel assembly 6. 2. Install oil seal 7 to the new wheel assembly 6.

10. Remove nut 2, lock washer 3 and nut 4. 11. Remove wheel assembly 6 from the rear axle. Be careful not to cause damage to the oil seal fitted to the rim. After removing the assembly, raise the counterweight to a position 400 to 500 mm (16 to 20 in.) from the floor. 12. Using a puller, remove outer race bearings 8 and oil seal 7 from the wheel assembly.

10 7 A

A 9 5 4 3

NOTE Replace the cap and bearings (inner and outer) if defective. 207030

25.4 mm (1 inch)

207029

4.4

REAR WHEELS: REMOVAL & INSTALLATION 3. Fill the rim and oil seal with grease. Do not overfill the oil seal to prevent leakage. Oil seal ▲

4. Tighten nut 4 to 137 N·m (14 kgf·m) [101 lbf·ft] torque and back it off 80°, then put lock washer 3. Install nut 2, tightening it to 157 N·m (16 kgf·m) [116 lbf·ft] torque. Check the hub bearing preload, making sure it is 2.5 to 6.4 N·m (25 to 65 kgf·cm) [1.8 to 4.7 lbf·ft]. If the preload is correct, bend lock washer 3.

• Fill with grease

207024

5. Check to make sure the preload is correct. Insert a 24mm round bar into the cast hole of the rim. Attach a spring balance to the round bar, and measure the tangential force.

Tangential force N (kgf) [lbf]

FBC15K FBC18K FBC18KL

FBC25KL,FBC30KL

33.1 to 86 (3.38 to 8.78) [7.4 to 19.3]

26.7 to 69.6 (2.73 to 7.10) [6.0 to 15.6]

▲

Bar

FBC20K,FBC25K

FBC25KE

207025

Tighten the inner nut to achieve the specified value. Reference value

Bar

2.5 to 6.4 N·m Preload for hub (25 to 65 kgf·cm) bearings [1.8 to 4.7 lbf·ft] Spring scale

207026

4.5

REAR WHEELS: REMOVAL & INSTALLATION

6. After adjusting the preload, tighten a new lock washer 3 and an outer nut 2 to the specified torque. Tightening torque for outer (lock) nut

157N·m (16 kgf·m) [116 lbf·ft]

Inside nut ••

Outside nut

207024

7. Bend the lock washer to both sides (inward and outward).

205436

8. Fill the cap with grease, and install the cap 1. 9. Raise the rear end of the truck and remove the blocking from the side frames. 10 Lower the truck until the rear wheels just touch the floor.

4.6

REAR AXLE: REMOVAL & INSTALLATION

Rear Axle Removal

6 7 6

5 4 3 203613

Sequence 1. Cap

4. Rim and tire

2. Nut and washer

5. Drag link

3. Bearing

6. Bearing support and bolts

7. Rear axle assembly

Start By: 1. Apply the parking brake and block the front wheels. 2. Raise the rear end of the truck with a jack and place wood blocks under the side frames (with the left and right rear wheels slightly clearing the floor). 3. A hoist can be used instead of the jack to raise the rear end (counterweight). 203622

4.7

REAR WHEELS: REMOVAL & INSTALLATION Suggestions

Installation

Removing Rear Axle Assembly

To install, reverse the removal sequence and do the following steps.

WARNING

Be sure the pressure in the hydraulic system is released before any lines or hoses are disconnected. 1. Put identification marks on the hoses, then disconnect them. 2. Support the rear axle at its center with a garage jack.

Adjusting Bearing Support Clearance Adjust the longitudinal clearance to 0.8 mm (0.031 in.) with the thrust washer and tighten the bolts holding the bearing support to the specified torque. Tightening torque for bearing support bolts

14.8 kgf•m (107 lbf•ft) [145 N•m]

3. Loosen and remove the axle mounting bolts.

Clearance: 0.8 mm (0.031 in.)

203615

Weight of Rear Axle FBC15K-18KL

60kg [132 lb]

FBC20K-30KL

85kg [187 lb]

4.8

200257

REAR AXLE: DISASSEMBLY

Disassembly REAR AXLE ASSEMBLY

17 16

17 19 13 11 2 10 9

8 7 6

9 5

12 207028

Disassembly Disassembly sequence 1 Taper roller bearing (inner), Retainer 2 Tie rod pin, Bolt, Spring washer, Plain washer, Collar, Grease nipple 3 Spherical bushing, Ring, Retainer, Dust seal 4 Tie rod 5 Kingpin plate, Shim 6 Kingpin, O-ring Remove parts 7 through 12 as an assembly. 7 Knuckle 8 O-ring 9 Taper roller bearing

10 11 12 13 14 15 16 17 18 19

Oil seal Cover, Retainer Boot Cover Clamp, Bolt, Spring washer Pipe (L.H., R.H.) Steering cylinder [Bolt, Spring washer, Nut] Elbow, O-ring Stopper bolt, Lock nut Rear axle housing

4.9

REAR AXLE: DISASSEMBLY Suggestions Removing Retainer and Bearing

Mark Cylinder End Caps

Use a puller to remove the retainer and inner bearing from the knuckle.

Mark the cylinder end caps for proper alignment before they are disassembled from the cylinder. Mark

203618

4.10

Mark

8609004

REAR AXLE: INSPECTION

Inspection after Disassembly Tie Rods and Pins

Seals and O-rings

1. Make sure that the pins are free of any surface flaws such as grooving or stepped wear. Examine the keeper plate weld for cracking.

Examine all seals and O-rings for damage such as cuts and tears. Replace seals which show signs of aging.

2. Examine the bearings for wear or damage. 3. Examine the tie rods for damage and alignment. Inspect the welds for signs of cracks.

NOTE If a pin must be replaced, replace its bearing as well.

Hydraulic Pipes Inspect the hydraulic pipes for cracks, especially at the joints with the end fittings. Check for leaks.

Tires Check the height of the solid rubber portion and, if worn down to 25.4 mm (1 in.), replace the tire.

NOTE

Kingpins Check the kingpins for any surface flaws such as grooving or stepped wear. Inspect the pins for cracks at the bearing shoulder.

Replace all tires even if only one tire is damaged. If new and used tires are mixed, rapid tire wear will result.

Kingpin Bearings Examine the rollers and bearing races for grooving, abrasive wear, pitting, bruising, or corrosion. Replace both the cup and cone of damaged bearings.

Knuckles Inspect the inside of each knuckle for wear or damage. Be sure to examine for casting cracks. Check the tie rod pin hole. Examine the wheel nut threads for damage.

25.4 mm (1 inch)

100880

Cylinder Rod Examine the rod for surface or plating damage. Inspect the rod for straightness. Examine the piston for damage. Check the tie rod pin hole for damage or wear.

4.11

REAR AXLE: REASSEMBLY

Reassembly 3 2

3 1 15 11 17 10 9

8 6 13

9 14

12 207028

Assembly sequence 1 Rear axle housing 2 Steering cylinder [bolt, spring washer, nut] 3 Elbow, O-ring 4 Pipe (L.H., R.H.) 5 Clamp, bolt, spring washer 6 Knuckle 7 Spherical bushing, ring, retainer, dust seal 8 O-ring 9 Taper roller bearing 10 Oil seal

4.12

11 12 13 14 15 16 17 18 19

Cover, retainer Boot Kingpin, O-ring, bolt, spring washer Kingpin plate, shim, bolt, spring washer Cover Tie rod Tie rod pin, bolt, spring washer, plain washer, collar, grease nipple Stopper bolt, lock nut Retainer, taper roller bearing

REAR AXLE: REASSEMBLY Suggestions Reassembling Steer Cylinder 1. Replace all seals and O-rings when reassembling the steer cylinder. Lubricate seals and O-rings lightly with hydraulic fluid.

4. Pressure test cylinder reassembly for leaks.

2. Assemble wiper seal and U-seal as shown.

FBC15K-18KL

FBC20K-30KL

107 (1522) [10,500]

163 (2320) [16,000]

Minimum test pressure

Unit: kgf/cm2 (psi) [kPa]

5. Use an alternating tightening pattern to tighten the mounting bolts when attaching the cylinder assembly to the axle beam.

Wiper seal

U-Seal 8609006

3. Align marks on the end caps to marks on the cylinder body. Tighten nuts. Tightening torque for cylinder nuts

2.1 ± 0.2 kgf•m (15.5 ± 1.5 lbf•ft) [21 ± 2 N•m]

Mark

Tightening torque for bolts

FBC20K-30KL

17.9 kgf•m (130 lbf•ft) [176 N•m]

26.7 kgf•m (193 lbf•ft) [262 N•m]

Reassembling Knuckles 1. Insert bearing cups into knuckles. Adequately fill bearing cages with “AUTOLEX A” grease. Apply a coat of grease to the oil seal groove. Insert the bearing cages in the knuckles and apply additional grease as required to meet the recommended amount.

Quantity of grease

Mark

FBC15K-18KL

FBC20K-30KL

40cc (2.44 in3)

80 cc (4.88 in3)

2. Reassemble remaining components (seals, O-rings, covers, and boots). 8609004

3. Assemble parts, knuckle 6 through Boot 12, and insert this sub-assembly into the rear axle housing.

4.13

REAR AXLE: REASSEMBLY Reassembling Kingpins 1. Install the kingpins and measure the distances “A” on both the left and right kingpins.

3. Measure the tangential force at point “C”. When the tangential force is larger than the values shown in the table below, add shims. When the tangential force is smaller than the values shown in the table below, remove shims. Repeat this procedure until the values in the table are attained.

Tangential force A

FBC15K-18KL

FBC20K-30KL

1.6 to 2.6 kgf (3.5 to 5.7 lb.) 15.7 to 25.5 N

2.5 to 4.5 kgf (5.5 to 9.9 lb.) 24.5 to 44.1 N

8609007

2. Add shims to each side to within 0.1 mm (0.004 in.) of the measured distance “A” and tighten bolt “B”.

8609009

4. Tighten kingpin keeper plate bolts.

Tightening torque for bolts

Shims

Bolt B

8609008

4.14

Kingpin Bolt

Keeper Plate Bolts

1.7 kgf•m (12.3 lbf•ft) [16.7 N•m]

3.4 kgf•m (24.6 lbf•ft) [33.4 N•m]

REAR AXLE: REASSEMBLY Reassembling Tie Rods Replace dust seals. Tighten tie rod pin bolts to the specified torque. Grease the joints using the grease zerks.

3. Reassemble rear axle hubs. The inner race of the inner bearing must be driven onto the shaft using a special tool as shown below.

0.7 kgf•m (5 lbf•ft) [6.9 N•m]

Tightening torque for bolts

Zerk

205022

Dust seals

Rod pin bolt 8609010

4. There is space between the two tapered roller bearings inside the rear axle hub. Be sure to fill this space with grease. Grease the oil seal lip groove and roller retainers, too. Do not overfill the oil seal lip groove as this can cause leakage.

Reassembling Rear Axle Hub 1. Using Installation Tool #91268-01500 or #64309-40400 install inner bearing races. Using Tool #91268-01400 or 91268-00400 install outer bearing races.

Bearing installer

FBC15K-18KL

FBC20K-30KL

91268-01500

64309-40400

Oil seal Fill with grease

8609002A

2. Pack bearing cones. 5. Install wheel assembly carefully so as not to damage the bearing or seal. 10 7 A

A 9 54 3 2 1

101744

4.15

REAR AXLE: REASSEMBLY 6. Install outer bearing and nut 4.

NOTE

7. Tighten nut 4 to 14 kgf•m (101 lbf•ft) [137 N•m] torque and back it off to 80°, then place lock washer 3. Install nut 2, tightening it to 16 kgf•m (116 lbf•ft) [157 N•m] torque. Check the hub bearing preload, making sure it is 25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m]. If the preload is correct, bend lock washer 3.

Preload for bearing is given in tangential force measurement and must be measured with a spring scale. Apply force to spring scale as shown in graphic #101653, read scale. Adjust nut 4 to achieve correct preload.

8. Check to make sure the preload is correct. Preload for hub bearings

Inside nut

25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m]

Outside nut Bar

8609002B

Preload for hub bearings Tangential Force

25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m] 8609002

Tightening torque for outer lock nut

16 kgf•m (116 lbf•ft) [157 N•m] Bar

Spring scale

101653

9. Install cap 1. 10. Raise the rear end of the truck and remove the blocking from the side frames. 11. Lower the truck until the rear wheels are on the floor.

4.16

REAR AXLE: INSPECTION

Inspection and Adjustment Minimum Turning Radius Adjustment 1. Using a turning radius gauge, measure the angular swing of rear wheels. 2. Setting the turning angle of each rear wheel to the specification is not enough. The truck must be driven to make the sharpest possible turn to either side, and the radius of the track left behind by the outer wheel must be measured for confirmation. The standard minimum turning radius is indicated below. FBC15K-18KL Steering Angle Inside Outside Tightening torque for knuckle stopper bolt lock nut

3. Drive the machine at low speeds in such a way as to make the sharpest possible turn to either side. Measure the radius of the track left by the outer wheel. 4. The minimum turning radius, R, is the distance from the turning center to the center of tire contact with the surface while the truck is executing its sharpest turn, plus the rear overhang (distance from center of rear tire to the outermost end of the counterweight).

FBC20-30KL

83° 54°

83° 56° 6.8 kgf•m (49 lbf•ft) [67 N•m]

FBC15K

1787 (70.4)

FBC18K

1787 (70.4)

FBC18KL

1841 (72.5)

FBC20K

1890 (74.4)

FBC25K

1890 (74.4)

FBC25KE

1991 (78.4)

FBC25KL

1991 (78.4)

FBC30K

2045 (80.5)

FBC30KL

2045 (80.5)

202800

Turning radius [Unit: mm (in.)]

4.17

REAR AXLE: STEERING CYLINDER STEERING CYLINDER Disassembly *: Parts contained in repair kit

10 *

11 9

11 3 * 4 5

* 6

* 7

7 *

A 2

6 *

5 4

* 3 8

1 207036

Disassembly sequence 1 2 3 4 5

Nut, Spring washer, Tie rod Remove parts 7 through 12 as assembly. Cylinder head O-ring Snap ring Bushing

NOTE (1) Do not remove bushing 5 from the cylinder head 2 if acceptable. (2) Do not remove bearing 11 from piston rod 9 if acceptable.

4.18

6 7 8 9 10 11

Wiper U-seal Cylinder tube Piston rod Guide ring, Piston seal Stopper ring

REAR AXLE: STEERING CYLINDER Suggestions Mark Cylinder End Caps Mark the cylinder end caps for proper alignment before they are disassembled from the cylinder.

Mark

Mark 207035

Inspection and Repair 1 Cylinder tube 8: Check for wear, damage or rust inside the cylinder. 2 Piston rod 9: Check for rust, damage, scratches or impact marks on the rod surface. 3 Rings and gaskets: Replace the entire seal kit. A: Standard value Unit: mm (in.)

205439

FBC15K-18KL FBC20-30KL

Internal diameter of A cylinder tube 1

63(2.480)

75(2.953)

External diameter of A piston rod 2

40(1.575)

50(1.968)

207034

4.19

REAR AXLE: STEERING CYLINDER Reassembly 5

5 1

13 4

12 •

•

9 8 6 7

Assembly sequence 1 Piston rod 2 Piston seal 3 Guide ring 4 Cylinder tube 5 Cylinder head 6 Bushing

7 8 9 10 11 12

207034

Snap ring U-seal Wiper O-ring O-ring Tie rod

13 14 15 16

Spring washer Nut Pivot joint Stopper ring

Suggestions 1. Replace all seals and O-rings whenever reassembling steer cylinder. Lubricate seals and O-rings lightly with hydraulic fluid. 2. Assemble wiper seal and U-seal as shown. 3. Align marks on the end caps to marks on the cylinder body. Tighten nuts. Wiper

U-seal

207042

Unit: N·m (kgf·m) [lbf·ft] Tightening torque for cylinder nuts N·m (kgf·m) [lbf·ft]

Mark

21±2 (2.1±0.2) [15.5±1.5]

4. Pressure test cylinder reassembly for leaks. Unit: kPa (kgf/cm2) [psi]

Minimum test pressure

4.20

FBC15-18KL

FBC20-30KL

10500 (107) [1522]

16000 (163) [2320]

Mark 207035

Chapter 5: Brake System Description .................................................................................................... 5.1 Automatic Adjusting Device ....................................................................... 5.1 General Information ................................................................................... 5.1 Master Cylinder Disassembly............................................................................................... 5.2 Inspection after Disassembly..................................................................... 5.3 Reassembly ............................................................................................... 5.3 Service Brakes Disassembly (FBC15K - 18KL) ................................................................................... 5.4 (FBC20K - 30KL) ................................................................................... 5.5 Inspection after Disassembly..................................................................... 5.7 Reassembly (FBC15K - 18KL) ................................................................................... 5.8 (FBC20K - 30KL) ................................................................................... 5.9 Wheel Cylinders Disassembly............................................................................................... 5.12 Inspection after Disassembly..................................................................... 5.13 Reassembly ............................................................................................... 5.13 Inspection and Adjustment......................................................................... 5.14

BRAKE SYSTEM: DESCRIPTION

Description Automatic Adjusting Device

205955

General Information This device adjusts the drum-to-lining clearance automatically. As the clearance increases due to lining wear, the lever mechanism of this device turns the adjusting screw by one notch or tooth to reposition the shoes closer to the drum. This corresponds to 1/24 of one rotation or 15°. In the course of usage, the adjusting process repeats itself at long intervals.

5.1

MASTER CYLINDER: DISASSEMBLY

Master Cylinder Disassembly

9 8 7

6 5

91484-37100 FBC15K - 18KL 91246-07200 FBC20K - 30KL

1 2

97146-10000A

1. Taper plug

6. Oil tank assembly

2. Master cylinder body

7. Push rod

3. Repair kit

8. Jam nut

4. Cap assembly

9. Clevis

5. Level sensor

10. Push rod assembly

NOTE The parts* to be changed periodically are included in the Repair Kit.

5.2

MASTER CYLINDER: INSPECTION & REASSEMBLY Inspection after Disassembly Brake Fluid Level Sensor

Piston

1. Fill the reservoir with brake fluid. Connect the level sensor connector at the bottom of the fluid reservoir and turn the key to ON.

Replace the piston if it is damaged. Check the piston clearance in the cylinder body. Replace the cylinder body and piston if the clearance is in excess of the service limit. Clearance between piston and cylinder

0.020 to 0.105 (0.00079 to 0.00413)

0.2 (0.008)

Unit: mm (in.) A = Assembly Standard B = Repair or Service Limit DOWN = ON

Return Spring

UP = OFF

Replace the return spring every year. 200270

Primary Cup, Secondary Cup, and Valve 2. The sensor is satisfactory if the brake fluid level warning lamp on the monitor flashes when the reservoir filler is in the DOWN position and goes off when it is in the UP position.

Check these rubber parts for swelling, tearing, and deterioration from aging. Replace them every year.

Cylinder Body

Reassembly

1. Check the bore of the cylinder for rust, corrosion, and scoring.

To reassemble, reverse the procedure for disassembly and do the following steps.

2. Check the inlet port and relief ports for cleanliness. Also check the threads in the screw connection of each joint for damage. Make sure the boot is free from defects.

1. Clean all metal parts with a volatile cleaning solvent. Dry them with pressure air. 2. Apply a thin coat of rubber grease (Metal Rubber #20) or brake fluid to the piston cups and the cylinder bore. Master Cylinder Adjustment: Adjust master cylinder only after pedal height adjustment has been made (See pg. 5.18). With master cylinder installed and push rod connected to brake pedal, use the clevis pin to adjust the master cylinder push rod so there is 0.5 to 2.8mm of free play between the end of the push rod and cylinder position contact. Tighten jam nut on push rod clevis assembly.

5.3

SERVICE BRAKES: DISASSEMBLY

Service Brakes Disassembly (FBC15K - 18KL) 1

2 16

20 19 7

22 6 26 27

17 15

11 14 25

18 12

97146-11800A

Components 1. Service Brake Assembly

15. Spring

2. Wheel cylinder assembly

16. Pin

3. Backing plate

17. Spring

4. Primary shoe and lining assembly

18. Strut

5. Secondary shoe and lining assembly

19. Spring washer

6. Parking Lever

20. Retainer

7. Adjusting screw

21. Bolt with washer

8. Adjusting lever

22. Snap ring

9. Spring

23. Cover

10. Cable guide

24. Parking cable assembly

11. Fitting cable

25. Spring

12. Spring

26. Spring washer

13. Shoe guide plate

27. Bolt

14. Cup 5.4

SERVICE BRAKES: DISASSEMBLY

Disassembly (FBC20K - 30KL) 1

2 16

5 26 9 20 19 7

22 6

31 30

4 17

14 15 14 18

11 12

97246-10900A

Components 1. Service Brake Assembly

10. Self-locking nut

21. Bolt with washer

2. Wheel cylinder assembly

11. Fitting cable

22. Snap ring

3. Backing plate

12. Spring

23. Cover

4. Primary shoe and lining assembly

13. Shoe guide plate

24. Parking cable assembly

14. Cup

25. Spring

5. Secondary shoe and lining assembly

15. Spring

26. Spring

16. Pin

27. Pin

17. Spring

28. Sheave

18. Strut

29. Plain washer

19. Spring washer

30. Bolt

20. Retainer

31. Spring washer

6. Parking Lever 7. Adjusting screw 8. Adjusting lever 9. Spring

Start By: 1. Remove the front wheel. 2. Remove the wheel hub and brake drum.

4. Disconnect the brake pipe from the wheel brake assembly.

3. Separate the parking brake lever and cable at the bottom of the wheel brake. 5.5

SERVICE BRAKES: DISASSEMBLY Suggestions Removing Return Springs

Removing Hold-Down Springs

Use a special tool to remove the return springs.

Use a special tool to remove the hold-down springs.

Special Tool

Part Number

Special Tool

Part Number

Spring remover

64309-15411

Spring remover

64309-15412

200271

5.6

200272

SERVICE BRAKES: INSPECTION Inspection after Disassembly Backing Plate

Brake Drums

1. Check the backing plate for cracks.

Check the inside (friction) surface of the drum for abnormal wear, grooving, and other defects. Minor grooving can be removed by grinding, provided that the service limit on the inside diameter is not exceeded.

2. Tighten the backing plate mounting bolts to the specified torque. Tightening torque for backing plate mounting bolts

16 kgf•m (116 lbf•ft) [157 N•m]

Inside diameter of brake drum

Shoes and Linings 1. Check each shoe and lining for cracks. 2. Replace the lining if it is dirty, greasy, burnt, or glazed.

FBC15K - 18KL

FBC20K-30KL

254 + 0.13 0

(10.0 + 0.0051 0)

310 + 0.15 0 (12.2 + 0.0059 0)

256 (10.08)

312 (12.28)

Unit: mm (in.) A = Assembly standard B = Repair or service limit

3. Check the thickness of the lining. Replace the lining if it exceeds the service limit.

Adjusting Screws Check the wheel teeth for wear. Turn the screw by hand to ensure its rotating parts turn freely.

203005

Lining thickness

FBC15K - 18KL

FBC20K-30KL

4.87 (0.19)

6 (0.24)

2.5 (0.10) maximum

3 (0.12) maximum

Unit: mm (in.) A = Assembly standard B = Repair or service limit

200274

Parking Brake Cable Replace a cable if it is permanently stretched, rusted, or damaged.

Other: 1. Check the return springs for cracks or fatigue. 2. Check the adjusting springs for cracks or fatigue. 3. Check the fitting cables for stretching.

5.7

SERVICE BRAKES: REASSEMBLY

Reassembly (FBC15K - 18KL) 6

12 13

5 8 4 7

11 9 9

14 16 15

Section A-A

205960

Sequence 1. Backing plate

9. Pin, hold-down spring, and cup

2. Parking brake cable

10. Shoe guide plate

3. Wheel cylinder

11. Fitting cable

4. Parking brake lever

12. Return spring

5. Shoe and primary lining

13. Cable guide

6. Retainer and washer

14. Adjusting lever and adjusting spring

7. Shoe and secondary lining

15. Adjusting screw

8. Strut and anti-rattle spring

16. Return spring

5.8

SERVICE BRAKES: REASSEMBLY

Reassembly (FBC20K - 30KL) A

11 9

7 4 8

10 10

12 5

14 15

Section A-A

A 205961

Sequence 1. Backing plate

9. Strut and anti-rattle spring

2. Parking brake cable

10. Pin, hold-down spring, and cup

3. Wheel cylinder

11. Shoe guide plate

4. Parking brake lever

12. Fitting cable

5. Shoe and primary lining

13. Return spring

6. Retainer and washer

14. Adjusting lever and adjusting spring

7. Pin, sheave, and washer

15. Adjusting screw

8. Shoe and secondary lining

16. Return spring

5.9

SERVICE BRAKES: REASSEMBLY Suggestions Installing Wheel Cylinder

Greasing

Apply retaining compound to the mounting face of the wheel cylinder before positioning the cylinder in place. Secure it by tightening to the specified torque:

Apply a thin coat of the specified brake grease to each of the following parts.

Tightening torque for wheel cylinder

FBC15K - 18KL

FBC20K-30KL

0.8 to 1.2 (6 to 9) [8 to 12]

1.8 to 2.7 (13 to 20) [18 to 26]

Unit: kgf•m (lbf•ft) [N•m]

1. Shoe ledges (6 places): The ledges are the portions of the backing plate in contact with the shoe. 2. Anchor pin surface in contact with the shoe ends.

Installing Shoes Make sure that each push rod of the wheel cylinder is snugly fitted to its shoe web.

Installing Return Springs Use a special tool to install the return springs to the backing plate pins Special Tool

Part Number

Spring installer

65309-15413

200275

200276

5.10

SERVICE BRAKES: REASSEMBLY Installing Automatic Adjusting Device 1. Clean the adjusting screw and associated parts, then grease the screw threads and screw socket. Be sure the screw turns freely when rotated by hand. If the screw is hard to turn, replace it. 2. The right and left adjusting screws are colorcoded. • Right-hand adjusting screw and lever (lefthand thread) is yellow. • Left-hand adjusting screw and lever (righthand thread) is white.

200277

NOTE After reassembly, bleed air out of the brake fluid lines. (Refer to INSPECTION AND ADJUSTMENT, p. 5.15).

5.11

WHEEL CYLINDER: DISASSEMBLY

Wheel Cylinders Disassembly 10 7 6

12 11

5 9

4 2

97246-10900B

Sequence 1. Connecting link

8. Spring

2. Boot

9. Cup

3. Piston

10. Piston

4. Piston cup

11. Boot

5. Body

12. Connecting Link

6. Bleeder screw 7. Cap

NOTE The parts (*) to be changed periodically are included in the repair kit.

5.12

WHEEL CYLINDER: INSPECTION & REASSEMBLY

Inspection after Disassembly Cylinder Bodies

Piston Cups

1. Check the bore for rusting, corrosion, and scoring.

Check for swelling or other defects. Replace the cups at the time of overhaul and every year.

2. Check the threads of the bleeder screw and oil pipe for damage.

Boots

Pistons

Replace the boots if they are hardened, damaged, or otherwise deteriorated.

1. Check the sliding surface for rusting or scratching.

Reassembly

2. Check the piston clearance in the cylinder body. Replace the cylinder body and piston if the clearance exceeds the service limit.

To reassemble, reverse the procedure for disassembly and do the following: 1. Coat the piston cups and the cylinder bore with brake fluid. 2. Be careful not to damage the lips of the cups.

200280

Clearance between piston and cylinder

A B

FBC15K - 18KL

FBC20K-30KL

0.040 to 0.125 (0.00157 to 0.00492)

0.020 to 0.105 (0.00079 to 0.00413)

0.15 (0.0059)

Unit: mm (in.) A = Assembly standard B = Repair or service limit

5.13

BRAKE SYSTEM: INSPECTION

Inspection and Adjustment Automatic Adjusting Device 1. Have the service brake properly set with the drum-to-lining clearance adjusted to specification. Pull the adjusting lever by giving a push to the cable, as shown, to see if the lever turns the adjusting screw by one tooth and, as the push is released, returns to its original position. If it does, the device is in satisfactory condition.

3. When the automatic adjusting device is suspected of malfunctioning during normal use of the machine, check for the following causes: a. Adjusting spring is not correctly hooked to the primary shoe. b. Any one of these parts is in bad condition and needs replacing: 1) fitting cable 2) adjusting lever 3) adjusting screw

Manual Adjustment The drum-to-lining clearance can be adjusted by rotating the adjusting screw with a screwdriver on to the toothed wheel. The hole through which the screwdriver tip can be inserted is in the backing plate. 200281

2. If the lever fails or is sluggish to turn the adjusting screw in the above test, the likely cause is that the lever is not properly positioned relative to the toothed wheel. Be sure that the lever is positioned so that its actuating tip touches the toothed wheel at about 9 mm (0.35 in.) under the center line of the screw, as shown below.

9 mm (0.35 inch) 200282

5.14

200283

BRAKE SYSTEM: INSPECTION Brake Pedal Adjustment

Bleeding Air Out of Brake Fluid Line

Set the dimensions A, B, and C to the specified values.

Whenever any part of the brake fluid line is disconnected in servicing work, an air bleeding operation must be performed to complete the job. Air trapped in any part of the fluid line will cause the brake pedal to feel spongy.

After the shoe linings have been replaced, turn the adjusting screw as far as it will go (until the clearance becomes zero) and back it off by the amount of rotation shown below. FBC15K - 18KL:

19 clicks

FBC20K - 30KL:

16 clicks

Height from floor to pedal (A) Stroke (to a point where brakes start to apply) (B)

Air Bleeding Operation Procedure: 1. Tie a flexible tube, such as a vinyl pipe, to the bleeder screw on the wheel cylinder. Insert the free end of the tube into a vessel filled with brake fluid.

98mm ± 3 mm 1 ton 80mm ± 3mm 2/3 ton 3 to 10 (0.12 to 0.4)

Clearance between piston 0.5 to 2.8 (0.02 to 0.11) and push rod (C) Unit: mm (in.)

2. Pump the brake pedal and depress it all the way. While keeping the pedal depressed, loosen the bleeder screw. When air bubbles cease to come out, tighten the screw. Repeat this process until nothing but brake fluid flows into the vessel. 3. Repeat procedure at each wheel brake, and fill up the brake fluid reservoir to level.

B A Push rod

200285

C Stop bolt

8609011

NOTE Be sure that the reservoir never becomes empty of fluid at any time during the procedure. Use specified brake fluid. Avoid mixing different brands of brake fluid before and after filling up the reservoir.

Brake Test After completion of necessary adjustments, test the brake force by operating the truck at a speed of 10 km/h (6.2 mph). Refer to Manual Adjustment for necessary readjustment.

5.15

Chapter 6: Steering System Steering System Description ..................................................................................................6.1 Steering System ......................................................................................6.1 Oil Flow Sequence ...............................................................................6.1 General Information..............................................................................6.1

Steering Gear Steering Wheel Removal ...................................................................................................6.2 Installation ................................................................................................6.2 Steering Gear ..............................................................................................6.3 Inspection after Removal ............................................................................6.4 Disassembly ................................................................................................6.5 Working Rules and Tips ...........................................................................6.6 Suggestions .............................................................................................6.6 Inspection after Disassembly ...................................................................6.6 Reassembly.................................................................................................6.7 Suggestions..........................................................................................6.8

Steer Pump Removal ......................................................................................................6.9 Installation ...................................................................................................6.10 Disassembly ................................................................................................6.11 Sequence .................................................................................................6.11 Working Rules and Tips ...........................................................................6.12 Suggestions .............................................................................................6.12 Inspection after Disassembly ...................................................................6.14 Reassembly.................................................................................................6.15 Sequence .................................................................................................6.15 Suggestions .............................................................................................6.16 Inspection after Reassembly....................................................................6.18

STEERING SYSTEM: DESCRIPTION

Steering System Description Steering System

3 2

8609044

Oil Flow Sequence 1. From hydraulic tank

4. Steering cylinder

2. Steering pump

5. Mast operating valve

3. Steer gear

6. To hydraulic tank

General Information This steering system is an open-center type, where the steering fluid is provided by a dedicated steering pump. The oil is constantly available and flows through the steer gear and back to the tank via the mast operating valve. In this type of steering system, only the small dedicated steer pump is pressurized, providing an efficient, energy-conservation system.

6.1

STEERING GEAR: REMOVAL & INSTALLATION

Steering Gear Removal Steering Wheel

8609016

Sequence 1. Nut, washer 2. Wheel

Removal

Installation

Use a special tool.

To install, follow the reverse of the removal sequence.

Special Tool

Part Number

Wheel puller

91268-10600

Wheel puller

203466A

6.2

STEERING GEAR: REMOVAL & INSTALLATION Steering Gear

Sequence 1. Column & Kick cover mounting hardware 2. Column & Kick covers 3. Hoses, connectors and o-rings 4. Steer column mounting bolts 5. Steer column 6. Steer gear

WARNING

Hydraulic pressure can cause personal injury. Before any steering system hydraulic lines or components are disconnected, make sure all hydraulic pressure is released in the steering system. Move the steer wheels to the left and right, then straight.

NOTE For servicing the steer cylinder, see REAR AXLE section.

6.3

STEERING GEAR: REMOVAL & INSTALLATION

Inspection after Removal 1. Inspect the grommets for cracks or tears in the rubber or for signs of aging. Check the O-rings for damage.

Installation To install, follow the reverse order of the removal sequence. Tighten bolts to the specified torque

Tightening torque for bolts

6.4

2.9 ± 0.3 kgf•m (20.9 ± 2.1 lbf•ft) [28.4 ± 2.9 N•m]

STEERING GEAR: DISASSEMBLY

Disassembly Steering Gear 9

5 7 8 16

4 3 2 14

13 12 1

11 10

Sequence 1. Mounting cap, cap screws, dust seal

9. Centering Springs

2. Pressure seal

10. O-ring

3. Thrust races, Thrust bearings & retaining ring

11. Gerotor

4. Spool

12. O-ring

5. Long Drive Pin

13. Housing

6. Drive Tube

14. O-ring

7. Short Drive Pin

15. Tank Plug

8. Sleeve

16. Manual Steering Balls

6.5

STEERING GEAR: DISASSEMBLY Working Rules and Tips The steering gear, complete with the control valve, is a precision-machined component. As such, it must be handled with extreme care. Cleanliness is imperative: work in a clean place and use clean tools. 1.Clean the disassembled parts with a volatile solvent such as trichlene or chlorobenzene, and dry them with compressed air. This does not apply to rubber parts. 2.Oil seals, O-rings, and the like are rubber parts. Never clean them with solvent. Blow dirt off rubber parts with compressed air and keep them immersed in a pool of hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced. Rubber parts are expendable components that should be replaced once a year. 3.Parts to be installed by pressing or forcing need special treatment. a. Oil Seals Oil seals, once removed, must not be reused. After disassembly, examine the oil seals in place (in the gear box and side cover). If they are in good condition, leave them in place. When installing a replace-ment oil seal, be careful not to score or scratch the lip area.

Suggestions: The Steer Gear is designed with very few serviceable components. Only disassemble the steer gear if you plan to replace one of the following: 1. Dust Seal 2. Pressure Seal 3. O-rings 4. Thrust Race and/or Bearings If replacing these parts does not improve performance, you must replace the entire Steer Gear Assembly. Refer to your Parts Manual for ordering information. IMPORTANT: Before you begin disassembly, scribe a line across housing gerotor and mounting cap for reference alignment when reassembling the unit. 1.Remove the five cap screws and the end cap. Remove the dust and pressure seals from the end cap using a thin-bladed screwdriver. 2.Remove the O-ring from the groove in the housing. 6.6

3.Remove the Gerotor to gain access to the other O-ring; remove. 4.Slide the Thrust Races and Bearing off the spool. 5.Replace the worn components. See “Inspection after Disassembly” section. 6.Reassemble the components from items 1-3 per the instructions given in the “Reassembly” section. 7.Remove the Tank Plug using Special Tool 97E67-00200. 8.Remove and, if necessary, replace the O-ring.

Inspection after Disassembly 1.Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leaks. 2.Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towels because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts.

STEERING GEAR: REASSEMBLY

Reassembly Steering Gear 12

15 13 11 9 17 16

7 1

3 4

18 8

5 10

Sequence 1. O-ring

10. Spool

2. Tank Plug

11. Sleeve

3. Housing

12. Centering Springs

4. O-ring

13. Short Drive Pin

5. Gerotor

14. Drive Tube

6. Mounting cap

15. Long Drive Pin

7. Pressure seal

16. Retaining Ring

8. Dust Seal

17. Thrust Bearing and Races

9. Manual Steering Balls

18. Capscrews

6.7

STEERING GEAR: REASSEMBLY Suggestions: NOTE: These instructions are more in depth than routine service should require. DO NOT disassemble the steer gear further than required to replace serviceable components. Doing so may result in replacing entire gear.

6.8

1 Install o-ring (82,6 [3.25 OD) on tank plug. 2 Assemble tank plug into housing. Torque tank plug to 47,5 Nm [35 lb-ft]. 3 Install o-ring (82,6 [3.25 OD) into groove. 4 Lay gerotor on the housing,lining up bolt holes, check alignment per scribed (mark) line.. 5 Install pressure seal into inside cavity of mounting cap (25,4 [1.00] OD x 3,2 [.12] W). 6 Install dust seal (25,4 [1.00] OD x 3,2 [.12] W) into mounting cap. 7 Install manual steering balls (9) into spool. Grease balls to retain in holes. 8 Insert spool into sleeve, lining up the spring slots. 9 Insert smaller centering spring onto spool/ sleeve assembly. 10 Install larger centering spring onto spool/ sleeve assembly. 11 Insert shorter drive pin. 12 Install drive tube assembly, wider groove downward. 13 Slide spool/sleeve/tube assembly into housing bore, through the gerotor star. Before spool/sleeve/tube reaches the tank plug,line up pin slot in gerotor with pin slot in drive tube, insert longer drive pin, then continue to slide spool/sleeve/tube into housing until the pin sets into the gerotor. 14 Install the retaining ring into groove on spool. 15 Install bearing race-bearing-bearing race onto the retaining ring. 16 Grease o-ring (82,6 [3.25] OD) and install into mounting cap. 17 Carefully install mounting cap over spool so as not to cut or damage seals. Lining up bolt holes, check alignment per scribed (mark) line. 18 Install 5 bolts. torque to 23Nm [200 in-lb].

STEER PUMP: DESCRIPTION

Steer Pump Removal

Sequence 1. Motor mounting bracket

3. Motor

2. Motor mounting hardware

4. Pump mounting hardware

5. Pump

Start By: 1. Remove the battery. 2. Remove the acid tray. 3. Disconnect the cables and wires from the steer pump motor. Mark the wire leads and cables so they can be correctly reconnected. 4. Disconnect the hydraulic lines from the pump.

6.9

STEER PUMP: DESCRIPTION Suggestions

Installation

Removing the Motor and Pump Assembly

1. To install, reverse removal sequence.

After disconnecting the steer pump hoses, motor cables, and harness leads, remove the pump and motor assembly by removing the motor bracket mounting hardware where the bracket is bolted to the frame.

Removing the Pump Remove the pump from the motor.

6.10

STEER PUMP: DISASSEMBLY

Disassembly 8

4 2 6

3 5 1

Sequence 1. Cover and mounting bolts

5. Rotor and vanes

2. O-ring

6. Retaining ring

3. Spring and Pressure plate

7. Shaft and bearing

4. Ring and locating pins

8. Body, O-ring, and seal

6.11

STEER PUMP: DISASSEMBLY Working Rules and Tips

Suggestions

The steer pump is a precision-machined component and must be handled with extreme care. Cleanliness is imperative: use clean tools and work in a clean place.

Removing the Motor and Pump Assembly

1. Clean the disassembled parts with a volatile solvent such as trichlene or chlorobenzene and dry them with compressed air. This does not apply to rubber parts. 2. Oil seal, O-rings, and the like are rubber parts. Never wash them with solvent. Blow dirt off rubber parts with compressed air and keep immersed in a pool of hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced. Rubber parts are expendable components and should be replaced yearly.

Disconnect the steer pump hoses, motor cables, and harness leads. Remove the pump and motor assembly by removing the motor bracket mounting hardware where the bracket is bolted to the frame.

Removing the Pump Remove the pump from the motor.

Removing The Pump Cover Remove the four bolts holding the rear cover on the pump. Remove the cover. Remove the O-ring located in the groove of the cover.

3. Parts to be installed by pressing or forcing need special treatment. Oil Seals An oil seal, once removed, must not be reused. After disassembly, examine the oil seal in place (in the housing) and, if in sound condition, leave it in place. When installing a replacement oil seal, be careful not to score or scratch its lip portion.

8609075

Removing the Spring Lift the spring off the pressure plate.

8609076

6.12

STEER PUMP: DISASSEMBLY Removing the Pressure Plate

Removing the Retaining Ring

Lift the pressure plate off of the ring and remove the two locating pins from the ring.

The shaft and bearing assembly is held in place by an internal retaining ring on the driven end of the pump. Remove the retaining ring using a standard retaining ring tool.

8609077

Retaining Ring

Removing the Rotor and Vanes Remove the rotor and the vanes. Take care not to lose any of the vanes.

8609080

8609078

Removing the Ring Lift the ring off of the pump body.

8609079

6.13

STEER PUMP: DISASSEMBLY Removing the Shaft and Bearing

Removing the Seal and O-ring

1. Tap the end of the shaft very lightly to remove it from the pump body. Take extreme care not to damage the end of the shaft.

1. Examine the shaft seal in place in the housing. If it is in sound condition, do not attempt to remove it. Instead, use it as part of the rebuilt unit. If there is any damage to the seal, remove it and do not reuse it.

2. Remove the external retaining ring from the shaft to allow removal of the bearing. Tap the end of the shaft very lightly to separate the bearing from the shaft. Take extreme care not to damage the end of the shaft.

2. Remove the O-ring from the slot in the body.

8609082 8609081

Inspection after Disassembly 1. Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leaks. 2. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towels because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts.

6.14

STEER PUMP: REASSEMBLY

Reassembly

2 1 4 5 7 8

8609083

Sequence 1. Body and seal

5. Rotor and vanes

2. Shaft and bearing

6. Pressure plate

3. Retaining ring

7. Spring

4. Ring

8. Cover

6.15

STEER PUMP: REASSEMBLY Suggestions

Reassembling the Shaft and Bearing Press the bearing onto the shaft and secure it with the external retaining ring.

NOTE Replace all old seals with new seals. Lubricate all seals with clean petroleum jelly such as Vaseline.

Reassembling the Shaft Seal 1. Install the seal in the housing, orienting the seal lip as shown. Take care not to damage the seal during installation.

8609085

2. The seal must be bottomed against the shoulder when installed.

Reassembling the Shaft and Body Install the shaft and bearing assembly into the body, taking care not to damage the shaft seal during installation. Secure the shaft by installing the retainer ring.

8609084

Retaining ring

8609086

6.16

STEER PUMP: REASSEMBLY Reassembling the Ring

Reassembling the Pressure Plate

Press the O-ring into the groove in the body. Place the ring on the body, aligning the bolt holes and the pin holes. Install the two pins through the ring and into the body.

Install the pressure plate by slipping it over the two pins

8609089 8609087

Reassembling the Spring Slip the spring over the spring seat of the pressure plate.

Reassembling the Rotor and Vanes Slip the rotor over the splined portion of the shaft. Insert a vane in each of the slots in the rotor.

8609090 8609088

6.17

STEER PUMP: REASSEMBLY Reassembling the Cover

Inspection after Reassembly

1. Press the O-ring into the groove in the cover. Place the cover on the ring and align the four bolt holes. Take care to properly orient the discharge port to its original position prior to assembly.

Check the pump for smooth, free rotation. Check for leaks after reinstallation in the truck.

2. Install and tighten the cover bolts.

8609091

Tightening torque for cover bolts

6.18

4.8 to 6.2 kgf•m (35 to 45 lbf•ft) [47 to 61 N•m]

Chapter 7: Hydraulic System Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 7.1 7.2 7.3 7.5 7.6 7.7 7.8

Removal and Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Mounting Flange Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Bushes and Balance Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22

Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27

Lift and Tilt Cylinders Removal Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31 Disassembly Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35 Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36 Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36

Inspection and Adjustment Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40 Adjusting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.42

HYDRAULIC SYSTEM: DESCRIPTION

Hydraulic System Description Schematic for Trucks

1. Hydraulic tank

4. Steer gear

7. Down safety valve

2. Hydraulic lift pump

5. Main control valve

8. Lift cylinder

3. Steer pump

6. Flow regulator valve

9. Tilt cylinder

10. Steering cylinder

General Information The hydraulic pump draws oil from the oil tank and delivers it to the main control valve, which dispenses it for lift and tilt functions. The steer gear and steer pump are covered in the STEERING SYSTEM section and the steering cylinder is covered in the REAR AXLE section.

7.1

HYDRAULIC SYSTEM: DESCRIPTION Hydraulic Tank 1

4 3

8609093

1. Cap

3. Drain plug

5. Suction line strainer

2. Oil level gauge

4. Return line filter

6. Lift cylinder pipe

General Information The tank contains internal filtering means including a strainer on the suction line and a filter on the return line. The lift cylinder return pipe allows the cylinders to draw fluid when they retract, providing the bore walls with oil which inhibits corrosion.

7.2

HYDRAULIC SYSTEM: DESCRIPTION Hydraulic Pump

8609094A

General Information This gear pump is capable of developing very high pressure on its discharge side. A special arrangement is incorporated in the pump construction for the purpose of keeping the side clearances minimized between bushings on the one side and pump gears on the other. Note, in illustration 203585 (page 7.6), that discharge pressure is applied to the back of each bushing through internal oilways.

7.3

HYDRAULIC SYSTEM: DESCRIPTION Hydraulic Pump Operation

Pressure Loading Principle

Essentially the pump consists of two gears—the drive gear and the driven gear—closely fitted in the housing. The oil is carried around the periphery of the revolving gears from the suction to the discharge side. The teeth meshing between the two gears prevents the return of oil from the discharge to the suction side.

This pump is a self-balanced type based on the principle of pressure loading, balancing for equal pressure on all sides of the revolving gear. This reduces bushing and gear wear. In operation, the high-pressure oil on the discharge side is fed back to the suction side. On the suction side, pressure is exerted equally on both sides of the gears and shafts, thereby cancelling out unequal pressure to balance the pump.

Driven Gear Clearance

Drive Gear 203585

Discharge side

7.4

200333

HYDRAULIC SYSTEM: DESCRIPTION Control Valve

1 2 3

11 5

1. Inlet Spool

8. To tank

2. Lift Spool

9A. Main relief valve, Auxiliary Valve (back)

3. Tilt Spool

9B. Auxiliary Relief Valve (front)

4. Auxiliary Attachment Spool

10. Tie bolt

5. Flow Control Screws

11. Nut

6. Pump port

12. Switches

7. From steering control valve

General Information The control valve consists of three valve blocks, all spool-type. The spools are finished by lapping for their respective blocks and their combination should not be changed. The lift valve assembly has a built-in load check valve. The tilt valve spool has a built-in tilt lock valve. When necessary, the attachment valve assembly has a built-in overload relief valve. If the overload relief valve is not used, a shutoff valve is installed.

7.5

HYDRAULIC SYSTEM: DESCRIPTION Lift and Tilt Cylinders

200345

205979

General Information The left and right lift cylinders are single-acting type. The left and right tilt cylinders are double-acting type. The piston rod carries a screw-on socket. The socket is repositioned as necessary by turning when the cylinder is connected to the outer mast. This feature allows the tilt cylinders to move in unison. The tilt angle is increased or decreased with the spacer and shim of each cylinder.

7.6

HYDRAULIC SYSTEM: DESCRIPTION Flow Regulator Valve

From control valve

To lift cylinder

To control valve

From lift cylinder

203558

General Information The flow regulator valve is located between each lift cylinder and control valve. It limits the flow of oil forced out of the cylinder when the loaded forks are lowered to keep a safe constant lowering speed regardless of load.

7.7

HYDRAULIC SYSTEM: DESCRIPTION Down Safety Valve

Burst

When hose burst

Normal

204971

General Information The down safety valve is built in the oil pipe joint at the bottom end of the lift cylinder. This valve is internally provided with an orifice to prevent shock when the valve is closed. In the valve having no orifice, the oil leaks around the valve to prevent shock.

Valve Types Down safety valves are available in six types differing in terms of shutoff flow and identified by the number punched on the flat (indicated as “a” on illustration 201731A). The numbers are: 50, 70, 90, 100, 120, and 150. No. 90 and No. 120 valves each come in two kinds differing in screw thread size. Truck

Dual stage Dual-stage full panoramic free-lift panoramic

Triple-stage full free-lift panoramic

1st lift cylinder

2nd lift cylinder

1st lift cylinder

2nd lift cylinder

FBC15 K-18KL

FBC20K-25KE

120

FBC25K-30K

120

201731A

Top View:

• Dual-stage panoramic lift cylinder • Dual-stage full free-lift panoramic, 1st and 2nd cylinders • Triple-stage full free-lift panoramic, 2nd lift cylinder

Bottom View: • Triple-stage full free-lift panoramic 1st lift cylinder 7.8

REMOVAL: GENERAL WARNING

Removal and Installation Warning

WARNING

Hydraulic oil under pressure can remain in the hydraulic system after the truck and pump have been stopped. To avoid personal injury, this pressure must be released before any work is done on the hydraulic system. To prevent possible injury, lower the lift bracket to the ground, turn the truck off, and move the control levers to make sure all hydraulic pressure is released before any fitting, plug, or hose is loosened, tightened, removed, or adjusted. Always move the forklift truck to a clean and level location away from the path of other machines. Be sure that no personnel are near the machine when the truck is running and tests or adjustments are being made.

7.9

HYDRAULIC PUMP: REMOVAL

Hydraulic Pump Removal

8609094A

Sequence 1. Hardware 2. Pump

Start By: 1. Disconnect the battery from the truck. 2. Disconnect the hoses attached to the pump fittings. 3. Disconnect the power cables and wire leads from the pump motor. 4. Raise the truck enough to allow the pump and motor assembly to be removed from below the truck. Make sure that the truck is stable and secure in the raised position.

7.10

5. Secure the motor from above with a crane, hoist, or other adequate device, or support it at its center with a garage jack. 6. Remove the motor and pump assembly from the truck. 7. Remove the hydraulic fittings from the pump.

HYDRAULIC PUMP: INSTALLATION

Installation 1. To install, follow the reverse sequence of the disassembly procedure. Before installing hydraulic fittings in the pump, inspect all O-rings for damage or aging and replace them as required. 2. Tighten hose to the following specifications.

Tightening Torque for Hose FBC15K-18KL Supply hose from pump to mast operating valve

FBC20K-30KL

6.5 ± 0.7 kgf•m 10.3 to 11.7 kgf•m (48 ± 5 lbf•ft) (74 to 85 lbf•ft) [65 ± 7 N•m] [101 to 115 N•m]

8609137

3. Lube pump splines before installing into pump motor. Use molybdenum disulfide grease.

HYDRAULIC PUMP APPLICATIONS

Market No. Am. Europe

No. Am.

Europe

Capacity UL 15, 18 E 25KL, 30 EE 15, 18 N/A 15, 18 EE 15, 18 E 18KL E, EE 25KL, 30 E 20, 25, 25KE E 20, 25, 25KE E, EE 25KL, 30 E 20, 25, 25KE N/A 25KL, 30

Pump Motor 6 5/8" 9" 8" 8" 8" 8" 8" 8" 9" 9"

Voltage 36 36/48 48 36/48 48 36/48 36/48 36/48 36/48 36/48

48/80

97E71-00030 23cc

97E71-00040 25cc

97F71-00020 29cc

9721-00700 29cc

standard gear

split gear

standard gear

split gear

7.11

HYDRAULIC PUMP: DISASSEMBLY

Disassembly Premium Pump 2

3 9 4

7 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

Start By: Externally clean the pump to make sure that it is free of all matter that may contaminate the pump parts during disassembly, inspection, or reassembly.

7.12

9. Body and rear bushes

HYDRAULIC PUMP: DISASSEMBLY

Disassembly Standard Pump 2

5 3 1 4 7 9 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

9. Body and rear bushes

Working Rules and Tips The hydraulic pump is a precision-machined component and as such must be handled with extreme care. Clean-liness is imperative: use clean tools and work in a clean place. 1. Clean the disassembled parts with a volatile solvent such as trichlene or chlorobenzene and dry them with compressed air. This does not apply to rubber parts.

Oil Seal An oil seal, once removed, must not be reused. After disassembly, examine the oil seal in place (in the pump flange) and, if in good condition, leave it in place. When installing a replacement oil seal, be careful not to score or scratch its lip portion.

2. Oil seals, O-rings, and the like are rubber parts. Never clean them with solvent. Blow dirt off rubber parts with compressed air, and keep them immersed in hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced. Rubber parts are expendable items that should be replaced once a year. 3. Parts that are installed by pressing or forcing need special treatment. 7.13

HYDRAULIC PUMP: DISASSEMBLY Suggestions

Removing the Flange

Removing the End Cover 1. Lightly mark the end cover, pump body, and mounting flange to ensure proper reassembly.

Turn the unit over and lightly tap the mounting flange to disengage it from the locating dowels. Slide the flange squarely off the shaft.

2. Remove the rear bolts, spring washers, and the end cover.

Removing the Seals Remove the O-ring from the pump body. Remove the bush seal and the backup seal from the rear bushings.

8609101

Removing the Shaft Seal Remove the internal retaining clip in the front of the flange. Push the shaft seal squarely out of the mounting flange. 8609100

8609102

7.14

HYDRAULIC PUMP: DISASSEMBLY Removing the O-ring and Seals

Separating the Gear Pack

Remove the O-ring from the groove in the body of the pump. Remove the bush seal and the backup seal from the front bushings.

1. Separate the gears, key, and balance plate from the drive shaft and driven idler shaft. 2. Note the position of the balance plate to ensure proper location during reassembly.

Removing the Rear Bushes Remove the remaining rear bushes from the body bore.

8609103

Removing the Bushings Before removing the internal components, mark the bushings to denote the location in the body on a plain area away from the seal location mark.

8609105

FD = Bush on flange end of the drive shaft FI = Bush on flange end of idler shaft CD = Bush on the cover of priority valve end of the drive shaft CI = Bush on the cover end of the idler shaft

Removing the Drive Shaft With the unit lying on its side, hold the drive shaft and pull it squarely out of the body, bringing with it the bushings and the complete gear pack.

8609104

7.15

HYDRAULIC PUMP: DISASSEMBLY

Inspection after Disassembly Body 1. Inspect the body bore cut-in where gears wipe into the body. 2. The body can only be reused if the cut-in is bright and polished in appearance and the depth does not exceed .08 mm. 3. The body should be replaced if the surface is scored, has a matte appearance, or shows signs that the tips of the gears have dug in and torn away the surface material. 4. The body should be inspected to ensure that there is no superficial damage which may adversely affect performance or sealing. Pay particular attention to the port threads and body O-ring seal recesses.

3. The bush bearing liners are acceptable if they are not scored or do not show other damage. The general outside area of the bush should not show any prominent signs of wear.

Gears 1. The gear side faces should be examined for bushing or scoring. Often operation on contaminated fluid shows scoring between the root of the gear and the journal, which leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a sharp-pointed tool across the surface from the journal outwards towards the tip of the gear, then the gear must be replaced.

Mounting Flange Face

2. The gear teeth should be carefully examined to ensure that there are no signs of bruising or pitting.

1. The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the regions where the body O-rings and bush seals contact, which could result in external leakage.

3. The journal bearing surfaces should be completely free from scoring or bruising. The surface should be highly polished and smooth to the touch.

2. Check the shaft seal recess for scoring or damage that could result in oil leakage around the outer diameter of the shaft seal. A replacement shaft seal can be refitted with Loctite hydraulic sealant to overcome slight damage in this area.

4. Examine the area where the shaft seal lips run on the drive shaft. This shows up as polished ring or rings. If a noticeable groove can be felt, or if there is scoring, the shaft should be replaced.

Bushes and Balance Plate

5. Examine drive keyway in driveshaft journal extension to ensure it is not damaged or chipped.

1. The side faces which abut the gears should be perfectly flat and show no signs of scoring. Characteristically there are bright polished areas on this surface caused by loading against the gear side faces. This is often more pronounced on the low-pressure side. These should be replaced if there is any general scoring or fine scoring with a matte appearance or tearing of the surface material. 2. Often, the tips of the opposing gears have wiped an overlap in a half-moon shape. There must be no noticeable wear step as it is critical that the bush side face and balance plate are completely flat to the gear side face.

7.16

6. If the driveshaft is not damaged from the drive coupling and the gears have not been harmed as described above, then the gears can be reused. If the gears are damaged, they must be replaced as a matched set. 7. As a matter of good practice, when pumps have been dismantled, all the seals should be replaced.

HYDRAULIC PUMP: REASSEMBLY

Reassembly Trucks with Standard Hydraulic Pump

5 3 1 4 7 9 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

9. Body and rear bushes

Start By: Ensure that all parts are perfectly clean. Lubricate the bushes and gears with clean hydraulic fluid. Ensure that the O-ring recess and end faces of the body remain dry. This will assist the assembly of the components with the body bores.

7.17

HYDRAULIC PUMP: REASSEMBLY

Reassembly Trucks with Premium Hydraulic Pump

3 9 4

7 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

7.18

9. Body and rear bushes

HYDRAULIC PUMP: REASSEMBLY Reassembling the Rear Bushes 1. Install the rear bushes (marked CD and CI) into the undowelled end of the body.

Fixturing with the End Cover Use the end cover to temporarily fixture the parts as they are reassembled. Place the end cover on its back and set the undowelled end of the body against it so that the dowels are pointing up.

Reassembling the Balance Plate 1. Hold the driveshaft and driven gear of the idler shaft together and refit the balance plate in its original position.

8609107

2. The C-shaped cutout in the bushes must be to the side of the body with the cusp removal flat.

2. The two grooves in the plate must be to the low-pressure side of the pump (the side where the body bores meet in a point). With the drive shaft nearest to you, these grooves will be on the left-hand side as shown for the counterclockwise rotation.

3. The diagram below shows the location of the driveshaft and the front bushes and seals installed. Location dowels

Flange end

Cusp Removal Inlet 8609109

Position of driveshaft Counterclockwise Rotation

8609108

7.19

HYDRAULIC PUMP: REASSEMBLY Reassembling the Gear Pack 1. Fit the key into the keyway in the driveshaft and then carefully fit the gear over the key. Fit the second gear on the idler shaft. 2. Keeping the gear pack together, carefully feed the assembly into the body bores with the driveshaft positioned as previously shown.

Reassembling the O-ring and Seals Fit a new O-ring, bush seal and backup seal, ensuring that the seals locate correctly in the seal grooves.

8609112

8609110

Premium pump configuration

Reassembling the Shaft Seal 1. Fit a new shaft seal into the recess in the mounting flange with the “garter” spring facing into the pump. 2. If the seal recess was scored, then Loctite hydraulic sealant must be applied to the outer diameter of the seal. 3. Apply a coat of high-melting-point grease to the shaft seal lips. 4. Reinstall the retaining ring. Ensure that it is located in its groove.

Standard pump configuration

Reassembling the Front Bushes Refit the front bushes (FD and FI) into their original bores, remembering that the C-cutout must be to the side of the body with the cusp removal flat. They must match the rear end bushes.

8609102

8609111

7.20

HYDRAULIC PUMP: REASSEMBLY Reassembling the End Cover:

Reassembling the Flange Slip the shaft seal and flange assembly over the driveshaft and carefully refit the mounting flange, ensuring that it is positioned squarely onto the dowels in the body.

Replace end cover and refit the bolts and washers. Tighten the bolts.

End cover

8609115A 8609113

Reassembling the Rear O-ring and Seals

FBC15K - 18KL

FBC20K-30KL

1. Hold the whole unit together and carefully turn it over. Ensure that it is supported on the mounting flange, not the driveshaft.

4.7 to 5.2 kgf•m Tightening torque (34 to 38 lbf•ft) for bolts [46 to 51 N•m]

9.0 to 10.4 kgf•m (65 to 75 lbf•ft) [88 to 102 N•m]

2. Remove the end cover and install a new Oring, bush seal, and backup seal.

NOTE Lube splines before installing in pump motor. Use molybdenum disulfide grease.

8609114

7.21

HYDRAULIC PUMP: INSPECTION Inspection after Reassembly Pour a small amount of clean hydraulic fluid into a port and check that the shaft can be rotated without undue force using a smooth-jawed vise.

Running In After Reassembly A unit which has been reassembled with either new gears, bushes, or body, must be carefully run in before it is subjected to full working conditions. Ideally, this should be done on a test rig, where pressure can be applied gradually and any wipings from the body cut-in can be arrested by filters.

Test unit

Tank

It is recommended that, initially, the unit is run in at 1500 rpm at zero pressure for one minute. The pressure should then be increased in intervals of 35 bars a minute until maximum pressure is reached. Check the system temperature frequently, ensuring that it does not exceed the maximum permissible temperature of 80°C. If the temperature exceeds the system or unit specification, the test must be delayed and operated off-load until the temperature is lowered to an acceptable range. Typical pump ratings are shown in the table below.

Pressure gauge Micronic filter

Relief valve

Strainer

Variable restrictor

Flow meter

Typical pump test circuit

8609116

Typical performance applicable when using ISOVG 32 at 40°C (104°F) Pump Part Number

Test Speed

Max. Continuous Pressure

Flow Rate

97E71-00030 1500 rpm

[185 bar] (2683 psi) 204 kg/cm2

9.11 GPM 34.5 L/min

97E71-00040 1500 rpm

[190 bar] (2755 psi) 209 kg/cm2

9.91 GPM 37.5 L/min

97F71-00020 1500 rpm

[247 bar] 11.49 GPM (2900 psi) 43.5 l/min 220 kg/cm2

97271-00700

[185 bar]

11.49 GPM

(2683 psi)

43.5 l/min

1500 rpm

204 kg/cm2

7.22

CONTROL VALVE: REMOVAL

Control Valve Removal

Sequence 1. Auxiliary lines, connectors, and O-rings 2. Steering return hose and connector 3. Lift pipe 4. Delivery hose, connector, and O-ring

5. Tilt lines, connectors, and O-rings 6. Return hose. 7. Control valve 8. Switches

Start By: 1. Remove the floorplates and the dashboard cover. 2. Tilt the mast to vertical position, lower the forks all the way, and relieve the pressure in the hydraulic lines. 3. Disconnect the battery 4. Disconnect the wire leads to the valve switches.

7.23

CONTROL VALVE: INSTALLATION

Control Valve Installation

1. To install, follow the reverse of the disassembly sequence. Before installing hydraulic fittings in the pump, inspect all O-rings for damage or aging and replace them as required. 2. Tighten hoses to the specifications shown in the chart.

7.24

Tightening Torque for Hoses A

Tilt hoses

25 ± 0.5 N•m 2.5 ± 0.5 kgf•m 18 ± 3.6 lbf•ft

Delivery hose FBC15K - 18K

65 ± 7 N•m 6.5 ± 0.7 kgf•m 47 ± 5.1 lbf•ft

Delivery hose FBC20-30K

100 ± 10 N•m 10 ± 0.1 kgf•m 72 ± 7.21 lbf•ft

Left Pipe

50 ± 7 N•m 5.1 ± 0.7 kgf•m 36 ± 5.1 lbf•ft

Aux Hoses

48 ± 5 N•m 5.0 ± 0.5 kgf•m 36.2 ± 3.6 lbf•ft

Steer Gear Return Hose

Return Hose

25 ± 5 N•m 2.5 ± 0.5 kgf•m 18 ± 3.6 lbf•ft 100 ± 10 N•m 10 ± 1.0 kgf•m 72 ± 7.2 lbf•ft

CONTROL VALVE: DISASSEMBLY

Disassembly

7.25

CONTROL VALVE: DISASSEMBLY Sequence 1. Aux Relief Valve

32. Seals

2. Main Relief Valve

33. Flow Control Screw

3. Tie Rod Nuts

34. Seals

4. Tie Rod Nuts

35. Lift Spool Section

5. Second Auxiliary Spool Section

36. Spring and Poppet

6. Spring and Poppet

37. O-ring

7. O-ring

38. Cap Screws

8. Cap Screws

39. Cap

9. Cap

40. Switch Assy

10. Switch Assy

41. Screws

11. Screws

42. Seals

12. Seals

43. Plugs

13. Flow Control Screw

44. O-rings

14. Seals

45. Connector

15. Auxiliary Spool Section

46. Inlet Section Spool

16. Spring and Poppet

47. Plug

17. O-ring

48. O-ring

18. Cap Screws

49. Plug

19. Cap

50. O-ring

20. Switch Assy

51. Tie Rods

21. Screws 22. Seals 23. Flow Control Screw 24. Seals 25. Tilt Spool Section 26. Spring and Poppet 27. O-ring 28. Cap Screws 29. Cap 30. Switch Assy 31. Screws

NOTE: Do Not remove spools from housing! 7.26

CONTROL VALVE: INSPECTION & REASSEMBLY Suggestions

Reassembly

Main Relief Valve

Before Reassembly; 1. Wash all parts except for O-rings with solvent.

NOTE

2. Apply hydraulic oil to O-rings when installing them.

To remove main relief valve for cleaning or inspection, loosen its plug. Loosening the lock nut will disturb the pressure setting.

Do not remove the main relief valve unless it is defective. This also applies to shut-off valve assembly.

3. Make sure that each spool moves freely. 1. Lay out valve components on a clean, flat working surface. The inlet assembly will include an o-ring, and the spool sections include an o-ring, a load check poppet and a load check spring. Tools required for basic valve assembly include 1/2” and 9/16” open or box end wrenches and a torque wrench with thin wall sockets.

Plug

2. Assemble tie rod nuts to one end of each tie rod with one or two threads showing. Insert rods through tie rod holes of inlet (larger tie rod at top). Lay inlet on end with tie rods up, place o-ring into position.

Lock nut

3. Place first spool section (o-ring side up) on inlet section, position o-ring and insert load check poppet (nose down) and spring (behind poppet) into load check cavity as shown. Repeat this procedure for each spool section; the load check springs are compressed by the following sections during assembly.

205025

Auxiliary Relief Valve NOTE To remove auxiliary relief valve for cleaning or inspection, loosen its plug. Loosening the lock nut will disturb the pressure setting.

Do not remove the auxiliary relief valve unless it is defective. This also applies to shut-off valve assembly.

Plug

4. Position end section on last spool section and hand tighten tie rod nuts. The end section is a “turn around” section without ports. Universal outlet / power beyond section and power beyond and closed center sections are also used as end sections. These end sections do not have o-ring grooves. 5. Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections; snug tie rod nuts to about 10 ft-lb. Final torque the two 1.2” nuts to 14 ft-lb; final torque the 9/16” nut to 33 ft-lb. check for proper spool movement. 6. Install auxiliary valves and plugs and torque to proper specifications

Lock nut

205025

7.27

LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION

Lift and Tilt Cylinders Removal Lift Cylinders

3 5

1 207068

Sequence 1. Hose guard

4. Cylinder clamp (cushion, collar, and shims)

2. High-pressure hose

5. Lift cylinder and bracket

3. Set bolt and shims

7.28

LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION Suggestions 1. Removing hose guard: With the lift bracket raised to the maximum height, remove each hose guard from the front side of the mast.

! CAUTION Be careful not to touch the lift control lever.

2. Lowering lift bracket: Lower the lift bracket by carefully operating the lift control lever. 3. Disconnecting high-pressure hoses: Disconnect the high-pressure hoses at the joints indicated by arrows. Use a container to catch oil flowing out of the hoses.

Right-hand cylinder Left-hand cylinder

204933

7.29

LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION Removing Set Bolts

Removing Lift Cylinders

1. Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, clovehitch a sling to the mast with protective wad.

Attach a lift sling to the lift cylinder from the rear side of the mast and remove the cylinder. Attach the sling before removing the cylinder clamp.

204935 204934

Installation

NOTE The rod end of either lift cylinder is shimadjusted to eliminate the difference in stroke between the cylinders. Before removing the stopper bolts, make a record of the number of shims and the cylinder to which the shims are fitted.

2. Place wood blocks under the inner mast and detach the sling. Use blocks strong enough to support the mast.

Lift Cylinders To install, reverse the removal sequence and do the following steps. 1. Extend and retract the lift cylinders several times under no-load conditions to expel air from the cylinder circuits and to make sure the cylinders move smoothly. 2. Check the oil level in the hydraulic tank with the oil level gauge. 3. Check that the lift height is correct. 4. After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders (refer to MAST AND FORKS).

202983

7.30

LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION

Removal Tilt Cylinders

2 4

3 1 206883

Sequence 1. Tilt socket pin (spacer) 2. Rubber hose (O-ring) 3. Cylinder pin (spacer) 4. Tilt cylinder

Start By: 1. Lower the forks all the way and tilt the mast fully forward. 2. Hitch lifting slings to the top crossmember of the outer mast by passing them through the round holes. Take up the weight of the mast with a hoist.

Suggestions 1. Retracting piston rod: Remove tilt cylinder pin (item 1), and retract the piston rod all the way.

207085

2. Disconnecting hoses: Disconnect hoses (item 2) from the cylinder at the connectors. Use a container to catch oil from flowing out of the cylinder. Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of the cylinder when the cylinder is removed. 7.31

LIFT & TILT CYLINDERS: REMOVAL & INSTALLATION Suggestions Removing Tilt Socket Later Version

WARNING

If both tilt cylinders are to be removed at the same time, make sure that the mast is held either by a hoist or is securely supported and held in place by blocks.

1 4

206883

1. Rubber hose 2. Tilt socket pin, bolt, washer 3. Tilt cylinder pin, bolt, washer 4. Tilt cylinder

NOTE When the tilt cylinders are to be replaced, it is necessary to adjust the cylinder stroke and tilt.

7.32

LIFT & TILT CYLINDERS: DISASSEMBLY

Disassembly Lift Cylinders 1

5 4 3

204948

Sequence 1. Bracket assembly 2. Holder, wiper ring, U-ring and O-ring 3. Bushing and bearing

4. Piston rod, snap ring, holder, U-ring, nylon heel, and piston ring 5. Cylinder tube

Suggestions Removing Piston Rod Draw the piston rod out gently, taking care not to damage the sealing members fitted to the piston.

200349

7.33

LIFT & TILT CYLINDERS: DISASSEMBLY

Disassembly Tilt Cylinders ✱ Parts contained in seal kit 4

3 ✱

1 ✱

✱

207050

Sequence 1. Tilt socket, bushing, bolt, washer, nut, and grease fitting

3. Piston rod, piston seal, and nut 4. Cylinder tube and bushing

2. Bushing, O-ring, dust seal, packing and buffer ring

NOTE Do not remove the tilt socket and cylinder tube bushing unless they are defective.

Suggestions Removing Bushing 1. Wrap the cylinder with a wad of cloth and hold it in a vise. Using a wrench, remove the bushing from the cylinder. 2. When removing the bushing from the piston rod, be careful not to rub the buffer ring, packing, etc., against the threads of the piston rod. 200351

7.34

LIFT & TILT CYLINDERS: FLOW REGULATOR VALVE

Flow Regulator Valve Disassembly

1 5

4 203559

Sequence

Inspection after Disassembly

1. Lock nut

1. Check the springs for fatigue.

2. Plug and O-ring

2. Check the valve seats for damage. Check the sliding surfaces for evidence of binding and repair as necessary.

3. Spring and shims 4. Piston, pin, washer, spring, and valve 5. Valve body

3. Check the sliding surfaces of the piston and valve body for damage.

NOTE Replace the flow regulator valve as an assembly if any part is defective.

7.35

LIFT & TILT CYLINDERS: DISASSEMBLY

Inspection after Disassembly

Precautions for Reassembly

Lift and Tilt Cylinders

1. Wash all parts clean, making sure that each part is clear of any gritty particles.

Cylinder Tube

2. Before inserting the piston rod complete with the piston, apply hydraulic oil to the bore wall of the cylinder tube and to the sealing parts: O-rings, U-rings, wiper rings, nylon heels, piston seals, dust seals, and packings—so they will slide smoothly into the bore.

1. Check the bore wall for wear, grooving, scratch marks, and rusting. 2. Check the welds for cracks.

Piston Rod 1. Check for deflection in the manner shown.

200319

3. When clamping the cylinder tube in the vise in order to run the head into the cylinder tube, be careful not to distort the tube #4 and #117. Before fitting the piston seal to the tilt cylinder piston, squeeze the seal by hand 5 or 6 times to soften it. Hold the piston steady by clamping the rod in a vise and apply a small amount of hydraulic oil to the seal. Fit a portion of the seal to the groove and push the rest of the seal into place a little at a time until the seal is in the groove. 4. Be sure to torque the nut, not the bolt when re-installing the tilt cylinder. Torque to 108 to 118 N•m; 11 to 12 kgf•m.

2. Check for surface flaws such as grooving, scratch marks, rusting, and wear. The rod must be replaced if its threads show signs of stripping or any other damage.

Packings and Rings 1. Check the packings and the lips of dust seals for damage, distortion, and deterioration due to aging. 2. Check each ring for deterioration due to aging. 200352

200353

7.36

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Inspection and Adjustment Hydraulic Tank

NOTE

Hydraulic Oil 1. Check the hydraulic oil in the tank for cleanliness. Oil appearing dirty or whitish (showing more or less emulsification) must be changed.

A general rule: in any machine, regardless of the mast-and-attachment combination, the oil level should not be above the “H” mark on the level gauge when the mast is all the way down.

2. Refill capacities in the amount of oil required.

WARNING

Suction Strainer

Remove the hydraulic tank filler cap only after the truck has been stopped and the fill cap is cool enough to remove with your bare hand.

Check the suction strainer for clogging or damage.

Return Filter Check the return filter for clogging or damage.

Hydraulic Tank Refill Capacities FBC15K - 18KL

FBC20K/25K

FBC25KE/30KL

18 (4.8)

24 (6.3)

30 (7.9) Unit: liter (U.S. gal)

7.37

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Control Valve External Leakage 1. Check for oil leaks from the joint between adjacent valve housings sealed by O-ring. 2. Check for oil leaks from the scrapers sealed by O-rings.

2. Quickly disconnect the oil return hose and start collecting the oil coming out of the valve from the oil return port A.

3. Check for oil leaks from the screw connections.

Internal Leakage It is not practical to check the control valve alone for internal leakage. The correct way to check the control valve in place under normal operating conditions follows. The internal leakage to be checked includes leakage occurring at the lift spool, tilt spool, tilt lock valve, and check valves. [Test oil temperature: approx. 50°C (122°F)] 1. Pick up a load equal to the rated capacity. Lift it approximately 1 meter (3 ft) high. Tilt the mast forward 3° - 4° and stop the truck.

500 cc (30.5 cu. in.) maximum

3. If the tilt cylinders or lift cylinders drift (the mast tilts forward or the fork lowers) excessively even though the amount of oil collected in 15 minutes is less than 500 cc (30.5 cu. in.), measure the internal leakage of each cylinder. (The measurement is the assembly standard and not the service limit.)

3° - 4°

approx. 1 meter (3 feet) 203521A

7.38

Amount of oil collected for 15 minutes

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Main Relief Valve Adjustment 1. Screw in special tool (6V3965) pressure port with o-ring into delivery hose port on valve(B). 2. Attach a pressure gauge capable of measuring up to 250 kgf•cm2 (3555 psi) [25,000 kPa] to the pressure port. 3. Start the truck and move the control lever to the backward tilt position and hold. If the relief pressure reading is 185 ± 5 kgf/cm2 (2631 ± 71 psi) [18,142 ± 490 kPa]

4. If the setting is incorrect, loosen the lock nut of the adjusting screw and, while observing the pressure gauge reading, slowly turn the adjusting screw in either direction until the gauge indicates the prescribed set value. 5. While holding the adjusting screw, tighten the lock nut to secure the adjusting screw. 6. After securing the adjusting screw, recheck the setting. Main relief valve setting

when the tilt cylinders reach the end of their stroke, the main relief valve setting is correct.

185 ± 5 kgf/cm2 (2631 ± 71 psi) [18,142 ± 490 kPa]

Main relief valve

Auxiliary Relief Valve Adjustment 1. Screw in special tool (6V3965) pressure port with o-ring into delivery hose port on valve(B). 2. Attach a pressure gauge capable of measuring up to 250 kgf•cm2 (3555 psi) [25,000 kPa] to the pressure port. 3. Start the truck and move the Auxiliary 1 control lever to the far right position and hold. If the relief pressure reading is 158 ± 5 kgf/cm2 (2250 ± 71 psi) [15,513 ± 490 kPa]

the auxiliary relief valve setting is correct.

158 ± 5 kgf/cm2 (2250 ± 71 psi) [15,513 ± 490 kPa]

Auxiliary relief valve

7.39

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Lift and Tilt Cylinders Mast Tilt Angle Adjustment

NOTE

1. Place machine in a horizontal position. 2. Tilt the mast all the way backward, and stop the truck. 3. Measure the tilt angle of the mast at both sides. 4. To adjust the tilt angle, loosen bolt A of the tilt cylinder socket, and adjust the cylinder stroke by turning the rod on either cylinder so that there is no difference in stroke between the cylinders.

It is not necessary to adjust the forward tilt angle, provided that the backward tilt angle is properly adjusted.

Forward/backward tilt angle

5° – 6°

Lift Cylinder Stroke Adjustment 1. Slowly raise the inner mast and check the stopping manner of the left and right piston rods at the moment the inner mast reaches its maximum lift height.

207054

Tightening torque for tilt cylinder socket bolt

127 to 152 (13 to 15.5) [94 to 112] 204698

2. If the top of the mast rocks at that moment, it should be adjusted with shims. Abnormal conditions will appear as a time lag in stopping between right- and left-hand piston rods and rocking of the rod with a longer cylinder stroke.

7.40

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Adjusting Method 1. Raise the inner mast, place blocks under the right and left sides of the mast, and lower the mast until it rests on the blocks.

3. Extend the piston rod and tighten the cylinder stopper bolt. Remove the blocks from under the inner mast. 4. Slowly lower the inner mast all the way to make sure that the piston rods move smoothly.

Flow Regulator Valve Measure the lowering speed with rated load. If the speed is out of specification, repair or replace the flow regulator valve. For the specification of lowering speed, refer to SERVICE DATA.

202983

1. Remove the stopper bolt at the top of the lift cylinder which stopped first, retract the piston rod, and insert the shims at the top of the piston rod end. Stopper bolt 205972

Shims

200365

NOTE To retract the piston rod, move the lift control lever to the lowering position to let the oil escape from the lift cylinder.

7.41

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Testing Lift Cylinder Drift Test

Tilt Cylinder Drift Test

1. Pick up a load equal to the rated value, tilt the mast to the vertical position, raise the forks 1 to 1.5 m (3.3 to 4.9 ft) and stop the truck.

1. Pick up a load equal to the rated value, tilt the mast to the vertical position, raise the forks about 50 cm (20 in.) and stop the truck.

2. Scribe a line on the mast column and measure the drift of the lift cylinder (drop for 15 minutes)

2. Measure the drift extension of the tilt cylinder for (extension) 15 minutes.

206891

207056

Lift cylinder drift (rated load)

FBC15K - 25KE

FBC25KL/30KL

50 (2.0) maximum

40 (1.6)

FBC15K-18KL

FBC20-25KE

FBC25KL/30KL

Tilt cylinder drift 22 (0.9) (rated load) maximum

20 (0.8)

15 (0.6)

Unit: mm (in.)/15 min

Piping 1. Check each hydraulic circuit for leaks. 2. Check to make sure that each hose is free from twisting or excessive loops.

7.42

Chapter 8: Mast and Forks Description ................................................................................................... 8.1 Removal and Installation.............................................................................. 8.2 Disassembly ................................................................................................ 8.4 Inspection after Disassembly ....................................................................... 8.6 Reassembly ................................................................................................. 8.7 Inspection and Adjustment........................................................................... 8.8 Forks ......................................................................................................... 8.8 Chain Tension Adjustment ........................................................................ 8.9 Clearance Adjustment on Lift Bracket ...................................................... 8.10 Mast Clearance Adjustment...................................................................... 8.13 Main Roller Shim Replacement ................................................................ 8.15 Mast Strip Adjustment............................................................................... 8.15 Tilt Angle Adjustment ................................................................................ 8.16 Lift Cylinder Stroke Adjustment................................................................. 8.17 Bleeding Lift Cylinders .............................................................................. 8.17 Service Data ................................................................................................ 8.19 Troubleshooting............................................................................................ 8.20

MAST AND FORKS: DESCRIPTION

Mast and Forks Description G 1 A

2 3

Forward

Detail of A

Forward

Detail of F

D Forward

Forward

C Detail of B, C

Detail of D

Forward

Detail of E

Detail of G 207082

207081

Components 1. Inner mast

A. Main roller

E. Main roller

2. Outer mast

B. Main roller

F. Main roller

3. Lift chain

C. Main roller

G. Mast strip

4. Lift bracket

D. Side roller

5. Mast support bearing cap The simplex mast features two lift cylinders placed behind the mast columns, right and left, to provide maximum forward visibility. Mast strips are fitted to the top end parts of outer mast. These strips are for backing up the inner mast when the mast is tilted backward.

Diam. of main roller

FBC15K - 18KL

FBC20K/25K/ 25KE/25KL/30KL

99 (3.90)

113.8 (4.48)

100 (3.94)

115 (4.53)

101 (3.98)

116 (4.57)

102 (4.016)

117 (4.606) Unit: mm (in.)

8.1

MAST AND FORKS: REMOVAL & INSTALLATION

Removal and Installation Mast and Lift Bracket Assembly

6 207083

Sequence 1. Nut

4. Tilt socket pins

2. Forks and lift bracket

5. Tilt cylinders

3. High-pressure hose for lift cylinders

6. Mast-support bearing caps and bushing

Suggestions Removing Lift Bracket 1. Tilt the mast forward, and lower the inner mast all the way. Slacken the lift chains, and remove the nuts from the anchor bolts. 2. Tilt the mast back to vertical position. Secure the lift bracket to prevent it from falling over. Raise the inner mast until the lift bracket becomes free. Then, back the truck away, leaving the lift bracket and fork assembly standing on the floor. 207084

8.2

MAST AND FORKS: REMOVAL & INSTALLATION Removing Lift Cylinder High-Pressure Hoses With the mast in the lowest position, disconnect the hoses at the flow regulator valve.

Removing Mast Support Bearing Caps 1. Scribe marks on the bearing caps before removing them.

Removing Tilt Cylinders 1. Attach a sling to the holes, left and right in the top cross member of the mast, and lift the mast with a hoist. Marks

207087

2. Remove the cap bolts and lift off the mast assembly, laying it down flat on a level floor.

207085

NOTE Lay the mast assembly on a floor large enough for disassembly.

NOTE Be sure to use a hoist having a capacity enough to carry the weight of the mast assembly.

Weight of Components FBC15K-18KL FBC20/25/

25KE/25KL

Gross (Simplex 3.3 m mast)

520 (1150)

725 (1600)

FBC30KL 830 (1830)

Unit: kg (lb)

2. Remove the tilt socket pins, and separate the masts from the tilt cylinders.

Tilt socket pin

207086

8.3

MAST AND FORKS: DISASSEMBLY

Disassembly 10

12 15

9 2

8 2 6 6 7 6

1 5

4 207088

Sequence 1. Nut 2. Forks and lift bracket 3. Backrest 4. Main roller and shims 5. Main roller and shims 6. Side roller, bracket, and shims 7. Hose guard 8. Lift hose (high pressure) (Rubber hose, T-joint and down safety valve) 9. Snap ring and chain wheel

8.4

10. Cylinder clamp, seat, shims, cushion, collar and bolts 11. Bolt and shims 12. Mast strip and shims 13. Main roller and shims 14. Main roller and shims 15. Inner mast 16. Lift cylinders 17. Outer mast

MAST AND FORKS: DISASSEMBLY Suggestions Removing Mast Strips and Main Rollers Remove bolts 10, 11 to free lift cylinder 16. Cross the tops of the two lift cylinders. Slide inner mast 15 toward the bottom of outer mast 17, and remove main rollers 13, 14 and mast strips 12.

Removing Inner Mast After removing the main rollers, attach a sling to the inner mast crossmember and slide the inner mast toward the top of the outer mast until it gets clear of the outer mast roller shafts. Sling the inner mast again and remove it from the outer mast.

207089

8.5

MAST AND FORKS: DISASSEMBLY Inspection after Disassembly Mast 1. Check each roller for wear, binding or other defects. 2. Check each roller for flat spots on rolling surface. 3. Check the mast member and the welds of crossmembers, shafts and supports for cracks. 4. Check the mast support bushings for wear or other damage.

Lift Chains, Chain Wheels and Chain Wheel Supports 1. Measure the length of each chain to be sure that two chains are equal in length. Also check the chains for wear, evidence of breakage, link binding and twist. 2. Check each chain anchor bolt for cracks or damaged thread. 3. Check each chain wheel support and chain wheel for crack or wear. Check to be sure that the wheels are capable of smooth rotation. 4. Measure sections of chain that travel over the chain wheel. Length of Chain (Per 20 Links) FBC15K-18K FBC20/25/ 25KE/25KL 18KL

207090

Lift Bracket

2. Check the welds of the bracket for cracks. 3. Check the finger bar for bend or distortion.

Finger bar

207091

5 mm (0.2 in.) maximum A = Assembly standard

8.6

318 (12.52)

381 (15.00)

508 (20.00)

327 (12.87)

392 (15.43)

523 (20.59)

Unit: mm (in.) A = Assembly standard B = Repair or service limit

Mast Strips

1. Check the main rollers and side rollers for smoothness of rotation. Inspect each roller for wear and cracks.

Distortion of finger bar

FBC30KL

Check the mast strips for damage, wear or distortion.

MAST AND FORKS: REASSEMBLY

Reassembly To reassemble, follow the reverse of disassembly sequence and do the following steps:

Adjusting Mast and Lift Bracket Clearance Rollers for mast and lift bracket are available in three sizes (diameters) for selective use. Select the size that will provide a longitudinal clearances of 1 mm (0.04 in.) and less. Clearance

Mast Supports 1. Check mast support bushing for wear. Replace if worn. 2. Apply a grease to the inside surfaces and grooves of the caps. 3. Install mast support bushings and caps with beveling toward the center of truck respectively. Greasing will be facilitated if the mast is lifted by placing wooden blocks under it.

Mast cap Bushing Clearance

Upper/middle roller

Lower roller

Apply grease

207096

Side with wider cut 203712

Roller Sizes Diameter of main roller

FBC15K-18K FBC18KL

FBC20K/25K/ 25KE/25KL/30KL

Precautions for Installing Chain Anchor Kit

99 (3.90)

113.8 (4.48)

100 (3.94)

115 (4.53)

Be careful not to install the center plate in the position for link plate.

101 (3.98)

116 (4.57)

102 (4.016)

117 (4.606)

2 3

Unit: mm (in.)

Cylinder Clamps Install each lift cylinder in place (in vertical position) by fitting to the support, and see if there is any clearance between the outer mast and cylinder. Reduce the clearance, if any, to zero by shimming.

1 4

Stamped mark 207094

1. Link plate (marked) 2. Center plate (not marked) 3. Link 4. Split pin

Shims

207093

8.7

MAST AND FORKS: REASSEMBLY

Inspection and Adjustment Forks 1. Carefully inspect the forks for cracks. Special attention should be given to the heel section A, all weld areas and B mounting brackets. Forks with cracks should be removed from service. “Wet Test” magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results.

3. Check the fork blade D. The fork should be withdrawn from service if the thickness is reduced to less than the tolerant thickness. Check the heel of fork. Fork blade length may also be reduced by wear, especially on tapered forks and platens. Remove the forks from service when the blade length is no longer adequate for the intended loads.

B D

Toe

Heel

101628

2. Check the difference in height of one fork tip to the other when mounted on the fork carrier. A difference in fork tip height can result in uneven support of the load and cause problems when entering loads. The maximum allowable difference in fork tip elevation C is 5 mm (0.20 in.) for pallet forks. Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference.

101629

8.8

101630

Tolerant Thickness

Standard

Limit

FBC15K

40 (1.6)

31 (1.2)

FBC18K/18KL

40 (1.6)

33 (1.3)

FBC20K

45 (1.8)

36 (1.4)

FBC25/25KE/25KL

45 (1.8)

39 (1.5)

FBC30KL

45 (1.8)

40 (1.57) Unit: mm (in.)

MAST AND FORKS: INSPECTION & ADJUSTMENT Chain Tension Adjustment

Tightening Torque

WARNING

Personal injury can be caused by sudden movement of the mast and lift bracket. Blocks must be used to prevent the mast and lift bracket from any movement while the adjustments are made. Keep hands and feet clear of any parts that can move.

FBC15K-18K/18KL/20K/25K/25KE/25KL

FBC30KL

Nut 2 Nut 3

57 (5.8) [42.0]

84 (8.6) [62.2]

Nut 1

98 (10) [72.3]

147 (15.0) [108.5] Unit: N•m (kgf•m) [lbf•ft]

1. Have the truck standing on a level floor, with the mast vertical and the forks lowered to the floor. Check to be sure that the lift cylinders are fully retracted.

6. Adjust until tension is equal on both chains.

2. Set the anchor bolts with nut 3. 3. Raise the forks slightly and push the chains inward midway between the chain wheel and anchor alternately to check the tension. When adjusting the chains by means of the nut 3, tilt the mast forward to slacken the chains to facilitate adjustment. 4. Turn nut 3 to adjust the chain tension. Then, hold the anchor bolt in place with a wrench and tighten nut 2 to the specified torque. 5. Hold nut 3 in place with a wrench, and tighten nut 1 to the specified torque.

Anchor bolt

2 nut

3 nut 1 nut 102709

8.9

MAST AND FORKS: INSPECTION & ADJUSTMENT Clearance Adjustment on Lift Bracket Longitudinal Clearance Adjustment on Lift Bracket Main Rollers 1. Raise the forks a little from the floor.

Roller Sizes

2. Insert a bar between the upper part of lift bracket and the inner mast, and push the inner mast to one side. Using a feeler gauge, measure the clearance F between the main roller and inner mast on the opposite side. F

Diameter of main roller

FBC15K - 18KL

FBC20K/25K/ 25KE/25KL/30KL

99 (3.90)

113.8 (4.48)

100 (3.94)

115 (4.53)

101 (3.98)

116 (4.57)

102 (4.016)

117 (4.606) Unit: mm (in.)

4. Lift bracket main rollers (upper and center rollers). The upper rollers should be the same in size or 1-rank larger than the center rollers. F

207095

0.1 to 1.0 mm (0.004 to 0.039 in.)

Clearance F

3. If the clearance F is out of specification, use oversize rollers.

Lower roller

8.10

Upper/middle roller

207096

MAST AND FORKS: INSPECTION & ADJUSTMENT Lateral Clearance Adjustment on Lift Bracket Main Rollers and Side Rollers 1. Raise the mast all the way. 2. Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket. 3. Go over to the opposite side of the mast, and push the lift bracket to one side with a bar. Set the indicator to zero. 4. Insert a bar between the inner mast and lift bracket on the indicator side, and push the lift bracket to the opposite side.

For the lift bracket upper main roller or center main roller, to extend 0.5 mm (0.02 in.), insert a 0.5 mm (0.02 in.) shim (a) on the inside and remove the 0.5 mm (0.02 in.) shim (b) from the lower stopper, then tighten the bolts. Inner mast

Shims (b)

Shims (a)

207156

203818

5. Read the indicator. Clearance G

0.1 to 0.5 mm (0.004 to 0.020 in.)

6. Adjust clearance G1 between the middle main roller and weld plate 2 at the maximum lift position by increasing or decreasing the thickness of the shim. 1

1 G1

202276

8.11

MAST AND FORKS: INSPECTION & ADJUSTMENT Lateral Clearance Adjustment on Lift Bracket Main Rollers and Side Rollers, continued 7. Lower the lift bracket slightly below its maximum lift position, then adjust clearance G2 between the side roller and mast by increasing or decreasing the thickness of the shim.

8. With the lift bracket at the maximum lift position, adjust clearance G3 with shims.

Side roller

Side Roller

207158

202277

Adjust the side roller clearance by adding shims under the roller bracket.

Shims

Shims Roller

Bracket

8.12

207157

207098

MAST AND FORKS: INSPECTION & ADJUSTMENT Mast Clearance Adjustment Longitudinal Clearance Adjustment on Mast Main Rollers

Lateral Clearance Adjustment on Inner Mast Main Rollers

1. Tilt the mast all the way backward.

1. Raise the mast all the way.

2. Using a feeler gauge, measure the clearance H between the inner mast lower roller and the outer mast.

2. Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast.

0.1 to 1.0 mm (0.004 to 0.039 in.)

3. Go over to the opposite side of the mast, and push the inner mast against the outer mast. Set the indicator to zero.

Clearance H

3. If the clearance H is out of specification, use oversize rollers. Roller Sizes Diameter of main roller

FBC15K - 18KL

FBC20K/25K/ 25KE/25KL/30KL

99 (3.90)

113.8 (4.48)

100 (3.94)

115 (4.53)

101 (3.98)

116 (4.57)

102 (4.016)

117 (4.606) Unit: mm (in.)

J 204886

4. Insert a bar between the outer and inner masts on the indicator side, and push the inner mast to the opposite side. 5. Read the indicator.

0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance J

207099

J 207101

8.13

MAST AND FORKS: INSPECTION & ADJUSTMENT 6. If the clearance J is out of specification, adjust it by using shims.

Shims 207103

207102

6. If the clearance K is out of specification, adjust it by using shims.

NOTE Refer to Main Roller Shim Replacement.

Lateral Clearance Adjustment on Outer Mast Main Rollers

Shims

1. Raise the mast all the way. 207104

2. Set a dial indicator on the outer mast with its contact point rested on the inner mast. 3. Go over to the opposite side of the mast, and push the outer mast against the inner mast with a bar. Set the indicator to zero. 4. Insert a bar between the outer and inner masts, and push the inner mast to the opposite side. 5. Read the indicator.

Clearance K

0.1 to 0.5 mm (0.004 to 0.020 in.)

204889

8.14

NOTE Refer to Main Roller Shim Replacement.

MAST AND FORKS: INSPECTION & ADJUSTMENT Main Roller Shim Replacement

Mast Strip Adjustment

1. Remove the lift bracket from the mast.

1. Check the clearance L with the clearance between the outer mast rollers and inner mast set to zero (0) in maximum lift position.

NOTE Refer to REMOVAL AND INSTALLATION, 1. Lift Bracket Removal.

2. Lower the inner mast below the outer mast as follows: a. Raise the front end of the machine, and block that end with a jack stand or the like. b. Remove the upper set of bolts from the lift cylinders, and lift the inner mast with a hoist. Remove the hose guard. c. Remove the clamps from the lift cylinders. Pull the bottom ends of the cylinders from the outer mast, tilt the cylinders to the center of the mast, and tie them to the crossmember of outer mast with rope. d. Slowly lower the inner mast until it comes in contact with the lift cylinders. e. Now the main rollers can be removed from the inner and outer masts. Remove the mast strips and shims in advance because they are apt to come off under this condition.

200391

0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance L

2. If the clearance L is out of specification, adjust it by means of shims.

NOTE Refer to Main Roller Shim Replacement.

3. After adjusting the all clearance, move the mast and lift bracket slowly to make sure that they move smoothly through their full stroke.

Shims

202961

200392

8.15

MAST AND FORKS: INSPECTION & ADJUSTMENT Tilt Angle Adjustment 1. Adjust the tire pressure correctly and keep the truck level. 2. Tilt the mast all the way backward and stop the engine 3. Measure the backward tilt angle of the mast at both sides. 3. To adjust the tilt angle, loosen the bolt of tilt cylinder socket, and adjust the cylinder stroke by turning the rod on either cylinder so that there is no difference in stroke between the cylinders, left and right.

Bolt 207105

NOTE It is not necessary to adjust the forward tilt angle if the backward tilt angle is properly adjusted.

Forward/backward tilt angle

8.16

5° to 6° (standard)

5. After adjusting the tilt angle, tighten the socket bolts to the specified torque. Tightening torque for tilt cylinder socket bolt

127 to 152 (13 to 15.5) [94 to 112] Unit: N•m (kgf•m) [lbf•ft]

MAST AND FORKS: INSPECTION & ADJUSTMENT Lift Cylinder Stroke Adjustment 1. Slowly raise the inner mast, and check how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. 2. If the top of the inner mast rocks at that moment, make a shim adjustment. Abnormal condition can be told by a little time lag in stopping between the piston rods, left and right, and rocking of the rod with a longer cylinder stroke.

2. Remove the set bolt at the top of lift cylinder which stopped first, retract the piston rod, and insert shims at the top of piston rod end. 3. Extend the piston rod, and tighten the cylinder set bolt. Remove the blocks from under the inner mast.

Set bolt Shims

200365

204698

4. Slowly lower the inner mast all the way to make sure that the piston rods move smoothly and that the left and right lift cylinders come to the end of stroke simultaneously.

Adjusting Method 1. Raise the inner mast, place blocks under the left and right sides of the inner mast, and lower the mast until it rests on the blocks.

Bleeding Lift Cylinders When air and oil remaining inside the air chamber of the rod and inside the rod chamber between the tubes are compressed, they open the check valve and flow out of the cylinder. Therefore, there is no need to bleed the lift cylinders.

202983

8.17

MAST AND FORKS: SERVICE DATA

Service Data Inner mast F

L G1

G3 G2 B

Lift Bracket A K H

E J

Outer mast

207106

8.18

MAST AND FORKS: SERVICE DATA

Service Data Truck Model

Item Difference in height between fork tips

Forks Chains

5 (0.20) 125 x 45 (4.92 x 1.8)

FBC15K 100 x 31 (3.9 x 1.2) FBC18K 100 x 33 (3.9 x 1.3)

FBC20K 100 x 38 (3.9 x 1.5) FBC25/25KE 100 x 40 (3.9 x 1.57)

125 x 39 (4.92 x 1.53)

318 (12.52)

381 (15.00)

508 (20.00)

327 (12.87)

392 (15.43)

523 (20.59)

99 (3.90)

113.8 (4.48)

101 (3.94)

115 (4.53)

101 (3.98)

116 (4.57)

102 (4.016)

117 (4.606)

(width x thickness) Length of tilt chains (per 20 links)

Rollers

FBC30K-30KL

100 x 40 (3.9 x 1.6)

Thickness of forks

Diameter of main roller

FBC20K-25KL

100 x 40 (3.9 x 1.6)

Mast and Lift Bracket

FBC15K-18KL

Diameter of side roller

42 (1.65)

Distance between outer mast main rollers (inside to inside) A

523 (20.59)

575 (22.64)

Distance between inner mast main rollers (outside to outside) B

581 (22.87)

639 (25.16)

Distance between lift bracket main rollers (outside to outside) C1

485 (19.09)

535 (21.06)

Distance between lift bracket main rollers (outside to outside) C2

487 (19.17)

537 (21.14)

Distance between lift bracket main rollers (outside to outside) D

491 (19.33)

539 (21.22)

Distance between lift bracket side rollers (outside to outside) E

496 (19.53)

546 (21.50)

Longitudinal clearance of lift bracket middle rollers (with forks slightly lifted) F

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket middle main rollers (fully raised) G1

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket lower main rollers (fully raised) G3

0.1 to 0.5 (0.004 to 0.020)

Longitudinal clearance of mast main rollers (in the whole lift range) H

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of inner mast main rollers (fully raised) J

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of outer mast main rollers (fully raised) K

0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L

0.1 to 0.5 (0.004 to 0.020)

8.19

MAST AND FORKS: TROUBLESHOOTING

Troubleshooting Complaint

Possible Cause

Lift bracket and inner mast will not move smoothly

a) Main rollers and side rollers having no proper clearance b) Rollers involved binding on their shafts c) Rollers damaged d) Improper mast-to-strip clearance

Lift bracket or inner mast cocks

a) Too much clearance on side rollers, or side rollers damaged b) Lift chains unequally tensioned c) Shim adjustments unequally made on left and right lift cylinders (at maximum height)

Mast makes noise

Rollers not rotating smoothly on their shafts, or damaged

Load drops (drifts)

a) Lift cylinder packing damaged b) Lift cylinder bore grooved c) Control valve defective

Mast shakes entirely

Mast-support bushing worn

Mast is distorted

Improper loading or overload

Fork tips differ in height

a) Finger bar bent b) Forks bent c) Distortion of mast due to off-center loading

8.20

Chapter 9: Troubleshooting Section Front Axle and Reduction Differential ........................................................... 9.1 Brake System................................................................................................ 9.2 Steering System............................................................................................ 9.4 Hydraulic System .......................................................................................... 9.6 Rear Axle ...................................................................................................... 9.8 Mast and Forks ............................................................................................. 9.9

TROUBLESHOOTING: FRONT AXLE & REDUCTION DIFFERENTIAL

Troubleshooting Section Front Axle and Reduction Differential Complaint Gear noise comes out continuously during normal cruising run

Irregular noise comes out during normal travel

Abnormal noise comes out when turning a corner

Differential overheats

Possible Cause

Remedy

Teeth worn excessively or tooth contact out of adjustment in spiral bevel drive

Readjust or replace

Bearing preloads too much or too little, or bearings are worn excessively

Readjust or replace

Hub bearings broken

Replace

Improper tooth contact between reduction pinion (on output shaft) and reduction gear

Readjust

Bearings associated with spiral bevel drive or hub bearings broken

Replace

Differential side gears have broken teeth, or thrust washers worn

Replace gears or washer

Metal piece in axle housing

Clean and replace oil

Bolts securing axle shaft or differential carrier are loose

Retighten

Fit differential gears in differential case are out of specification due to wear

Replace worn parts

Broken teeth on differential pinions or side gears, or pinions seized on spiders

Replace defective parts

Bearings broken due to too large a preload

Replace bearing and readjust preload

Backlash between reduction pinion (on output shaft) and reduction gear too small

Replace bearings and readjust preload and backlash

9.1

TROUBLESHOOTING: BRAKE SYSTEM

Brake System Complaint Lack of braking force

Service Brakes

Pedal stroke is too large

Uneven braking (machine pulls to one side)

Brake squeals

Brake chatters or clatters

9.2

Possible Cause

Remedy

Oil leaking past primary cup in master cylinder

Replace piston cup if cylinder is worn. Replace cup and fluid if the cup is distorted.

Oil leaking past cups in wheel cylinders

Replace pipe and connector and retighten

Oil leaking from oil pipe connection

Retighten

Shoe linings excessively worn

Replace

Linings dirty with oil or grease

Clean or replace

Air trapped in brake oil line

Bleed air at master cylinder and wheel cylinder

Piston cup defective in master cylinder

Replace

Not enough fluid in reservoir

Refill

Push rod-to-piston clearance too large in master cylinder

Readjust

Brake fluid leakage

Replace piston cup if cylinder is worn. Replace the cup and fluid if the cup is distorted.

Automatic adjusting device out of order

Check cable guide and adjusting spring installation. If they are defective, replace fitting cable, lever and adjusting screw.

Lining or drum dirty with oil or grease in less effective brake

Clean or replace

Wobbly or loose-mounted drum in less effective brake

Replace drum. Readjust and retighten.

Linings glazed

Replace shoe & lining assembly

Linings badly worn

Replace

Backing-plate securing bolts loose

Retighten

Wheel bearings loose

Readjust preload and retighten

Brake drum dirty

Clean

Anchored ends of shoes rattling on anchor

Repair or replace

Shoe ledges badly worn

Replace backing plate

Piston badly worn in wheel cylinder

Replace

TROUBLESHOOTING: BRAKE SYSTEM

Parking Brake

Complaint

Remedy

Lever stroke is too small

Lining-to-drum clearance too small

Readjust

Squeals during traveling

Lining-to-drum clearance too small

Readjust

Brake drum badly distorted

Repair or replace

Parking brake cable longer than specified

Check drum-to-lining clearance and, if brake will not apply, turn adjusting knob clockwise

Linings worn to service limit

Replace shoe & lining assembly

Lining-to-drum clearance too small

Readjust

Lack of brake lever operating effort

Readjust to 25 to 30 kgf (55 to 66 lbf) [245 to 294 N]

Will not apply

Complaint Hard steering

Possible Cause

Remedy

a) Overloaded steer axle

Reduce load

b) Damaged mechanical linkage

Replace

c) Dry mechanical linkage joints

Lubricate

d) Mechanical joints too tight

Readjust

e) Kingpin bearings improperly preloaded

Readjust

a) Damaged or worn mechanical linkage

Replace

b) Loose cylinder piston

Replace cylinder rod

a) Damaged or worn mechanical linkage

Replace

b) Tire diameter differs between right and left

Replace tire

Erratic steering

Loose cylinder piston

Replace cylinder rod

Excessive free play

Damaged or worn linkage between cylinder

Replace

at steered wheels

and steered wheels

Axle shimmy

a) Excessive clearance between the kingpin

Truck wanders Steering System

Possible Cause

Truck drifts

Repair or replace

and its bearings b) Worn or damaged hub bearing

Replace

Rear tires wear

Tire on one side differs in kind or brand

Replace tires

prematurely

from that on the other side.

or unevenly

9.3

TROUBLESHOOTING: STEERING SYSTEM

Steering System Complaint Slow steering, hard steering or loss of steering

Truck wanders

Possible Cause

Remedy

Worn or malfunctioning pump

Replace

Malfunctioning relief valve

Readjust or replace

Worn or malfunctioning steer gear

Replace

Pipe or tube flattened, or restriction in an oil line

Clean or replace

Air in system

Low level of oil

Fill as required

Leaking joint

Tighten joint

Pinched pipe or hose

Straighten or replace

Worn steer gear

Replace

Worn steer gear

Replace

Leakage of cylinder seals or at lines between steer gear and cylinder

Repair

Temporary hang-up in steering

Thermal shock—caused by actuation of hydraulic lift and tilt for long periods of time without actuation of steering system, creating more than a 28°C (50° F) temperature differential between the oil in the tank and the oil in the steer gear.

Correct operating procedure

Erratic steering

Air in system

Low level of oil

Fill as required

Leaking joint

Tighten joint

Pinched pipe or hose

Straighten or replace

Steering slip

Spongy or soft steering

9.4

Thermal shock damage to steer gear

Replace

Air in system

Low level of oil

Fill as required

Leaking joint

Tighten joint

Pinched pipe or hose

Straighten or replace

Air trapped in cylinder

Bleed air

TROUBLESHOOTING: STEERING SYSTEM

Complaint Steering wheel turns with no axle response

Possible Cause Problem with steering column

Air in steer gear

Remedy

Column loose or damaged

Repair or replace

Column splines damaged or disengaged from steer gear

Repair or replace

Starved at startup

Temporary

Starved from long period of non-use Temporary No flow to steer gear

Low oil level

Fill as required

Ruptured hose

Replace

Thermal shock damage to steer gear Replace Blown piston seal Steering instability or oscillation

Air in lines

Replace Pump sucking air at inlet

Check joints

Components or lines contain air

Bleed circuit

Improper relief setting

Readjust

Steering wheel turns in wrong direction

Lines connected to wrong cylinder ports

Correct connections

Excessive freeplay

At steering wheel

Loose steering wheel nut

Tighten

Damaged or worn column shaft

Replace

Leaky cylinder seals

Replace

At steered wheels Binding or poor centering of steering wheel

Steer gear locks up

Binding or misalignment between column and steer gear

Readjust steer gear mounting bracket or replace rubber mounting grommets

High back pressure in tank return line

Clear blockages

Contamination in steer gear unit

Clean unit

Contamination in steer gear unit

Clean unit

Insufficient hydraulic power

Check pump and power supply

Worn or damaged steer gear or steer gear pin

Replace

9.5

TROUBLESHOOTING: HYDRAULIC SYSTEM

Hydraulic System Complaint

Possible Cause

Will not lift or tilt

Not enough oil in hydraulic tank

Refill

Relief valve out of order because of: 1) Seized main valve 2) Broken valve spring

Replace Replace relief valve

Oil pump defective

Replace

Control valve switch misaligned or defective

Readjust or replace

Relief valve out or order because of: 1) Too low a relief valve setting 2) Defective plunger and poppet seat 3) Weakened spring 4) Damaged O-ring in valve case

Readjust Replace relief valve Replace relief valve Replace O-ring

Oil pump defective

Replace

Piston seals worn or damaged

Replace

Rpm too low

Adjust

Control lever installed loose, resulting in not enough spool stroke

Repair or replace

Tank strainer clogged

Clean or replace

Pump not delivering enough oil

Repair or replace

Sleeve seized in flow regulator valve

Repair

Dirt in flow regulator valve

Clean, repair system and replace defective hose

Abnormal resistance to flow due to flattened hose or local clogging

Replace hose

Piston rod distorted Control lever installed loose, resulting in not enough spool stroke

Repair or replace Repair or replace

Air in oil circuit

Bleed air by operation cylinder through full stroke

Not enough oil in hydraulic tank

Refill

Control valve spool leaking internally

Replace

Lift connector on bottom of control valve

Torque to 33 ± 3.5 ft•lbs

Will not lift rated load

Lift and Tilt Cylinders

Lift speed is too low

Lowering speed is too low

Cylinder vibrates when actuated

Load will not hold

Remedy

not tight

9.6

Sliding (inside) surface of cylinder tube slightly grooved

Repair or replace cylinder assembly

Sliding (inside) surface of tube badly grooved

Replace

Piston seals broken or distorted

Replace seal kit

Oil leakage from piping

Repair or replace

TROUBLESHOOTING: HYDRAULIC SYSTEM

Lift and Tilt Cylinders, continued

Complaint Mast tilts forward (drifts)

Bushing leaks

Hydraulic Tank

Hydraulic tank heats excessively

Cylinders move too slowly

Hydraulic Pump

Cylinders move too slowly

Noisy

Possible Cause

Remedy

Control valve spool leaking internally

Replace

Foreign particles lodged between packing and mating surface

Replace packing

Piston seal damaged

Repair

Cylinder distorted

Repair or replace

Foreign particles lodged between sealing members such as oil seals and dust seals

Replace

Oil seals and dust seals defective

Replace

O-rings damaged

Replace

Cylinder distorted

Repair or replace

Oil viscosity improper

Change oil

Overload

Check working conditions and, if overloaded, urge the operator to stay within the load limit

Local overheating of oil line due to a large restriction flow

Repair or replace

Relief valve adjustment improper

Readjust pressure setting

Pressure drop due to weakened or broken springs

Repair or replace and readjust

Hydraulic pump worn

Replace

Outlet pipe or tube flattened, or restriction to flow

Repair or replace

Shortage of oil due to a natural loss

Refill

Oil leakage due to damaged oil line seals

Repair or replace

Oil viscosity too high

Change oil

Hydraulic pump defective

Check pump and piping; repair or replace

Oil leakage from oil line

Check oil for level and condition; and/or change oil

Abnormal rise in oil temperature

Check control valve spools for misalignment: repair or replace

Hydraulic pump leaking internally

Replace pump

Poor pumping

Refill

Cavitation

1. Check suction pipe for any flat portion or loose connection; retighten or replace 2. Check shaft oil seal for airtightness; replace pump 3. Check pump body for any outside interference; repair

9.7

TROUBLESHOOTING: REAR AXLE

Rear Axle Complaint Hard steering

Possible Cause

Remedy

Low pump pressure

Check pressure, replace pump as needed

Damaged mechanical linkage

Replace

Dry mechanical linkage joints

Lubricate

Mechanical joints too tight

Readjust

Kingpin bearings improperly preloaded

Readjust

Damaged or worn mechanical linkage

Replace

Loose cylinder piston

Replace cylinder rod

Damaged or worn mechanical linkage

Replace

Tire diameter differs between right and left

Replace tire

Erratic steering

Loose cylinder piston

Replace cylinder rod

Excessive freeplay at steered wheels

Damaged or worn linkage between cylinder and steered wheels

Replace

Axle shimmy

Excessive clearance between the kingpin and its bearings

Repair or replace

Worn or damaged hub bearing

Replace

Tire on one side differs in kind or brand from that on the other side

Replace tires

Truck wanders

Truck drifts

Rear tires wear prematurely or unevenly

9.8

TROUBLESHOOTING: MAST & FORKS

Mast and Forks Complaint Lift bracket and inner mast do not move smoothly

Possible Cause Main rollers and side rollers have proper clearance Rollers involved are binding on their shafts Rollers damaged Improper mast-to-strip clearance

Lift bracket or inner mast cocks

Too much clearance on side rollers, or side rollers are damaged Lift chains unequally tensioned Shim adjustments unequally made on left and right lift cylinders (at maximum height)

Mast makes noise

Rollers not rotating smoothly on their shafts or are damaged

Load drops (drifts)

Lift cylinder packing damaged Lift cylinder bore grooved Control valve defective

Entire mast shakes

Mast-support bushing worn

Mast is distorted

Improper loading or overload

Fork tips differ in height

Finger bar bent Forks bent Distortion of mast due to off-center loading

9.9

Chapter 10: Maintenance Service Data Maintenance Service Data .......................................................................... 10.1 Front Axle and Reduction Differential....................................................... 10.1 Transfer Case........................................................................................... 10.3 Rear Axle.................................................................................................. 10.4 Brake System ........................................................................................... 10.6 Steering System, ...................................................................................... 10.11 Hydraulic System ..................................................................................... 10.13 Mast and Forks (Simplex Mast) ............................................................... 10.16 Tightening Torques for Standard Bolts and Nuts ........................................ 10.18 Fine Thread—With Spring Washer .......................................................... 10.18 Fine Thread—Without Spring Washer ..................................................... 10.19 Coarse Thread—With Spring Washer...................................................... 10.20 Coarse Thread—With Spring Washer...................................................... 10.21 Maintenance Chart ...................................................................................... 10.22 Planned Replacement Parts........................................................................ 10.28 Lubrication Information ................................................................................ 10.29 Chart......................................................................................................... 10.29 Lubricant Specifications ........................................................................... 10.30 Recommended Brands of Lubrications .................................................... 10.30 Weight of Major Components (Approximate) .............................................. 10.31 Special Service Tools .................................................................................. 10.32 Special Tool Illustrations........................................................................... 10.33 Inspection Guide.......................................................................................... 10.36

SERVICE DATA: FRONT AXLE

Maintenance Service Data Front Axle and Reduction Differential Truck Model

Item

Face runout of axle shaft flange Runout of axle shaft (1/2 of dial indicator reading)

Hubs and Wheels

Preload for hub bearing 1, kgf•cm (lb•ft) [N•m] Tightening torque kgf•cm (lbf•ft) [N•m]

FBC15KFBC18KL

FBC20KFBC30KL

0.05 (0.0020)

0.5 (0.020)

0.5 (0.020) max

1.0 (0.039) max

2.0 (0.079)

5 to 50 (0.4 to 3.6) [0.5 to 4.9]

Hub bearing lock nuts (outer) (2)

20 (145) [196]

Axle shaft bolts (3)

8.8 (64) [86]

Backing plate bolts (4)

6 (43) [59]

18.5 (134) [181]

Hub bolt lock nuts (5)

6 (43) [59]

18.5 (134) [181]

Frame support bolts (6)

Wheel nuts (7)

22.9 (166) [225] 16 (116) [157]

38.5 (278) [378]

203665

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.1

SERVICE DATA: FRONT AXLE Front Axle and Reduction Differential, continued Item

Gear backlash (1)

Truck Model

FBC15K/18K/18KL/20K/25K/25KE/25KL/30KL

0.18 to 0.23 (0.0071 to 0.0091)

0.5 (0.020)

0.02 to 0.07 (0.0008 to 0.0028)

0.35 (0.0138)

Fit of bevel pinion on spider (2)

15 to 30 (1.1 to 2.2) [1.5 to 2.9] Preload for differential case side bearings (3) kgf•cm (lbf•ft) [N•m]

A 1.3 to 2.5 kgf (2.9 to 5.5 lbf) [13 to 25 N]

Hubs and Wheels

as force applied to reduction gear in tangential direction

Face runout of reduction gear (4)

0.05 (0.0020) max

0.05 (0.0020)

0.15 to 0.25 (0.0059 to 0.0098)

0.07 to 0.17 (0.0028 to 0.0067)

0.5 (0.020)

Reduction gear bolts (7)

12 (87) [118]

Side bearing cap bolts (8)

12.8 (93) [126]

Carrier bolts (9)

6.1 (44) [60]

Differential carrier cover bolts (10)

3.4 (25) [33]

Backlash between reduction gear and pinion (5) Free movement (looseness) of axle shaft splines (6)

Tightening torque kgf•cm (lbf•ft) [N•m]

10 9

3 8 2

1 203664

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.2

SERVICE DATA: TRANSFER CASE

Transfer Case N•m

kgf•m

lbf•ft

33±2

3.4±0.2

24.6±1.4

Cover-to-traction motor

Side cover

39.2±3.9 4.0±0.4

29.0±2.9

Plug or pulse generator

54.0±4.9 5.5±0.5

39.7±3.6

case-to-cover

39.2±3.9 4.0±0.4

29.0±2.9

Lock nut

292±20 30.0±2.0

217±14.5

Transfer Case

Supply liquid gasket onto the face of flange. 4 2

1 5 209009

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.3

SERVICE DATA: REAR AXLE

Rear Axle Item

FBC15K-18KL

FBC20K- 30KL

Oscillating angle

3°

Toe-in

0°

Caster

0°

Camber

1°

Total fore-aft play of axle at center pin (1)

0.8 (0.031)

1.2 (0.047)

Turning Angle

Tightening torque, kgf•m (lbf•ft) [N•m] Rear Axle

Truck Model

Inside (2)

83°

Outside (3)

54°

56°

Support bolts (4)

14.8 (107) [145]

Stopper bolt nuts (5)

6.8 (49) [67]

Cylinder minimum test pressure,

107 (1522) [10,500]

163 (2320) [16,000]

kgf•cm (psi) [kPa]

8609145

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.4

SERVICE DATA: REAR AXLE Rear Axle, continued Item

Tightening torque kgf•m (lbf•ft) [N•m]

Truck Model

FBC15K-18KL

FBC20K- 30KL

Outer locknut (6)

16 (116) [157]

Cylinder nuts (7)

1.9 to 2.3 (14 to 17) [19 to 23]

Cylinder bolts (8)

17.9 (130) [176]

26.7 (193) [262]

Kingpin bolts (9)

1.7 (12.3) [16.7]

3.4 (24.6) [33.4]

Tie rod bolts (10)

0.7 (5) [6.9]

25 to 65 (1.8 to 4.7) [2.5 to 6.4]

Preload for hub bearing (11) kgf•m (lbf•ft) [N•m]

Rear Axle

7 10

11 6 8609146

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.5

SERVICE DATA: BRAKE SYSTEM

Brake System Truck

FBC15K - 30KL

Height of pedal (1)

89 ± 3 (3.5 ± 0.12)

Stroke (to point where brakes start to apply) (2)

3 to 10 (0.12 to 0.40)

Clearance between piston and push rod (3)

0.5 to 2.8 (0.02 to 0.11)

Item Model

Brake Pedal

3 8609147

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.6

SERVICE DATA: BRAKE SYSTEM Brake System, continued Item

Truck Model

FBC15KFBC18KL

FBC20K-30KL

Inside diameter of cylinder body (1)

19.05 + 0 0.052 (0.7500 + 0 0.00205)

22.22 + 0 0.052 (0.8748 +0 0.00205)

Diameter of piston (2)

19.05 -0.020 -0.053 (0.7500 -0.0079 -0.00209)

22.22 -0.020 -0.053 (0.8748 -0.0079 -0.00209)

Clearance between cylinder and piston

0.020 to 0.105 (0.00079 to 0.00413)

0.2 (0.008)

20 0 -0.3 (0.79 0 -0.012)

23.2 ± 0.25 (0.913 ± 0.0098)

replace every year

20.2 ± 0.2 (0.795 ± 0.008)

23.2 ± 0.25 (0.913 ± 0.0098)

replace every year

46.8 (1.843)

85 (3.35)

replace every year

Diameter of primary cup (lip side) (3)

Diameter of secondary cup (lip side) (4)

Master Cylinder

Free length of return spring (5)

Earlier Version

204936

Later Version 2 4

91246-07200

A = Assembly Standard B = Repair or service limit Unit: mm (in.) 10.7

SERVICE DATA: BRAKE SYSTEM Brake System, continued Truck Model

FBC15KFBC18KL

FBC20K-30KL

Inside diameter of cylinder body (1)

22.22 + 0 0.052 (0.8748 - 0 0.00205)

28.58 + 0 0.052 (1.1252 + 0 0.00205)

Diameter of piston (2)

22.22 - 0.040 - 0.073 (0.8748 - 0.00157 - 0.00287)

28.58 - 0.020 - 0.058 (1.1252 - 0.00079- 0.00228)

0.040 to 0.125 (0.00157 to 0.00492)

0.020 to 0.105 (0.00079 to 0.00413)

Item

Clearance between cylinder and piston

B Diameter of piston cup (lip side) (3)

0.15 (0.0059) 23.7 ± 0.2 (0.933 ± 0.0079)

A B

Wheel Cylinder

Return Spring (4)

replace every year

Free length

49.5 (1.95)

58 (2.28)

Length under test force

20 (0.79)

23 (0.91)

1.2 ± 0.1 (2.6 ± 0.2) [12 ± 1]

1.3 ± 0.1 (2.9 ± 0.2) [13 ± 1]

Test force kgf (lbf) [N]

B Tightening torque, kgf•m (lbf•ft) [N•m]

30.5 ± 0.25 (1.201 ± 0.0098)

Wheel cylinder bolts (5)

Bleeder screw (6)

replace every year 0.8 to 1.2 (6 to 9) [8 to 12]

0.6 to 0.9 (4 to 7) [6 to 9]

1.8 to 2.7 (13 to 20) [18 to 26]

2 200426

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.8

SERVICE DATA: BRAKE SYSTEM Brake System, continued Truck Model

FBC15KFBC18KL

254 + 0 1.3 (10.00 + 0 0.0051)

310 + 0 0.15 (12.20 + 0 0.0059)

256 (10.08)

312 (12.28)

4.87 (0.19)

6 (0.24)

2.5 (0.098) max

3 (0.118) max

Clearance between drum and lining (3) (one side)

0.2 to 0.5 (0.0079 to 0.0197)

0.2 to 0.6 (0.0079 to 0.0236)

Return spring (4)

Free length

102 (4.02)

Primary:120 (4.72) Secondary: 139.3 (5.48)

Length under test force

111 (4.37)

Primary: 134 (5.28) Secondary: 145.4 (5.72)

Test force, kgf (lbf) [N]

16 ± 1.6 (35 ± 3.5) [157 ± 16]

23 ± 2.3 (51 ± 5.1) [226 ± 23]

Item Inside diameter of brake drum (1)

Wheel Brakes

Thickness of lining (2)

FBC20K-30KL

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.9

SERVICE DATA: BRAKE SYSTEM Brake System, continued Truck Model

FBC15KFBC18KL

FBC20K-30KL

Free length

79 (3.11)

104 (4.11)

Length under test force

98.5 (3.88)

122 (4.80)

Test force, kgf (lbf) [N]

14 ± 1.4 (31 ± 3) [137 ± 14]

8 ± 0.8 (18 ± 2) [78 ± 8]

Tightening torque for backing plate bolts (6) kgf•m (lbf•ft) [N•m]

Item

Service Brakes

Adjusting spring (5)

16 (116) [157]

1 4

3 Secondary spring 4 5 Free length 203588

Locked position of lever A

4° to 5°

Lever operating effort (F)

25 to 30 (55 to 66) [245 to 294]

Parking Brake

F A

204967

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.10

SERVICE DATA: STEERING SYSTEM

Steering System Truck Model

Item Steering effort (at rim with truck on) kgf (lbf) [N]

FBC20K-30KL

1.3 (2.9) [12.8]

Tank Plug (1)

4.8 (35) [47.5]

Body cap screws (2)

2.3 (17) [23]

Steering Gear

Tightening torque kgf•cm, (lbf•ft) [N•m]

FBC15KFBC18KL

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.11

SERVICE DATA: STEERING SYSTEM

Steering System Truck Model

Steering Cylinder

Item

FBC15KFBC18KL

FBC20K-30KL

Inside diameter

63 (2.48)

75 (2.95)

Diameter of piston rod

40 (1.57)

50 (1.97)

Minimum test pressure for leaks, kgf•cm2 (psi) [kPa]

107 (1522) [10,500]

163 (2320) [16,000]

Tightening torque, kgf•cm, (lbf•ft) [N•m]

Cylinder nuts (1)

Mounting bolts (2)

2.1 ± 0.2 (15.5 ± 1.5) [21 ± 2] 17.9 (130) [176]

26.7 (193) [262]

8609149

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.12

SERVICE DATA: HYDRAULIC SYSTEM

Hydraulic System Truck Model

Simplex Mast

Item

18KL

20K

25K

Lowering speed (rated load) mm/sec (fpm)

Forward tilt angle

5°

Backward tilt angle

6°

Lift cylinder drift (rated load) mm (in.) / 15 min. [Oil temperature 45°C (113°F)]

50 (2.0) max

Tilt cylinder drift (forward) rated load mm(in.) / 15 min. [Oil temperature 45°C (113°F)]

Power steering relief valve setting kgf•cm2, (psi) [kPa]

Hydraulic Pump

18K

48 volt lift speed (rated load) mm/sec (fpm)

2 Main relief valve setting, kgf•cm , (psi) [kPa]

Control Valve

15K

Output, liter (cu. in.) / min

Standard

Premium Tightening torque for oil pump bolts kgf•m (lbf•ft) [N•m] Tightening torque kgf•m (lbf•ft) [N•m]

A A A

.34 (67) .32 (64) .47 (93) .40 (78) .58 (115)

.57 (113)

22 (0.9)

25KE

25KL

30K-30KL

.38 (74)

.32 (64)

.59 (116)

.52 (102)

40 (1.6)

20 (0.8)

15 (0.6)

SAME 51 (725)[5000] 55.2(3360) 2400 rpm

81.5 (1160) [8000]

60(3913) 2400 rpm

60(3913)2400rpm 69.6 (4549) 2400 rpm

60(3913)2400rpm DNA

69.6 (4539) 2400rpm

4.7 to 5.2 (34 to 38) [46 to 51]

Tie bolts (1/2 in.)

1.9 (14) [19]

Tie bolts (9/16 in.)

4.5 (33) [45]

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.13

SERVICE DATA: HYDRAULIC SYSTEM

Hydraulic System, continued Truck Model

Item

FBC15KFBC18KL

FBC20KFBC25KE

FBC25KLFBC30KL

45 +0.2 0

50 +0.2 0

55 +0.2 0

(1.77 +0.008 ) 0

(1.97 +0.008 ) 0

(2.17 +0.008 ) 0

[Piston] Inside diameter of cylinder tube (1)

Diameter of piston ring (2)

35 (1.38)

40 (1.57)

45 (1.77)

Thread diameter (3)

M49 x 1.5

M54 x 1.5

M59 x 1.5

170 to 240 (17.3 to 24.5) [125 to 175]

200 to 270 (20.4 to 27.5) [150 to 200]

270 to 304 (27.5 to 31.0) [200 to 225]

Lift Cylinder

Tightening torque (4) N•m (kgf•m) [lbf•ft] 3

Return Filter

207073

Tightening torque N•m (kgf•m) [lbf•ft]

49 ± 10 (5 ± 1) [36 ± 7.2]

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.14

SERVICE DATA: HYDRAULIC SYSTEM

Hydraulic System, continued Truck Model

Item

FBC15KFBC18KL

FBC20KFBC25KE

FBC25KLFBC30KL

63 +0.1 0

70 +0.1 0

80 +0.1 0

(2.48 +0.004 ) 0

(2.76 +0.004 ) 0

(3.15 +0.004 ) 0

63.12 (2.485 0)

70.12 (2.760 6)

80.12 (3.154 3)

-0.02 25 -0.05

30 -0.02

35 -0.025

A Inside diameter of cylinder tube (1) B [Guide bushing] Diameter of piston rod (2)

Inside diameter of mast-side socket bushing (fitted) (3)

0 0 35-0.012 (1.38-0.0005 )

Inside diameter of frame-side head bushing (fitted) (4)

32 +0.085 (1.26 +0.003 ) 0 0

32.6 (1.283)

[Guide bushing] thread diameter (5)

-0.000 8) (1.0 -0.002 0

-0.064

98) (1.38 -0.000 -0.002 52

M68 x 2

M75 x 2

M85 x 2

265 ± 29 (27 ± 3) [195 ± 22]

314 ± 31 (32 ± 3.2) [231 ± 23]

373 ± 37 (38 ± 3.8) [275 ± 27]

[Socket] thread diameter (6)

M24 x 1.5

M27 x 1.5

M30 x 1.5

Tightening torque, N•m (kgf•m) [lbf•ft]

Socket bolt (7)

Self-locking nut (8)

Tightening torque Tilt Cylinders

-0.05 -0.000 8) (1.18 -0.002 0

N•m (kgf•m) [lbf•ft]

Clearance between rod and guide bushing (9)

127 to 152 (13 to 15.5) [94 to 112] 127 ± 9.8 (13 ± 1.0) [94 ± 7.2]

235 ± 19.6 (24 ± 2.0) [174 ± 14.5]

0.06 to 0.111 (0.002 4 to 0.004 4)

39.2 ± 25 (40 ± 2.5) [289 ± 18.1]

0.075 to 0.139 (0.003 0 to 0.005 5) 0.35 (0.013 8)

9 3

Flow Regulator Valve

Flow rate (no load) liter (cu. in.) / min

50 (3051)

65 (3967)

207033

75 (4577)

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.15

SERVICE DATA: MAST AND FORKS

Mast and Forks (Simplex Mast) Truck Model

Item Difference in height between fork tips

Forks Chains

Thickness of forks

Rollers

FBC20 FBC25KE

FBC25KLFBC30KL

5 (0.20) 100 x 40 (3.9 x 1.6)

100 x 45 (3.9 x 1.8)

FBC15K

FBC20K

100 x 31 (3.9 x 1.2)

100 x 38 (3.9 x 1.5)

FBC18K/KL

FBC25K/KE/KL

100 x 33 (3.9 x 1.3)

100 x 40 (3.9 X 1.57)

318 (12.52)

381 (15.00)

508 (20.00)

327 (12.87)

392 (15.43)

523 (20.59)

99 (3.90)

113.8 (4.48)

100 (3.94)

115 (4.53)

101 (3.98)

116 (4.57)

102 (4.016)

117 (4.606)

(width x thickness) Length of tilt chains (per 20 links)

Mast and Lift Bracket

Diameter of main roller

FBC15KFBC18KL

125 x45 (4.92 x 1.8)

125 X 39 (4.92 x 1.53)

Diameter of side roller

42 (1.65)

Distance between outer mast main rollers (inside to inside) A

523 (20.59)

575 (22.64)

Distance between inner mast main rollers (outside to outside) B

581 (22.87)

639 (25.16)

Distance between lift bracket main rollers (outside to outside) C1

485 (19.09)

535 (21.06)

Distance between lift bracket main rollers (outside to outside) C2

487 (19.17)

537 (21.14)

Distance between lift bracket main rollers (outside to outside) D

491 (19.33)

539 (21.22)

Distance between lift bracket side rollers (outside to outside) E

496 (19.53)

546 (21.50)

Longitudinal clearance of lift bracket middle rollers (with forks slightly lifted) F

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket middle main rollers (fully raised) G1

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket lower main rollers (fully raised) G2

0.1 to 0.5 (0.004 to 0.020)

Longitudinal clearance of mast main rollers (in the whole lift range) H

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of inner mast main rollers (fully raised) J

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of outer mast main rollers (fully raised) K

0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L

0.1 to 0.5 (0.004 to 0.020)

A = Assembly Standard B = Repair or service limit Unit: mm (in.) 10.16

SERVICE DATA: MAST AND FORKS

Mast and Forks Truck Model

Item

FBC15K

FBC18K18KL

FBC20K FBC25K FBC25KE

Inner mast

FBC30K FBC30KL

L G1

Mast and Lift Bracket/Later Version

G2 B

Lift Bracket A

K H

E J

D Outer mast 207106

Tightening torque, kgf•m (lbf•ft) [N•m]

Distortion of finger bar

Mast support bolts

7.5 (54) [74]

18.2 (132) [178]

Chain wheel support bolts

9.9 (72) [97]

5 (0.2)

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.17

SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Fine Thread – With Spring Washer With Spring Washer

Metric Fine Thread

Nominal Size

Pitch

in.

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

0.24

0.04

0.75

5.4

7.4

0.98

7.1

9.6

1.3

9.4

12.7

0.32

1.25

0.05

1.7

12.3

16.7

2.3

16.6

22.6

3.1

22.4

30.4

0.39

1.25

0.05

3.5

25.3

34.3

4.6

33.3

45.1

7.1

51.4

69.6

0.47

1.25

0.05

6.5

47.0

63.7

8.4

60.8

82.4

12.5

90.4

122.6

0.55

1.5

0.06

10.4

75.2

102.0

13.5

97.6

132.4

19.5

141.8

192.2

0.63

1.5

0.06

15.8

114.3

154.9

20.6

149.0

202.0

29.3

211.9

287.3

0.71

1.5

0.06

22.9

165.6

224.6

29.8

215.5

292.2

42.2

305.2

413.8

0.79

1.5

0.06

31.7

229.3

310.9

41.2

298.0

404.0

58.5

423.1

573.7

0.87

1.5

0.06

42.2

305.2

413.8

54.8

396.4

537.4

77.8

562.7

763.0

0.95

1.5

0.06

55.8

403.6

547.2

72.5

524.4

711.0

102.6

742.1

1006.2

1.06

1.5

0.06

81.0

585.9

794.3

105.3

761.6

1032.6

148.0

1070.5 1451.4

1.18

1.5

0.06

112.2

811.5

1100.3

145.9

1055.3 1430.8

205.2

1484.2 2012.3

1.30

1.5

0.06

149.6

1082.1 1467.1

194.5

1406.8 1907.4

273.3

1976.8 2680.2

1.42

1.5

0.06

195.6

1414.8 1918.2

254.3

1839.4 2493.8

356.6

2579.3 3497.1

1.54

1.5

0.06

251.0

1815.5 2461.5

326.2

2359.4 3198.9

455.8

3296.8 4469.9

Note 1. The tolerance on these torques is ± 10%. 2. These torques are for “dry” conditions.

10.18

SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Fine Thread – Without Spring Washer Without Spring Washer

Metric Fine Thread

Nominal Size

Pitch

in.

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

0.24

0.04

0.88

6.4

8.6

1.1

8.0

10.8

1.5

10.8

14.7

0.32

1.25

0.05

2.0

14.5

19.6

2.7

19.5

26.5

3.7

26.8

36.3

0.39

1.25

0.05

4.2

30.4

41.2

5.4

39.1

53.0

8.3

60.0

81.4

0.47

1.25

0.05

7.6

55.0

74.5

9.9

71.6

97.1

14.7

106.3

144.2

0.55

1.5

0.06

12.2

88.2

119.6

15.9

115.0

155.9

23.1

167.1

226.5

0.63

1.5

0.06

18.6

134.5

182.4

24.2

175.0

237.3

34.5

249.5

338.3

0.71

1.5

0.06

26.9

194.6

263.8

35.0

253.2

343.2

49.7

359.5

487.4

0.79

1.5

0.06

37.3

269.8

365.8

48.5

350.8

475.6

68.8

497.6

674.7

0.87

1.5

0.06

49.6

358.8

486.4

64.5

466.5

632.5

91.5

661.8

897.3

0.95

1.5

0.06

65.6

474.5

643.3

85.3

617.0

836.5

120.7

873.0

1183.7

1.06

1.5

0.06

95.3

689.3

934.6

123.9

896.2

1216.0

174.1

1259.3 1707.3

1.18

1.5

0.06

132.0

954.8

1294.5

171.6

1241.2 1682.8

241.4

1746.0 2367.3

1.30

1.5

0.06

176.0

1273.0 1726.0

228.8

1654.9 2243.8

321.6

2326.1 3153.8

1.42

1.5

0.06

230.1

1664.3 2256.5

299.2

2164.1 2934.1

419.6

3035.0 4114.0

1.54

1.5

0.06

295.3

2135.9 2896.0

383.8

2776.0 3763.8

536.2

3878.3 5258.3

Note 1. The tolerance on these torques is ± 10%. 2. These torques are for “dry” conditions.

10.19

SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Coarse Thread – With Spring Washer With Spring Washer

Metric Fine Thread

Nominal Size

Pitch

in.

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

0.39

1.5

0.06

3.4

24.6

33.3

4.4

31.8

43.1

6.9

49.9

67.7

0.47

1.75

0.07

6.0

43.4

58.8

7.8

56.4

76.5

11.8

85.3

115.7

0.55

0.08

9.8

70.9

96.1

12.7

91.9

124.5

18.6

134.5

182.4

0.63

0.08

15.0

108.5

147.1

19.5

141.0

191.2

28.0

202.5

274.6

0.71

2.5

0.10

20.7

149.7

203.0

27.0

195.3

264.8

39.1

282.8

383.4

0.79

2.5

0.10

29.2

211.2

286.4

37.9

274.1

371.7

54.7

395.6

536.4

0.87

2.5

0.10

39.1

282.8

383.4

50.9

368.2

499.2

73.0

528.0

715.9

0.95

0.12

50.2

363.1

492.3

65.3

472.3

640.4

94.3

682.1

924.8

1.06

0.12

73.9

534.5

724.7

96.1

695.1

942.2

137.7

996.0

1350.4

1.18

3.5

0.14

98.9

715.3

969.9

128.4

928.7

1259.2

188.0

1359.8 1843.7

1.30

3.5

0.14

135.5

980.12 1328.8

176.1

1273.7 1727.0

252.6

1827.1 2477.2

1.42

0.16

170.9

1236.1 1676.0

222.3

1607.9 2180.0

326.3

2360.1 3199.9

1.54

0.16

226.3

1636.8 2219.2

294.1

2127.2 2884.1

420.0

3037.9 4118.8

1.65

4.5

0.18

280.9

2031.8 2754.7

365.2

2641.5 3581.4

523.9

3789.4 5137.7

Note 1. The tolerance on these torques is ± 10%. 2. These torques are for “dry” conditions.

10.20

SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Coarse Thread – Without Spring Washer Without Spring Washer

Metric Fine Thread

Nominal Size

Pitch

in.

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

0.39

1.5

0.06

4.0

28.9

39.2

5.2

37.6

51.0

8.1

58.6

79.4

0.47

1.75

0.07

7.1

51.4

69.6

9.2

66.5

90.2

13.8

99.8

135.3

0.55

0.08

11.5

83.2

112.8

14.9

107.8

146.1

22.0

159.1

215.7

0.63

0.08

17.6

127.3

172.6

22.9

165.6

224.6

33.0

238.7

323.6

0.71

2.5

0.10

24.4

176.5

239.3

31.8

230.0

311.9

46.0

332.7

451.1

0.79

2.5

0.10

34.3

248.1

336.4

44.6

322.6

437.4

64.3

465.1

630.6

0.87

2.5

0.10

40.0

289.3

392.3

59.9

433.3

587.4

85.9

621.3

842.2

0.95

0.12

59.0

426.7

578.6

76.8

555.5

753.2

111.0

802.9

1088.5

1.06

0.12

86.9

628.5

852.2

113.0

817.3

1108.2

162.0

1171.7 1588.7

1.18

3.5

0.14

116.3

841.2

1140.5

151.1

1092.9 1481.8

221.1

1599.2 2168.3

1.30

3.5

0.14

159.4

1153.0 1563.2

207.2

1498.7 2031.9

297.3

2150.4 2915.5

1.42

0.16

201.1

1454.6 1972.1

261.5

1891.4 2564.4

384.0

2777.5 3765.8

1.54

0.16

266.2

1925.4 2610.5

346.0

2502.6 3393.1

494.1

3573.8 4845.5

1.65

4.5

0.18

330.5

2390.5 3241.1

429.5

3107.3 4212.9

616.4

4458.4 6044.8

Note 1. The tolerance on these torques is ± 10%. 2. These torques are for “dry” conditions.

10.21

SERVICE DATA: GENERAL

Maintenance Chart Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.) may be used instead of service meter intervals if they provide more convenient servicing schedules and approximate the indicated service meter reading. Recommended service should always be performed at the interval that occurs first. Perform service on items at multiples of the original requirement. For example, at every 1200 hours or 6 months, also service those items listed under every 200 hours or monthly, every 50 hours or weekly and daily (pre-start). ● = Check or clean ★ = Change or adjust

Every 2400 hours or 1 year

Motors

Visual

●

Lubricate

Winding to case resistance

Test

●

Resistance to be > 1

Armature to case resistance

Test

●

Brush contact area

Visual

●

Change brush

Brush length

Visual

●

Change brush

Brush spring force

Test

●

Change spring

Commutator surface condition

Visual

●

Commutator discoloration

Visual

●

Interior, exterior cleanliness

Visual

●

How to Check

Every 50 hours or weekly

Bearing lubrication, damage

Inspection Point

Daily (pre-start)

Every 200 hours or monthly Every 1200 hours or 6 months

Maintenance Intervals

Steering wheel Free-play, looseness, rattling

Test

●

Operation

Test

●

Oil leaks

Visual

●

Mounting bolts, tightness

Wrench

●

Beam structural damage

Visual

Cylinder leaks

Visual

Cylinder mounting bolts

Wrench

●

Tie rod bearings and pins

Visual

●

Kingpin looseness

Test

●

Trunnion fore-aft looseness

Test

●

Steering gear

Steering linkage

10.22

Service Data

Mega Ω

Clean

● ●

●

Nominal 0.8 mm (0.031 in.) clearance

SERVICE DATA: GENERAL

Daily (pre-start)

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Maintenance Intervals

Height of pedal above floor

Scale

●

89 ± 3 mm (3.5 ± 0.12 in.)

Stroke to point where brakes start applying

Scale

●

3 to 10 mm (0.12 to 0.4 in.)

Performance

Test/spring balancer

Inspection Point

Brake pedal

How to Check

Parking brake ●

●

Brake hoses and pipes

Fluid leaks, damage or installation

Visual

●

Brake fluid

Level in reservoir

Visual

●

★

Wheel brakes

Master cylinder and wheel Overhaul/Visual cylinders—operation, wear and damage

Brakes drums and shoes Drum-to- lining clearance

Feeler gauge

Service Data

Lever lock position: 4° - 5° Operating effort: 25 to 30 kgf (55 to 66 lb) [245 to 294 N]

103cc (7.9 cu. in.)

★

●

FBC15K - 18KL 0.2 to 0.5mm (0.01 to 0.02) FBC20K-30KL 0.2 to 0.6mm (0.01 to 0.02)

Sliding surfaces of shoes and wear of lining

Disassemble/ calipers

●

FBC15K - 18K 2.5mm (0.10 in.) FBC20K-30KL 3.0mm (0.12 in.)

Drum—wear or damage

Visual scale

●

Service Limit: FBC15K - 18KL 254 + 0 0.13 mm (10.00 + 0 0.0051 in.) FBC20K-30KL 310 + 0 0.13 mm (12.20 + 0 0.0051 in.)

Free length of return springs

Scale

●

Operation of shoes

Test

●

Anchor pins—seizure

Visual

●

10.23

SERVICE DATA: GENERAL

How to Check Daily (pre-start)

Inspection Point

Dye check

●

Fitting cables– damage and length

Visual/scale

●

Ratchet–wear or damage

Visual

●

Cracks, distortion, or other defects

Dye check/ visual

●

Front wheel bearings–preload

Spring balancer

●

Backing plates Distortion, cracks, or damage

Front axle

Differential

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Maintenance Intervals

Fore-aft play

Test

●

Cracks, distortion, or other defects

Visual

●

Oil level and oil leaks

Visual

●

Service Data

Hub bearing preload

5 to 50 kgf (0.4 to 3.6 lbf•ft) [0.5 to 4.9 N•m]

FBC15K - 18KL 5.7 liters (1.5 U.S. gal)

FBC20-30KL 6.1 liters (1.6 U.S. gal)

Rear axle

Mounting bolts

Torque wrench

●

Front wheel bearings–preload

Spring balancer Torque wrench

●

Hub bearing preload

25 to 65 kgf (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m] Lock Nut (outside)

16 kgf•cm (116 lbf•ft) [157 N•m] Wheels

Tires–cuts or gouges

Visual

●

Tires–wear

Depth gauge

●

Tires–imbedded objects

Visual

●

Wheel nuts–tightness

Torque wrench

●

Front Wheel Nuts: FBC15K - 18KL 16 kgf•cm (116 lbf•ft) [157 N•m] FBC20K-30KL 38.5 kgf•cm (278 lbf•ft) [378 N•m] Rims–damage

10.24

Visual

●

SERVICE DATA: GENERAL

Hydraulic tank

How to Check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Inspection Point

Daily (pre-start)

Maintenance Intervals

●

Service Data

★

Oil level and contamination

Visual

Strainer—clogging

Visual

★

Return filter—clogging

Visual

★ ●

●

Hydraulic pump Oil leaks or abnormal noise

Visual / listen

Control valve

Oil leaks

Visual

Main relief valve setting

Pressure gauge

●

185 kgf/cm2 (2631 psi) [18,142 kPa]

Auxiliary relief valve setting

Pressure gauge

●

158±5 kgf/cm2

●

2250±71psi 15,513 ± 490 kpa ●

Overload relief setting (optional) Pressure gauge

Lift cylinders

Control levers and links—rattle

Test

●

Cracks, distortion, or other defects

Visual

●

Rod drift (rated load)

Visual/watch/ scale

●

FBC15K-25KE 50 mm (2.0 in.)/15 min

FBC25KL-30KL 40 mm (1.6 in.)/15 min

●

Attachment

Flow regulator valve

Mounting bolts—tightness

Wrench

Oil Leaks

Visual

Lowering speed

Watch/scale

●

● ●

●

Lowering speed (rated load)

FBC15K-25KE 520 mm/sec (102 fpm)

FBC25KL-30KL 500 mm/sec (98 fpm)

10.25

SERVICE DATA: GENERAL

Daily (pre-start)

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Maintenance Intervals

Cracks, distortion, or other defects

Visual

●

Oil leaks

Visual

●

Forward rod drift (rated load)

Watch/scale

●

● FBC15K - 18KL

Inspection Point

Tilt cylinders

How to Check

Service Data

22 mm (0.9 in.)/15 min FBC20K-25KL 20 mm (0.8 in.)/15 min FBC30KL 15 mm (0.6 in.)/15 min

Mounts—rattle or damage

Visual/free

●

Rod socket nut—tightness

Torque wrench

●

● FBC15K - 18KL 15 kgf·m (108 lbf•ft) [147 N•m] FBC20K-30KL 40 kgf·m (289 lbf·ft) [392 N·m]

Piping

Mast and lift bracket

●

Visual

●

Hose reels and swivel joint— distortion or other defects

Visual

●

Cracks, distortion, or other defects

Visual/ dye check

●

● Each roller to mast clearance (at max. height): 0.1 to 0.5 mm (0.004 to 0.020 in.)

Oil leaks

Visual

Rubber hoses: damage

Mast supports—rattle or damage Main rollers—clearance, damage

10.26

Feeler gauge/ dial gauge

●

SERVICE DATA: GENERAL

Lift chains and chain wheels

How to Check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Inspection Point

Daily (pre-start)

Maintenance Intervals

Length of lift chains (20 links) Scale

●

FBC15K - 18KL 318 mm (12.5 in.) FBC20K-25KL 381 mm (15.0 in.) FBC30KL 508 mm (20.0 in.)

Both chains to equal in tension

Tension deflection of lift chains Scale

●

Chains—damaged or rusting

Visual

●

Chains wheels—wear, distortion, or other defects

Visual

●

Chain wheel bearings—rattle

Feel

●

Chain anchor bolts—distortion Visual or damage Forks—wear and distortion

Visual/scale

●

Forks stopper pins— damage or distortion

Visual

●

Backrest mounting bolts— tightness

Torque wrench

●

Backrest—distortion or damage Visual

●

Lights

Operation

Test/visual

●

Turn signals (optional)

Operation

Test

●

Rear view Rear vision mirrors (optional)

Visual

●

Overhead guard Installation and damage

Visual/wrench

●

Chassis

Loosen bolts or nuts

Wrench

Operator’s seat— damage and installation

Visual

●

Lubrication points

Lubricate

●

Oil change

Inspect

●

Forks and backrest

Service Data

Fork thickness— refer to Service Data

●

Lubricate mast supports every 50 hours or weekly

10.27

SERVICE DATA: GENERAL

Periodic Replacement Parts The parts listed below are important for the safe operation of the truck, and especially designed to be replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here on all trucks brought into its care. Periodic Replacement Parts

Service

Period 1 month after delivery

1 month 6 months 1 year 2 years (200 hours) (1200 hours) (2400 hours) (4800 hours)

★

Rubber parts for brake master cylinder

Replace

●

★

Rubber parts for brake wheel cylinders

Replace

●

★

Replace

●

★

Replace

●

★

Rubber parts for steering cylinder

Replace

●

★

Lift chains

Replace

●

Hydraulic tank return filter

Replace

Drum to lining clearance

Motor brushes

Hydraulic hoses Hoses for power steering

●

Check or replace

●

Check or replace

●

★

10.28

Indicates important safety-related parts

HYDRAULIC OIL BRAKE FLUID

EVERY 2400 HR. OR 1 YEAR

TRANSFER AND DIFFERENTIAL OIL HYDRAULIC TANK OIL FILTER

EVERY 1200 HR. OR 6 MONTHS

Filter

OIL,

NOTE: REDUCE SERVICING INTERVALS IN DUSTY OR SEVERE CONDITIONS. REFER TO OPERATION MANUAL

DASH MONITOR

HORN

ACCELERATOR PEDAL

PARKING BRAKE

SERVICE BRAKES

STEERING

SEAT BELT AND RAILS

(FRONT/REAR)

97182-12900

REAR AXLE CENTER PIN

TIE ROD ENDS (4 FITTINGS)

BRAKE PEDAL

TILT CYLINDER (EACH SIDE)

FRONT AXLE SUPPORT (EACH SIDE)

TILT SOCKET (EACH SIDE)

CHANGE

MAST, FORKS, LIFT CHAINS

MAST STRIPS, ROLLER SURFACES (EACH SIDE) LIFT BRACKET SIDE ROLLERS (EACH SIDE)

EVERY 200 HR. OR MONTHLY

MAST SUPPORTS

EVERY 50 HR. OR WEEKLY

MULTIPURPOSE-TYPE GREASE ENGINE OIL

LIFT CHAIN (EACH SIDE)

CONTACTORS MOTOR BRUSHES

EVERY 600 HR. OR 3 MONTHS

DIFFERENTIAL OIL LEVEL

EVERY 200 HR. OR MONTHLY

SPECIFIC GRAVITY OF BATTERY BOLTS, NUTS

EVERY 50 HR. OR WEEKLY

LUBRICATE

BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW

BATTERY RESTRAINT

BATTERY ELECTROLYTE LEVEL

HYDRAULIC OIL LEVEL

BRAKE FLUID LEVEL

TIRES, WHEEL NUTS

OIL LEAKS

EVERY 10 HR. OR DAILY

CHECK

LUBRICATION AND MAINTENANCE CHART

SERVICE DATA: GENERAL

Lubrication Chart

10.29

10.30

Grease

Brake fluid

Hydraulic oil

Gear oil

(50) 10 |

SAE 10W

(32) 0 |

SAE 5W -30 to -10

(14) -10 | ISO Grade 68 SAE 80W AGMA-2EP

(-4) -20 |

ISO Grade 32 SAE 75W AGMA-1EP

(-22) -30 |

NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295 NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340

Chassis

F.M.V.S.S. No. 116—DOT 3 or DOT4 (SAE J1703)

API service classification multipurpose type GL-5 (hypoid gear oil)

Recommendation

Wheel bearings

Oil |

(68) 20 |

Recommendation for ambient temperatures [°C (°F)]

(86) 30 |

Gear Oil GX 80W90

Castrol Hypoy

Exxon

Castrol

■

Castrol LM Grease

----

Retinax A No. 1

Mobil Grease JL 77 No. 1

Consistency 310-340

NLGI No. 1

Brands of oil are subject to change without notice. When you buy oil, select recommended brands and check specifications.

Shell Spirax EP90

Shell

■

90 Pegasus Gear Oil

SAE90W

API service classification GL-5

Visc osity Manufacturer Mobil

Specifications

Gear Oil

EP 68 Gear oil with borate additives are not recommended. Greases

Castrol Spheerol API

Ronex MP

Retinax A No. 2

Mobil Grease JL 77 No. 2

Consistency 265-295

NLGI No. 2

Tellus oil T-32 Nuto H32 Castrol Hyspin AWS68

UNIVISN 22 Castrol Hyspin AWS32

Hydraulic oil 28 LP

SAE10W

Tellus oil 22

—

SAE5W

Hydraulic oils

• Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with the same brand at successive service intervals.

◆

SERVICE DATA: GENERAL

Fuel and Lubricant Specifications

SERVICE DATA: GENERAL

Weight of Major Components (Approximate) Component / Model

Counterweight Power train (Motor, transfer box, reduction gear and differential)

FBC15K FBC18K FBC18KL FBC20K FBC25K FBC25KE FBC25KL FBC30KFBC30KL 470(1036)

625(1378)

910(2006)

540(1190) 730(1609)

200 (441)

540(1190)

730(1609) 1060(2337)

215 (474)

Overhead guard

62.7 (138)

67.4 (149)

66.0 (146)

Rear axle

150 (331)

Mast (3.3 m simplex mast)

520 (1146)

725 (1598)

830 (1830)

Outer mast

140 (309)

190 (419)

205 (452)

Inner mast

135 (298)

180 (397)

190 (419)

Lift bracket (including backrest)

105 (231)

150 (331)

175 (386)

Forks (two)

80 (176)

130 (287)

165 (364)

Lift cylinder and related parts

60 (132)

75 (165)

95 (209)

Hydraulic motor

45 (99)

50 (110)

Traction motor

80 (176)

100 (220)

220 (485)

Unit: kg (lb)

10.31

SERVICE DATA: SPECIAL TOOLS

Special Service Tools Truck Models Ref. No.

Part No.

91268-00701

Part Name

Application

FBC

15K-18KL

20K-25KL

30K-30KL

Removal and installation of rear wheel nuts

●

91268-00300 Bevel pinion (or 91268-02100) puller

Removal of bevel pinion assembly

●

64309-11701

Gauge kit

Measurement of hydraulic pressure

●

91268-00800

Socket wrench

Removal/installation of front wheel hub nuts

●

03703-59001

Socket wrench

Removal/installation of front wheel hub nuts

●

—

91468-00300

Installer

Installation of front axle wheel bearing inner races

—

●

—

Socket wrench

94309-12300 7

91268-01500

Installer

Installation of rear axle inner bearing inner races

●

—

64309-40400

Installer

Installation of rear axle inner bearing inner races

—

●

91268-01400

Installer

Install rear axle outer bearing inner races

●

—

91268-00400

Installer

Install rear axle outer bearing inner races

—

●

64309-15411

Spring remover

Removal of return spring

●

64309-15412

Spring remover

Removal/installation of brake shoes

●

64309-15413

Spring hook

Installation of return spring

●

91268-10600

Steering wheel puller

Removal of steering wheel

●

91268-01600

Installer

Installation of tilt cylinder tube bushing

●

09305-00680

—

Remove / install tilt cylinder guide bushing

●

—

Hook wrench 09305-00750

—

●

—

09305-00800

—

●

64309-16300 or F4540-06300

Pipe connector

Measurement of control valve main relief pressure & overload relief pressure (to be used with 64309-17701 gauge kit)

●

97157-00100

Spring installer

Install centering spring in steer gear

●

64309-40100

Wheel puller

Removal of drive wheel hub

●

—

MH61017

Wheel puller

Removal of drive wheel hub

—

●

6V3965

Pressure Port

Main Relief Valve Pressure Check

●

97E67-00100

Transfer Bearing Removal of Bevel Pinion Shaft Tool

●

97E67-00200

Plug Assy Tool

●

10.32

Torque or Steer Gear Tank

SERVICE DATA: SPECIAL TOOLS

Special Tool Illustrations 2

M10 x 1.5

46 M14 x 1.5

164 95 250

17 10 22 155

91268-00701

91268-00300 91868-02100

91268-00800

64309-17701

5 90

91468-00300 64309-12300

03703-59001

91268-01500

64309-40400

10.33

SERVICE DATA: SPECIAL TOOLS 9

ø68

ø71

ø31

ø48

30 40 10 91468-00400

91268-01400

64309-15412

64309-15411

M12 X 1.25 M8 X 1.25

45 55

64309-15413

10.34

91268-10600

SERVICE DATA: SPECIAL TOOLS 16

ø35 ø32

45 Flame-hardened Hv >500, depth 2mm (0.08 in.)

09305-00680 09305-00750 09305-00800

91268-01600

64309-16300 F4540-06300

97157-00100

MH061017

64309-40100

6V3965

97E67-00100

97E67-00200

10.35

SERVICE DATA: GENERAL

Inspection Guide Check Antifriction bearings

For (item or defect)

How

ITEMS

Measure inside diameter with an indicator hole gauge and shaft outside diameter with an indicating micrometer

a) Fit on shaft b) Fit in housing

Measure outside diameter with an indicating micrometer and housing inside diameter with an indicator hole gauge

c) Preload (small initial load applied to absorb initial bearing deformation)

As stated in service manual

DEFECTS a) High running temperature (caused by over lubrication)

As shown

b) Noise (humming), vibration, or rough running

Radial bearing

c) Creep (marks of circumferential slip on inner ring’s surface in contact with shaft or on outer ring’s surface in contact with housing due to loose fit of bearing) d) Corrosion

e) True brineling (caused by careless installation or removal)

8609152

10.36

8609153

Visually

8609151

Thrust bearing

SERVICE DATA: GENERAL Check Antifriction bearings

For (item or defect)

How

f) False brineling (caused by a constant vibration or oscillation of non-rotating bearings through small arc)

Visually

8609154

g) Cracked race (caused by forcing bearing or oversize shaft or by cooking race when installing or removing)

Visually

8609155

h) Broken separator (caused by dirt, metal chips, or lack of lubricant)

Visually

8609156

i) Damaged seal (caused by improper use of tools)

Visually

8609157

j) Spalled race (caused by too loose a fit)

Visually

8609158

10.37

SERVICE DATA: GENERAL Check Antifriction bearings

For (item or defect)

How

k) Bad discoloration (caused by overheating due to poor lubrication)

Visually

8609159

i) Craters (caused by passage of electric current)

Visually

8609160

Bushings or sleeve bearings

ITEM Fit on shaft

DEFECTS Nicks, burrs, or other flaws on bearing surface

Fasteners

Gears

Determine by measuring inside diameter of bushing and outside diameter of shaft

Hold bushing toward a light and look through bore

DEFECTS a) Striped or otherwise damaged threads (bolts, nuts, screws, etc.)

Visually

b) Distortion or loss of tension (spring lock washers, snap rings, etc.)

Examine by compressing

ITEMS a) Fit on bearing, bushing, spline or key

As stated in service manual

b) Backlash

As stated in service manual

DEFECTS

10.38

a) Excessive wear on teeth, thrust faces, and end faces on hub

Visually

b) Scratching wear (caused by large particles other than associated with abrasive wear)

Visually

SERVICE DATA: GENERAL Check Gears

For (item or defect)

How

c) Abrasive wear (caused by fine particles carried in lubricant)

Visually

d) Overload wear

Visually

e) Pitting

Visually

f) Spalling

Visually

g) Overload breakage

Visually

h) Fatigue breakage

Visually

i) Corrosive wear

Visually

10.39

SERVICE DATA: GENERAL Check Keys and keyways Oil seals Roller chains and sprockets

How

For (item or defect) Wear on sides making parts not fit tightly

Examine by placing

Damage to lip

Visually

a) Wear on pins, bushings, rollers, and plates in each link tending to increase in pitch.

Visually

b) Wear on sprocket teeth

Visually

Chain load

Sprocket rotation New

Old 8609189

Rubber parts

Splines and serrations

Hardening or softening, swelling, tackiness, tearing, and deterioration due to aging

Visually

ITEM Fit DEFECTS a) Nicks, burrs, chips, etc.

Visually

b) Free movement (looseness) of mating splines

Examine

c) Excessive wear polish on sides (sliding fit splines)

Visually

d) Ridge or edge left between worn and unworn areas (sliding fit spline)

Visually

8609170

10.40

SERVICE DATA: GENERAL Check Springs

For (item or defect)

How

ITEMS

See specification

a) Type called for

Use a square

b) Squareness

8609171

c) Free length test

Examine

d) Test force DEFECTS a) Excessive clearance space between coils (compression springs) in free state

Visually

b) Any clearance space between coils (tension springs) in free state

8609172 8609173

c) Condition or ends or hooks

Visually

d) Cracks or breakage

Visually

10.41

TECHNICAL PUBLICATIONS FEEDBACK (Please Print)

Dealer name:

Submitted by:

Address:

P. O. Box:

City:

State:

Zip code:

Country:

The following discrepancy or omission has been discovered in: ❏

Operation & Maintenance Manual

❏

Option Bulletin

❏

Part List/Manual

❏

Special Instruction

❏

Service Manual

❏

Service Data manual

❏

Electronic Manual

❏

Other:

Publication #

Engine model #

Truck model #

Issue date #

Truck serial #

Page #

(Please print)

Explanation of discrepancy or omission:

Please fax or mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2121 W. Sam Houston Parkway N. Houston, Texas 77043-2305 Fax: 713-365-1616

Mitsubishi Caterpillar Forklift Europe B.V. Attn: Service Engineering P.O. Box 30171 1303 AC, Almere, The Netherlands Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Service Engineering No. 2 Tuas Avenue 20 Singapore 638818 Republic of Singapore Fax: 65-861-9277

Mitsubishi Forklift Trucks

Service Manual

FBC15K, FBC18K, FBC18KL, FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30K, FBC30KL Forklift Trucks

99759-73100

Service Manual GE SX Controls FBC15K, FBC18K, FBC18KL A3BC1-10200-up A3BC1-20200-up A3BC1-30200-up A3BC1-40200-up

FBC20K, FBC25K A3BC2-10200-up A3BC2-20200-up A3BC2-30200-up A3BC2-40200-up A3BC2-80200-up

FBC25KE, FBC25KL, FBC30K A3BC3-10200-up A3BC3-20200-up A3BC3-30200-up A3BC3-40200-up A3BC3-80200-up

FBC30KL A3BC4-40200-up

99759-74120

SAFETY PRECAUTIONS

Mitsubishi Forklift Trucks Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules and precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “CAUTION” or “WARNING” as shown below.

! WARNING The meaning of this “Safety Alert Symbol” is as follows: Attention! Become Alert! Your Safety is involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

Mitsubishi Caterpillar Forklift America Inc. (MCFA) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not allinclusive. If a tool, procedure, work method or operating technique not specifically recommended by Mitsubishi Caterpillar Forklift America Inc. (MCFA) is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Mitsubishi forklift truck dealers have the most current information available.

TABLE OF CONTENTS 1.

GENERAL INFORMATION & FEATURES Glossary............................................................................................................................... 1-1 Motor Options ...................................................................................................................... 1-5 Nameplate and Serial Number Locations............................................................................ 1-6 Features of the Control System........................................................................................... 1-7 Basics of Circuit Operation ................................................................................................. 1-8 Standard Display..................................................................................................................1-17 Premium Display..................................................................................................................1-18 Premium Display Set up Modes .........................................................................................1-19 Vehicle Monitoring System ..................................................................................................1-20 Traction Control Logic Flow Chart .......................................................................................1-21 General Maintenance Instructions .......................................................................................1-22 General Trouble Shooting Instructions ................................................................................1-24

2. PROGRAMMING Handset .............................................................................................................................. 2-1 Operation ............................................................................................................................. 2-2 GE Sentry Set-up Procedures ............................................................................................. 2-2 Set-up Procedures............................................................................................................... 2-2 Function Settings ................................................................................................................. 2-4 Controller Setup...................................................................................................................2-15 Traction Controller Settings ................................................................................................2-16 Accelerator Setup ................................................................................................................2-23 Pump Controller Settings.....................................................................................................2-25 Memory Maps ......................................................................................................................2-30 Speedometer Setup.............................................................................................................2-34

3. CHECKS & REPAIRS General Information ............................................................................................................. 3-1 Fuses .................................................................................................................................. 3-2 Exploded View of Contactor ................................................................................................ 3-3 Contactor Repair.................................................................................................................. 3-4 Truck Management Module ................................................................................................ 3-5 Thermal Transfer ................................................................................................................. 3-6 Traction Control ...................................................................................................................3-10 Trouble Shooting Tips (Motors) ..........................................................................................3-11 Unsatisfactory Brush Performance .....................................................................................3-12 Commutator Surfaces Conditions........................................................................................3-18

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM SX Control ........................................................................................................................... 4-1 Failures that Cause Reduced or No Motor Torque ............................................................. 4-2 Misoperation of Other Features .......................................................................................... 4-5

TABLE OF CONTENTS 5. WIRING Traction Bypass with Pump Contactor Schematic ............................................................... 5-1 Pump Contactor Schematic.................................................................................................. 5-3 Traction Bypass with Pump Contactor Schematic ............................................................... 5-5 Traction Bypass with Pump Control Schematic ................................................................... 5-7 Pump Control Schematic...................................................................................................... 5-9 Traction Motor Controller with Pump motor Controller and Bypass.....................................5-11 Voltage Checks.....................................................................................................................5-13 TMM7A (Truck Management Module) .................................................................................5-16 Pump Driver..........................................................................................................................5-18 Pump Time Delay ................................................................................................................5-19

6. DIAGNOSTIC STATUS CODES Basic Checks ....................................................................................................................... 6-1 Status Codes ........................................................................................................................ 6-2

GENERAL INFORMATION & FEATURES I 1.

GENERAL INFORMATION & FEATURES Glossary............................................................................................................................... 1-1 Motor Options ...................................................................................................................... 1-5 Nameplate and Serial Number Locations............................................................................ 1-6 Features of the Control System........................................................................................... 1-7 Basics of Circuit Operation ................................................................................................. 1-8 Display Standard. ................................................................................................................1-17 Display Premium..................................................................................................................1-18 Premium Display Set up Modes .........................................................................................1-19 Vehicle Monitoring System ..................................................................................................1-20 Traction Control Logic Flow Chart .......................................................................................1-21 General Maintenance Instructions .......................................................................................1-22 General Trouble Shooting Instructions ................................................................................1-24

GENERAL INFORMATION & FEATURES

Glossary Accelerator A device that converts mechanical movement into a voltage pattern to the logics for variable drive motor speed.

Bypass (1A) Contactor, Traction Switch that connects A2 traction motor cable to battery negative and bypasses the main power MOSFETs.

Activate A word used with a component or circuit. To change from the normal condition to the “activated” condition because of an application of force or electricity.

Capacitor Device used to store electrical energy for short periods of time. Also used in filtering voltage noise and electrical spikes. Cathode The negative (–) side of a diode.

Ammeter An electric meter used to measure current flow in amperes.

Circuit A way for current to go from the positive (+) side of an electrical power source to the negative (–) side of an electrical power source. This can be through wires and electrical components.

Ampere (or Amp) The unit of measure of current flow. The amount of current that one volt can push through a resistance of one ohm.

Closed Circuit Wiring or components in a circuit that have continuity.

Anode The positive (+) side of a diode. Armature The rotating portion of an electric motor or generator.

Coil A component made from many circles or turns of wire used to concentrate a magnetic field.

Battery Two or more cells connected together for a supply of electric current.

Commutator An armature component used to transfer current from the brushes to the armature windings.

BDI (Battery Discharge Indicator) An electrically controlled display showing the operator the state of battery charge.

Compound Motor A motor which has a field winding in series with the armature and a shunt field winding in parallel with the series winding and armature.

BJT (Bipolar Junction Transistor) A transistor that is used to control voltage going to a motor or other electrical device.

Conduct To allow the flow of current.

Brush A conductor, normally a block of carbon, that makes sliding contact between the stationary and moving part of the motor or generator. Bus Bar A heavy electrical conductor that carries high current from one point to another and to which other smaller wires are connected.

Conductor A material that provides a path for current flow. Connector Part if a wire assembly or harness that connects with another wire assembly or harness. Used for ease of assembly and disassembly. Contact Tips or Contacts The portion of a switch, relay or contactor where the circuit can be opened or closed.

1-1

GENERAL INFORMATION & FEATURES

Glossary Contactor Assembly An electrical component consisting of an electromagnetic coil and a set of heavy contact tips. Control current passes through the coil, building a magnetic field which closes or opens the contact tips.

Digital Signal A signal in which the elements may be either of two distinct values. For example high voltage, low voltage.

Contactor Coil An electromagnet used to close or open contact tips in a contactor assembly. Continuity Having the ability to allow current flow.

Diode A semiconductor device that allows current to flow in one direction, from the anode to the cathode. Display An electrical device that converts voltage inputs to a visual output. Drain Terminal of a MOSFET through which the main current flows.

Control Circuits The wires and components carrying low current used to signal the logics unit, turn on main components, or support auxiliary circuits (indicated by thin lines on a schematic). Counter Electromotive An opposing voltage set up by a collapsing or increasing magnetic field within a Force (CEMF) coil. Current The movement or flow of electricity through a conductor. A circuit must be complete for current to flow. Current Limit The maximum allowable current of a stalled drive motor. Current Sensor A hall-effect sensor in the motor circuit that produces an increasing voltage output as the motor current increases. Current Shunt A precision low-value resistor connected in series with the armature of a motor. The logics uses the measured voltage drop across the shunt to control maximum current allowed in selected power circuits. Deactivate To change from the activated condition back to the normal (deactivated) condition. It can be caused by the application of force, the removal of force, or the removal of electricity.

Electric Motor A device that changes electrical energy into mechanical energy to do work. Electrical Braking Electrically trying to rotate the drive motor opposite to the direction of truck movement. Electromagnet A coil of wire, most often wound on an iron core, which produces a strong magnetic filed when current is sent through the coil. Electromotive Force (EMF) The force that causes an electric current to flow in a circuit. This force is measured in volts. Field Effect Transistor (FET) A transistor in which the output current is varied by varying the value of an electric field within a region of the device. Field Windings The stationary coils that produce a magnetic field in motors and generators. Filter An electrical device or component for restriction or suppression of undesired voltage spikes.

1-2

GENERAL INFORMATION & FEATURES

Glossary Rotational Measure:

Fuse A component in an electrical circuit that will open the circuit if too much current goes through it.

HP = Torque X Speed 5252 • Torque in Foot - Pounds • Speed in revolutions per minute (RPM) • 5252 is a Constant

Gate Terminal of a MOSFET to which voltage is applied to turn the MOSFET on and off.

Indicator A lamp or LED that gives an indication of some vehicle condition when it turns on or flashes.

Generator A device that transforms non-electric energy (such as mechanical, thermal, etc...) into electrical energy.

Input A voltage change at the incoming connection of a component.

Grounded A wire or wires that are in contact with the metal chassis of the vehicle (ground). Can be caused by a loss of insulation from the wire, or by connecting the wire to the vehicle.

Insulator A material that has a very large resistance so that it will not let current flow through it.

Harness An assembly made of two or more wires that are held together.

LED Light Emitting Diode - a diode that emits light (lights) when current flows in the forward direction.

Heat Sink A mounting frame used for semiconductor cooling.

Logics or Logic Unit The main printed circuit board containing a microprocessor and circuits to condition the voltage signals that go into or come out of the logics. It electronically monitors and controls the truck’s functions.

Heat Sink Pad Thin metal sheet sandwiched between the heatsink of a controller and the frame of the truck used to better transfer the heat away from the controller.

Magnetic Field The area around a magnet where magnetic forces can be detected.

Hour Meter An electrically activated device used to record the amount of usage a truck receives.

Microprocessor A small computer chip preprogrammed to control the various electrical functions on a lift truck.

Horse Power A measure of the time-rate of doing work. 1 HP is defined as the equivalent of raising 33,000 pounds, one foot, in one minute.

MOSFET (Metal Oxide Semiconductor Field Effect Transistor) A fast switching transistor that is used to control voltage going to a motor or other electrical device.

Linear Measure: HP = Force X Distance 33,000 X Time

Normal Condition Words used with a switch or relay. Their normal condition is their condition when they are not controlled by the application of force, temperature, pressure, or electricity.

• Force in Pounds • Distance in Feet • Time in Minutes • 33,000 is a Constant

1-3

GENERAL INFORMATION & FEATURES

Glossary Surface Voltage or Charge Generally present just after the battery is unplugged from the charger.

Normally Closed (N.C.) A switch or relay whose contacts are closed in the normal condition.

Terminal An electrical connection point on an electrical component.

Normally Open (N.O.) A switch or relay whose contacts are open in the normal condition. OFF-Time The amount of time a current does not flow through a semiconductor.

Transistor A semiconductor device used as an electronic switch.

Ohm The unit of measurement of resistance. The amount of resistance that will let one volt push only one ampere of current through it, where R = E / I.

Torque The turning force or effect required to do work.

ON-Time The amount of time current flows through a transistor.

Torque = Force X Distance • Force in Pounds • Distance in Feet to center of rotation

Varistor An electrical filter that is usually terminated across the horn connections of a mechanical horn to eliminate voltage spikes when the horn is activated.

Open Circuit Wiring or components of a circuit that have no continuity.

Volt The unit of measurement of electromotive force. One volt is the force needed to make one ampere of current flow through one ohm of resistance in a circuit.

Optical Switch An electronic device made up of an infrared light signal generator and photosensitive signal receiver that changes an input digital voltage into an electrically isolated digital voltage output. Output The current flow from a component which initiated from a voltage change at the component’s input. PTC (Positive Thermal Coefficient Resistor) A resistor that is used in parallel with the tips of the line contactor to allow the main capacitors in the controller to charge quicker after the battery is plugged in. As the PTC conducts current, it heats up and its resistance increases. Each controller has an internal PTC that will slowly charge the main capacitors if the external PTC fails. Resistance Opposition to the flow of current in a circuit. The unit of electrical resistance is the OHM. The lower the resistance, the greater the current flow for a given voltage. Source Terminal of a MOSFET through which the main current flows. 1-4

Watt The unit of measurement of power. The amount of power used when one volt pushes one ampere of current through a resistance of one ohm. The result of amperes (current) multiplied by volts (voltage) is watts (power). Wire A conductor used to provide a path for current to flow to and from electrical components. Wiring Diagram A drawing using visual representation of components the way they actually look. It is used to show the locations of components and the connections between them. Zener Diode A special diode used to regulate voltage or as an overvoltage protector.

MOTOR OPTIONS MODEL

SERIAL #

TRACTION MTR

HYD PUMP MTR

FBC15K, FBC18K & FBC18KL

A3BC1-10200-up

6.62"

FBC15K, FBC18K & FBC18KL

A3BC1-20200-up

6.62"

FBC15K, FBC18K & FBC18KL

A3BC1-30200-up

FBC15K, FBC18K & FBC18KL

A3BC1-40200-up

FBC20/25K

A3BC2-10200-up

FBC20/25K

A3BC2-20200-up

11"

FBC20/25K

A3BC2-30200-up

FBC20/25K

A3BC2-40200-up

11"

FBC20/25K

A3BC2-80200-up

11"

FBC25KE/KL/30K

A3BC3-10200-up

FBC25KE/KL/30K

A3BC3-20200-up

11"

FBC25KE/KL/30K

A3BC3-30200-up

FBC25KE/KL/30K

A3BC3-40200-up

11"

FBC25KE/KL/30K

A3BC3-80200-up

11"

FBC30KL

A3BC4-40200-up

11"

1-5

GENERAL INFORMATION & FEATURES

Nameplate and Serial Number Locations

Nameplate Chassis Serial Number Mast Serial Number

Traction Motor Serial Number

Power Steering Motor Serial Number

Hydraulic Motor Serial Number

For Illustrative Purposes Only

Before Servicing Forklift Truck

! WARNING Before doing any maintenance or adjustments on the Forklift Truck, be sure to always use correct blocks to prevent the unit from rolling or falling. Raise the drive wheels off the ground. This can be done by tilting the mast all the way back, placing hard wood blocks under the mast then tilting the mast forward. Securely support with blocks. 1-6

◆ GE SX Control System Features The GE SX control monitors over seventy different system functions. Run-time fault conditions, when sensed, are indicated on the steering console display.

Mode/Fault Code Buttons

Fault Code Display Sequence When the truck key is switched off, the display shows truck hours, drive motor hours, and pump motor hours for four seconds each. At this point the mode buttons can be used to activate a display sequence of faults that caused the forklift truck to shut down. For details see instrument panels sections for both standard and premium displays.

Run-time Diagnostics

Mode/Fault Code Button

During truck start up or operation, a diagnostic code could appear on the display instead of the battery state of charge. If the GE SX Control System detects a problem, the ! symbol glows in the monitoring system action lights at the same time. The codes indicate an improper operating sequence or a defect in the truck electrical system.

Mode Buttons

Programmable Truck Operating Modes The GE SX Control System also allows users to modify how the truck operates for conditions where the truck is used. The operator can select from four operating modes.:

Run-time diagnostics cover the following areas of truck operation and protection:

1. Economy – slowest travel speed and acceleration. 2. Moderate – travel speed and acceleration somewhat slower than standard. 3. Standard – travel speed and acceleration suitable for the broadest range of applications. 4. High – Highest travel speed and acceleration.

• • • • • •

Drive motor and pump motor hours Service reminder hours Battery discharge level Motor brush wear (Premium Display Only) Stall protection Over-temperature protection of drive motor, pump motor, and the control panel • Brake fluid level

Each time the key is switched off then on again the controller remains in the previously selected mode. Operating Mode details differ depending on the display type. See the sections on Standard and Premium Instrument Panels for more information.

1-7

Basics of Circuit Operation Motor Characteristics Historically, most electric vehicles have relied on series motor designs because of their ability to produce very high levels of torque at low speeds. But, as the demand for high efficiency systems increases, i.e., systems that are more closely applied to customers’ specific torque requirements, shunt motors are now often being considered over series motors. In most applications, by independently controlling the field and armature currents in the separately excited motor, the best attributes of both the series and the shunt wound motors can be combined. As shown in from the typical performance curves of

to normal full load on level ground is less than 10%. For this reason, shunt motors are considered to be constant speed motors (Figure 2). In the separately excited motor, the motor is operated

STARTING CURRENT

FULL LOAD CURRENT

NO LOAD CURRENT

SPEED

ARMATURE CURRENT Figure 2

STARTING CURRENT

SPEED

FULL LOAD CURRENT

NO LOAD CURRENT

TORQUE

as a fixed field shunt motor in the normal running range. However, when additional torque is required, for example, to climb non-level terrain, such as ramps and the like, the field current is increased to provide the higher level of torque. In most cases, the armature to field ampere turn ratio can be very similar to that of a comparable size series motor (Figure 3.)

TORQUE

ARMATURE CURRENT Figure 1

Figure 1, the high torque at low speed characteristic of the series motor is evident.

STARTING CURRENT

FULL LOAD CURRENT

SPEED

NO LOAD CURRENT

In a shunt motor, the field is connected directly across the voltage source and is therefore independent of variations in load and armature current. If field strength is held constant, the torque developed will vary directly with the armature current. If the mechanical load on the motor increases, the motor slows down, reducing the back EMF (which depends on the speed, as well as the constant field strength). The reduced back EMF allows the armature current to increase, providing the greater torque needed to drive the increased mechanical load. If the mechanical load is decreased, the process reverses. The motor speed and the back EMF increase, while the armature current and the torque developed decrease. Thus, whenever the load changes, the speed changes also, until the motor is again in electrical balance.

TORQUE

ARMATURE CURRENT Figure 3

Aside from the constant horsepower characteristics described above, there are many other features that provide increased performance and lower cost. The following description provides a brief introduction to examples of some of these features.

In a shunt motor, the variation of speed from no load 1-8

Solid-State Reversing

Flexible System Application

The direction of armature rotation on a shunt motor is determined by the direction in which current flows through the field windings. Because the shunt motor field only typically requires about 10% of the armature current at full torque, it is normally cost effective to replace the double-pole, double-throw reversing contactor with a low power transistor H-Bridge circuit (Figure 4). By energizing the transistors in pairs, current can be

Because the shunt motor controller has the ability to control both the armature and field circuits independently, the system can normally be adjusted for maximum system efficiencies at certain operating parameters. Generally speaking, with the ability of independent field and armature, the motor performance curve can be maximized through proper control application.

LINE POS FUSE Q3

A1 + CAP

ARM Q2

A2 Q4

NEG Figure 4

made to flow in either direction in the field. The armature control circuit typically operates at 12KHZ to 15KHZ, a frequency range normally above human hearing. This high frequency coupled with the elimination of directional contactors, provides very quiet vehicle operation. The field control circuits typically operate at 2 KHZ. The line contactor is normally the only contactor required for the shunt motor traction circuit. This contactor is used for both pre-charge of the line capacitors and for emergency shut down of the motor circuit, in case of problems that would cause a full motor torque condition. The line can be energized and de-energized by the various logic combinations of the vehicle, i.e. activate on key, seat or start switch closure, and de-energize on time out of idle vehicle. Again, these options add to the quiet operation of the vehicle.

More Features with Fewer Components Field weakening with a series wound motor is accomplished by placing a resistor in parallel with the field winding of the motor. Bypassing some of the current flowing in the field into the resistor causes the field current to be less, or weakened. With the field weakened, the motor speed will increase, giving the effect of “overdrive”. To change the “overdrive speed”, it is necessary to change the resistor value. In a separately excited motor, independent control of the field current provides for infinite adjustments of “overdrive” levels, between motor base speed and maximum weak field. The desirability of this feature is enhanced by the elimination of the contactor and resistor required for field weakening with a series motor. With a separately excited motor, overhauling speed limit, or downhill speed, will also be more constant. By its nature, the shunt motor will try to maintain a constant speed downhill. This characteristic can be enhanced by increasing the field strength with the control. Overhauling load control works in just the opposite way of field weakening, armature rotation slows with the increase of current in the field. Regenerative braking (braking energy returned to the battery) may be accomplished completely with solidstate technology. The main advantage of regenerative braking is increased motor life. Motor current is reduced by 50% or more during braking while maintaining the same braking torque as electrical braking with a diode clamp around the armature. The lower current translates into longer brush life and reduced motor heating. Solid state regenerative braking also eliminates a power diode, current sensor and contactor from the circuit.

1-9

FEATURES OF SX FAMILY OF TRANSISTOR MOTOR CONTROLLERS

Handset. The C/L setting is based on the maximum thermal rating of the control. Because of the flyback current through Q2, the motor current is usually greater than battery current, except at 100% ON time.

Standard Operation With the accelerator at maximum ohms or volts, the creep speed can be adjusted by Function 2 of the Handset or a trimpot. The field control section allows the adjustment of the field weakening level in order to set the top speed of the motor. This top speed function (Minimum Field Current) is enabled when the armature current is less than the value set by Function 24 and the accelerator pedal is fully depressed. Top Speed can be adjusted by Function 7 of the Handset or a trimpot. The percent on-time has a range of approximately 0 to 100 percent. The SX controllers operate at a constant frequency and the percent on-time is controlled by the pulse width of the voltage / current applied to the motor circuits. Creep Speed With the accelerator at minimum volts, the creep speed can be adjusted by Function 2 of the Handset. At creep speed, the ON time can decrease to approximately 5%, with the OFF time at approximately 95%. At full transistor operation, this condition will be reversed (short OFF time, long ON time). This variation of ON and OFF time of the oscillator varies the voltage applied to the motor, thereby varying the speed of the motor for a given load. Control Acceleration This feature allows for adjustment of the rate of time it takes for the control to accelerate to 100% applied battery voltage to the motor on hard acceleration. Armature C/A is adjusted by Function 3 from 0.1 to 22 seconds.

Regenerative Braking to Zero Speed Slow down is accomplished when reversing direction by providing a small amount of retarding torque for deceleration. If the vehicle is moving, Q2 and the directional lever is ARM moved from one direction to the other, the regen signal is initiated. Once the regen signal Q1 has been initiated, the field curFigure 5 rent is increased (armature circuit shown in Figure 5). Armature current is regulated to the regen current limit as set by Function 9. As the vehicle slows down, the field current continues to increase, and transistor Q2 begins to chop. The field current will increase until it reaches a preset value set by Function 10, and transistor Q2 on-time will increase until it reaches 100% on-time. Once both of the above conditions have been met, and regen current limit can no longer be maintained, the braking function is canceled. The fields will then reverse, and the control reverts back to motoring. Part of the energy produced by the motor during regen is returned to the battery, and part is dumped in the motor as heat. Pedal Position Regenerative Braking

Current Limit This circuit monitors motor current by utilizing sensors in series with the armature and field windings. The information detected by the sensor is fed back to the card so that current may be limited to a pre-set value. If heavy load currents are detected, this circuit overrides the oscillator and limits the average current to a value set by Function 4 and Function 8 of the

This feature allows control of the stopping distance based on pedal position when there has been a “directional switch” change. Pedal position will reduce the regenerative current to as the accelerator is returned to the creep speed position. Maximum regenerative current is obtained with the accelerator in the top speed position.

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Auto Braking This feature is enabled by initiating a “neutral position” using either the directional switch or the accelerator switch. Once activated, Auto Braking operates similar to Pedal Position Regenerative Braking and is adjusted by using Function 21 of the Handset. Field Weakening This function allows the adjustment of the field weakening level in order to set the top speed of the motor. The function is enabled when the armature current is less than the value set by Function 24 and the accelerator pedal is fully depressed. It is important to note that this function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel, without the permission of MCFA Service Engineering. Speed Limits This feature provides a means to control speed by limiting motor volts utilizing three “adjustable speed limits. This motor volt limit regulates top speed of the transistor controller, but actual truck speed will vary at any set point depending on the loading of the vehicle. Each speed limit can be adjustable with the Handset using Functions 11, 12, and 13.

slowly down the grade when the accelerator or brake is released. Because the vehicle can gain significant speed during roll-back, the torque needed to re-start on the ramp is lower than an unrestricted roll-back speed. Steer Pump Contactor Time Delay This feature provides two options for SP time delay. Option 1 provides a 0.5 to 63 second time delayed drop out of the steer pump contactor when the Forward or Reverse directional switch is opened. This is the default option for function 18. This Option 1 is overridden by a 1.5 second time delayed drop out whenever the seat switch is opened. Option 2 provides a 0.5 to 63 second time delayed drop out of the SP contactor when the seat switch is opened. Static Return to Off (SRO) This inherent feature of the control is designed to require the driver to return the directional lever to the neutral position anytime he leaves the vehicle and returns. Additionally, if the seat switch or key switch is opened, the control shuts off and cannot be restarted until the directional lever is returned to neutral. A time delay of approximately 2 seconds is built into the seat switch input to allow momentary opening of the seat switch, if a bump is encountered.

Accelerator Volts Hold Off Ramp Start This feature provides maximum control torque to restart a vehicle on an incline. The memory for this function is the directional switch. When stopping on an incline, the directional switch must be left in its original or neutral position to allow the control to initiate full power when restarted. The accelerator potentiometer input will modulate ramp start current.

This feature checks the voltage level at the accelerator input whenever the key switch or seat switch is activated. If, at start up, the accelerator is calling for more than 20% of full speed, the control will not operate. This feature assures that the control is calling for low speed operation at start up.

Roll-Back Control This feature provides retarding torque to limit rollback speed in the non-travel direction when the accelerator pedal is released when stopping on a grade, or when the brake pedal is released when starting on a grade. This feature forces the vehicle to roll very

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Pulse Monitor Trip (PMT)

Systems Diagnostics

The PMT design contains three features which shut down, or lock out, control operation if a fault conditions occurs that would cause a disruption of normal vehicle operation:

The control detects the system’s present operating status and can be displayed to either the Dash Display or the Handset. There are currently over 70 status codes that are available with SX systems using Traction and Pump controls and Truck Management Module (TMM). Along with the status code display from the TMM, the SX control is capable of reducing the current to the motor, alerting the operator of a critical fault condition.

• Look ahead • Look again • Automatic look again and reset The PMT circuit will not allow the control to start under the following conditions:

Standard Status Codes • The control monitors both armature and field FET’s at start-up and during running. • The control will not allow the line contactor to close at start-up, or will drop it out during running, if either the armature or field FET’s are defective, so as to cause uncontrolled truck movement. Thermal Protector (TP) This temperature sensitive device is mounted to the heat sink of the power transistor (Q1). If the transistor’s temperature begins to exceed the design limits, the thermal protector will lower the maximum current limit, and maintain the transistors within their temperature limits. Even at a reduced current limit, the vehicle will normally be able to reach sufficient speed. As the control cools, the thermal protector will automatically reset, returning the control to full power.

The SX traction control has over 30 Status Codes that assist the service technician and operator in trouble shooting the vehicle. If mis-operation of the vehicle occurs, a status code will be displayed on the Dash Display for vehicles so equipped, or be available by plugging the Handset into the “P2 or P4” plug of the logic card. With the status code number, follow the procedures outlined in DIAGNOSTIC STATUS CODES to determine the problem and a solution. Note: The Status Code Instruction Sheets do not claim to cover all possible causes of the display of a “status code”. They do provide instructions for checking the most direct inputs that can cause status codes to appear. Stored Status Codes

Low Voltage Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at the control terminals. The SX control is designed for use down to 50 percent of a nominal battery voltage of 36-84 volts, and 75 percent of a nominal battery voltage of 24 volts. Lower battery voltage may cause the control to operate improperly, however, the resulting PMT should open the Line contactor, in the event of a failure.

This feature records the last 16 “Stored Status Codes” that have caused a PMT controller shut down and/or disrupted normal vehicle operation. (PMT type faults are reset by cycling the key switch). These status codes, along with the corresponding BDI and hourmeter readings, can be accessed with the Handset, or by using the RS 232 communications port and dumping the information to a Personal Computer terminal.

Hourmeter Readings This feature will display the recorded hours of use of the traction and pump control or contactor to the Dash Display each time the key switch is turned off.

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Maintenance Alert & Speed Limit This feature is used to display Status Code 99 and/or activate a speed limit when the vehicle operating hours match the hours set into the maintenance alert register. This feature is set with the Handset using Functions 19 and 20. The operator is alerted that maintenance on the vehicle is required. This function can be disabled be setting functions 19 & 20 to a value of 255. Battery Discharge Indication (BDI) The latest in microprocessor technology is used to provide accurate battery state of charge information and to supply passive and active warning signals to the vehicle operator. Features and functions: • Displays 100 to 0 percent charge. • Display blinks with 20% charge. Disables pump circuit with 10% charge. Auto ranging for 36/48 volt operation. Adjustable for use on 24 to 80 volts.

tactor coils. On command from the control card, these drivers initiate opening and closing the contactor coils. All driver modules are equipped with reverse battery protection, such that, if the battery is connected incorrectly, the contactors can not be closed electrically. Truck Management Module (TMM) The Truck Management Module is a multifunction accessory card, or an integral function of the GE Pump controls when used with the SX Traction control. The Module provides the OEM the ability to initiate status codes or operator warning codes to be displayed on the Dash Display, whenever a normally open switch or sensor wire provides a signal to the Module. The TMM Module can be used to display a separate status code indicating over-temperature of traction motors, hydraulic motors, or any other device or system that can activate a switch that closes.

Internal Resistance Compensation The TMM Module can also be used as a Brush Wear Indicator (BWI). The Brush Wear Indicator is designed to detect a “worn out brush” and display a fault code on the Dash Display to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface.

This feature is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI. Improper adjustment can cause the battery to be over discharged.

Display Modes The Dash Display allows the operator to select the best vehicle performance for changing application (task) conditions. There are four (4) modes that can be selected by depressing a push button on the dash display.(SEE SECTION ON DISPLAY) From the Display, the operator may select any of four pre-set interactive modes consisting of (4) Controlled Acceleration levels, (4) Auto Regen levels, (4) Lever Regen Levels and (4) Speed Limits. These interactive modes are “pre-set” using the Handset (Functions 48-63) or a personal computer (Functions 97-112). This feature allows the operator to select the best vehicle performance for changing application (task) conditions.

Circuit Board Coil Driver Modules Coil drivers are internal to the control card, and are the power devices that operate the Line and SP con-

Hydraulic Pump Control This hydraulic motor controller consists of the following features: • Four speeds, adjustable from 0 to 100% motor volts. Fixed speeds actuated by switch closure to negative. • Current limit and controlled acceleration adjustable. • Battery Discharge Indicator interrupt compatible. Operation of voltage regulator card: This card provides the basic functions required for controlling the pump control, optional contactors, and PMT functions. Battery positive is applied through a main control fuse to the key switch, energizing the control card power supply input to P1. When a pump line contactor (PL) is used, PMT operation is the same as outlined for the traction controllers.

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The four speed (motor volts) reference points P12, P19, P20 and P21 are selected by connecting these points independently to battery negative. The speed for the Auxiliary functions (Aux1/Aux2) is obtained by closing speed limit 1(SL1) at P1-12 to control negative. SL1 is adjustable by Function 11 using the Handset to adjust motor voltage from 0 to 100%. The specified motor volts will be regulated, however, the magnitude of motor current will vary depending on the loading of the vehicle. The speed for the first lift function (Lift0) is obtained by closing Speed Limit 2 (SL2) at P1-19 to control negative. SL2 is adjusted using the Handset and Function 12, similar to SL1. The speed for the tilt function (Tilt) is obtained by closing speed limit 3 (SL3) at P1-20 to control negative. SL3 is adjusted using the Handset and Function 13, similar to SL1. The speed for the second Lift function (Lift 1) is obtained by closing speed limit 4 (SL4) at P1-21 to control negative. SL4 is adjusted using the Handset and Function 14, similar to SL1. If more than one Speed Limit is activated, the selected speed with the highest motor volts will override the low motor volt speed. The current limit circuit is adjustable and operates the same as the traction current limit. The controlled acceleration circuit is adjustable and operates the same as the traction circuit. Adjustment range is from 0.1 to 22.0 seconds. The Battery Discharge Indicator (BDI) interrupt will disable the hydraulic controller if the connection at P10 loses the 12 volt signal from the traction control. BDI interrupt can be disabled by Function 17 using the Handset. Select card type with or without BDI function.

1-14

GE Information for Separately Excited Controls Example: Part Number: Argument Number:

IC3645 01

Argument 01:

Basic Electric Vehicle Control Number

Argument 02:

Control Type: SP SH SR

Argument 03:

Argument 07:

33 05

2 06

C3 07

Series Control (Pump) Separately Excited Control (Plugging) Separately Excited Control (Regen to Zero)

= = = =

120 volts 24 volts 36 volts 72/80 volts

4 5 6

6.86" 6.86" 8.66" 8.66"

6.67" 8.15" 8.13" 10.83"

= = =

= = = =

X X X X

Armature Current (2 characters) 22 33 40 etc.

Argument 06:

D 04

Package Size: D R U W

Argument 05:

= = =

4 03

Operating Voltage: 1 2 3 7

Argument 04:

SE 02

= = =

Field Current (1 character) 2 = 3 = 4 = etc.

220 Amps 330 Amps 400 Amps

20 Amps 30 Amps 40 Amps

Customer / Revision A1 B1 etc.

= =

Customer A / Revision 1 Customer B / Revision 1

1-15

48 volts 36/48 volts 24/36 volts

Standard Display Operation:

Premium Display Operation:

All segments on the display should turn on and the Vehicle Monitoring System Action Lights should light in a left to right chaser pattern. Then the seat belt icon should flash for 10 seconds (regardless of whether the seat belt is fastened or not). The 7-segment display should show the currently selected operating mode level, L1 through L4.

All segments on the LCD display and the Vehicle Monitoring System Action Lights should light in a chaser pattern from left to right. The seat belt icon should flash for 10 seconds (regardless of whether the seat belt is fastened or not). The time display area should show the currently selected operating mode for the drive motor controller and pump motor controller, D1-4 and P1-4.

The 7-segment display should read the battery state of charge in percentage format. This is a numeric value between zero and one hundred using the 3 rightmost digits.

The battery charge display area should show the battery state of charge, and the time display area should display either the time or date, whichever is selected.

NOTE: When the battery reaches a 20% state of charge the battery action light will flash continuously. At 10% charge the light remains on.

For both the Premium and Standard display options: If the display shows a fault code instead of the battery state of charge, this means a run-time fault has been detected. The fault must be corrected before you use the the forklift truck. See the sections on the Premium and Standard Displays for more information on run time fault codes.

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STANDARD DISPLAY Battery Discharge Indicator/ Hour Meter/Fault Code Indicator (for Run-time Diagnostics)

Monitoring System Action Lights

Mode/Fault History Button

Battery Discharge Indicator The 7-segment Light-Emitting Diode (LED) numeric display indicates the percentage of battery charge. When the number “100” appears, the battery is fully charged. Hour Meter Immediately after the key is turned to the off position, the numeric display enters the Hour Display Mode for 12 seconds. Truck hours, drive motor hours, and pump motor hours are consecutively displayed for 4 seconds each. Once the Hour Meter display cycle is complete, the display goes blank and enters Silent Mode. Mode/ Fault History Button Press and hold this button with the key switch on, to access the performance mode. For the first 2 seconds the button is held, the current operating mode will be displayed in “Lx” format using the 2 right most digits, where “x” is a numeric value between one and four. If the performance mode received from the controller is outside this range, the mode is displayed as “L=”. If the mode cannot be read at all, the mode is displayed as “LC”. Continuing to hold the button will cycle the display through the 4 performance levels. To select a new mode, release the button when the desired mode is displayed. This button is also used to access and navigate History Mode. History Mode While in Silent Mode, the user can access the history of the last 16 truck fault codes by pressing and holding the Mode/fault History Button. Unit behavior is then dependent on whether the truck is equipped with a pump controller or not. If equipped with the pump controller, hold the button cycles through a display of “d”, “P”, and a blank screen. Releasing the button on the “d” or “P” accesses the history folder for either the drive controller or pump controller respectively. If the Drive Controller History folder is select-

ed, the fault code, battery state of charge, and truck power steering pump hours are displayed for 3 seconds each. If the Pump Controller History Folder is selected, the display cycles through the fault code and pump controller hours for three seconds each. Pressing the Mode/fault History Button cycles the display to the next fault. The displayed item blinks briefly (to acknowledge the button having been depressed) before changing to the next fault. Releasing the button when the display is blank or turning the key switch to the on position, exits History Mode. If a pump controller is not installed, holding the button switches the display between “d” and a blank screen. Accessing the history folder for the drive controller and exiting History Mode require the same actions as if the unit was equipped with a pump controller. Fault Code Indicator A fault code will be displayed if a run-time fault is detected by the monitoring system. In addition, the Fault Code Indicator will light. A drive controller fault is displayed in an “-xx” format(where “x” is a number from 0 to 9). A pump controller fault is displayed in a “-1xx” format. If the fault code received is out of range “===” is displayed. Monitoring System Action Lights These symbols light when specific problems are detected. The truck should be stopped and corrective action should be taken immediately. These lights are identical for both the Standard and Premium Instrument Panels and will be detailed later.

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◆ Premium Display Drive Motor Icon Pump Motor Icon

Brush Wear Indicator

Battery Discharge Indicator Speed Display/Performance Mode Indicator/ Fault Code Indicator Truck Icon Monitoring System Action Lights History/Date/ Time Display Right Mode Button

Left Mode Button

Battery Discharge Indicator The Battery Charge Display Area shows the current battery state of charge on its bar graph in 10% increments. Time Display The Time Display Area can either show the time or date. Simultaneously depressing both Mode Buttons will switch the display between the time and date. For details on how to set the time and date see the Setup Mode section. Speed Display The Speed Display Area shows the current speed in either MPH or KPH depending on the unit mode. The appropriate MPH or KPH symbol is also lit to indicate which mode is active. For details on how to select a desired system of units, see the Setup Mode section.

Hour Meter Immediately after the key is turned to the off position, the numeric display enters the Hour Display Mode for 12 seconds. Truck hours, drive motor hours, and pump motor hours are consecutively displayed along with their corresponding icon for 4 seconds each. History Display After the hour display cycle is complete the truck enters Silent Mode. No activity is shown on the display or indicators when the truck is in this mode. By pressing the left or right buttons, History Display can be accessed for either the drive motor control or the pump motor control respectively. The corresponding motor icon illuminates to indicate which history folder is being accessed. Regardless of which is accessed, the display behaves the same way. The Speed Display Area displays the most recent fault code. The time display area cycles through 4 different items: battery state of charge, truck or pump hours, time, and date of the displayed fault. Pressing either button will cycle to the next fault in the history folder, and the display will blink briefly each time a button is pressed.

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◆ Premium Display continued Start-Up Once the key is turned on, the display enters a self test mode. All segments on the Liquid Crystal Display (LCD) and indicators are turned on in a left-to-right chaser pattern. After the self test is complete, the seat belt light will blink for 10 seconds regardless of whether the seat belt is fastened. Also, the currently selected drive controller and pump controller performance modes are displayed in an “dx_Py” format where “x” and “y” are numeric values between 1 and 4. If the performance mode information from either controller is outside of this range, “=” will be displayed instead of a number. If the performance mode information cannot be read, “dC” or “PC” will be displayed. Left Mode Button Pressing this button accesses the drive performance display mode. The drive motor icon illuminates and the current drive motor mode is displayed in the Speed Display Area. Pressing this button a second time within 4 seconds accesses the pump performance display mode and lights the pump motor icon. To return to normal operating mode press this button again. After 4 seconds, the performance display mode is exited automatically if no other buttons are depressed. This button also has several other functions described in other sections. Right Mode Button This button allows the user to change the current performance mode. By holding down this button while in either the drive performance display mode or pump performance display mode the unit will cycle through each available mode. Releasing the button while the desired mode is displayed will switch the unit to that mode. This button has several other functions described in other sections. Fault Code Indicator A fault code will be displayed in the Speed Display Area if a run-time fault is detected by the monitoring system. In addition, the Fault Code Indicator and any applicable icons will light.

Setup Modes Setup Mode is accessed by pressing both mode buttons simultaneously while the display is in Silent Mode. If the buttons are released within 10 seconds, Regular Setup Mode is accessed. If the buttons are held for longer than 10 seconds, the display blanks for 5 seconds and then enters Speed Sensor Setup Mode. In Regular Setup Mode the units system (imperial or metric) and the date and time can be set. Pressing the right button toggles between metric (indicated by KPH icon) and imperial (MPH icon). Pressing the left button selects the currently flashing mode and advances to the time setup mode. The time is displayed in the Time Display Area with the hours flashing. The right mode button changes the hour and the left mode button accepts the currently displayed hour. The minutes will then flash and can be set in the same manner. AM and PM are set next if the unit is in imperial mode. Once the time is set, the display switches to the current date. Date setup is identical to time setup, cycling through year, month, and day respectively. To exit Regular Setup Mode, press both the left and right buttons simultaneously. In Speed Sensor Setup Mode the current speed sensor setting flashes in the Speed Display Area. To scroll through the available speed settings, press and release the right mode button. Press the left mode button when the desired speed setting is displayed. The selected setting will stop flashing and both mode buttons must then be depressed to select the setting. The Speed Sensor mode must be adjusted according to the gear ratio and tire diameter. Settings 1 through 12 are for the 2 or 3 ton gear ratio and settings 14 through 25 are for the 1 ton gear ratio. If the truck has new, standard tires with no wear yet, a setting of 5 should be used on 2 or 3 ton trucks and a setting of 18 should be used on 1 ton trucks. Brush Wear Indicator Icon This icon lights if the system detects that either the drive or pump motor brushes are worn and need to be replaced. The corresponding motor icon (drive or pump) is illuminated with this icon.

Monitoring System Action Lights These symbols light when specific problems are detected. The truck should be stopped and corrective action should be taken immediately. These lights are identical for both the Standard and Premium Instrument Panels and are detailed following the Standard Instrument Panel section of this manual.

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◆ Vehicle Monitoring System – Action Lights

1. Service Due Action Light The wrench symbol lights when it is time for planned maintenance. The maintenance interval can be programmed into the GE SX Control System tp provide reduced drive performance when activated. 2. Seat Belt Warning Action Light The seat belt symbol flashes for the first 10 seconds after the key is turned on regardless of whether the seatbelt is fastened. 3. Over Temperature Action Light The thermometer symbol glows if an over-temperature condition develops in the drive motor, pump motor, or the controller. Reduced truck drive performance can be programmed into the GE SX Control System.

5. Brake Fluid Action Light The brake fluid symbol lights if the brake fluid reaches a predetermined low level. 6. Park Brake Action Light The park brake symbol lights when the park brake is applied. Do not drive the forklift truck with the park brake applied. 7. Fault Detection Light The fault code symbol lights whenever a fault code is being displayed. When some faults are detected, the truck shuts downs and cannot be operated until the cause of the fault is repaired.

4. Battery Charge Action Light The battery symbol flashes if the battery reaches the 20% charge level. If the charge level drops below 10%, the symbol glows solid. Reduced truck drive and/or lift performance can be programmed into the GE SX Control System.

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GENERAL INFORMATION & FEATURES

Traction Control Logic Flow Chart For Normal Operating Conditions Connect Battery

Battery Positive @ P1-1

Close Key Switch

Battery Positive @ P1-2

Close Seat Switch

Line contactor closes and battery positive @ control P, A1, A2 and F1 Circuit is energized to allow inputs from direction lever and accelerator

Select forward or reverse

Power Steer contactor closes

Depress accelerator which closes accelerator start switch

Voltage from accelerator potentiometer is applied to controller

The appropriate H-bridge transistors are turned on to apply voltage to the field

Q1 transistor turns on and voltage is applied to the armature

Truck moves in chosen direction

1-21

80 percent discharged with periodic equalizing charges.

General Maintenance Instructions The transistor control, like all electrical apparati, does have some thermal losses. The semiconductor junctions have finite temperature limits, above which these devices may be damaged. For these reasons, normal maintenance should guard against any action which will expose the components to excessive heat and/or those conditions which will reduce the heat dissipating ability of the control, such as restricting air flow. The following Do’s and Don’t’s should be observed: Any controls that will be applied in ambient temperatures over 100° F (40° C) should be brought to the attention of MCFA Service Engineering.

Visual inspection of GE contactors contained in the traction and pump systems is recommended to occur during every 160 hours of vehicle operation. Inspection is recommended to verify that the contactors are not binding and that the tips are intact and free of contaminants. It is not recommend that any type of welding be performed on the vehicle after the installation of the control(s) in the vehicle. MCFA will not honor control failures during the warranty period when such failures are attributed to welding while the control is installed in the vehicle. Cabling for Vehicle Retrofits

All external components having inductive coils must be filtered. Refer to vehicle manufacturer for specifications.

If an additional control or electronic device is added to the vehicle in the field, only MCFA recommended wires and cables should be used.

The wiring should not be directly steam cleaned. In dusty areas, blow low-pressure air over the control to remove dust. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash the control, and then low-pressure air should be used to completely dry the control. For the control to be most effective, it must be mounted against the frame of the vehicle. The metal vehicle frame, acting as an additional heat sink, will give improved vehicle performance by keeping the control package cooler. Apply a thin layer of heattransfer grease such as Dow Corning 340, and a metal heatsink pad between the control heat sink and the vehicle frame.

RF Interference To prevent radio frequency (RF) interference, care should be taken in routing power cables in the vicinity of radio-controlled devices. Suppression Unless specifically noted otherwise, suppression (for example, a snubber) is required on all inductive devices. This suppression minimizes noise and prevents damage caused by electrical surges.

Control wire plugs and other exposed transistor control parts should be kept free of dirt and paint that might change the effective resistance between points. CAUTION: Electric braking should not be used when the vehicle is jacked up and the drive wheels are in a free wheeling position. The higher motor speeds can create excessive voltages that can be harmful to the control. Do not hipot (or megger) the control. Use a lead-acid battery with the voltage and ampere hour rating specified for the vehicle. Follow normal battery maintenance procedures, recharging before 1-22

Recommended Lubrication of Pins and Sockets Prior to Installation 1. Disconnect plug from controller or mating plug. WARNING: Before conducting maintenance on the vehicle, jack up the drive wheels, disconnect the battery and discharge the capacitors. To discharge the capacitors, connect a 150 ohm, 25 watt resistor (Part No. 358280) between the positive and negative terminals on the control panel for at least 20 seconds.

2. Locate the plug that contains the socket (female) terminals. Maintenance needs only to be per formed on the plug containing the socket (female) type terminals. Reconnecting the plugs will lubricate the pin (male) terminals. 3. Clean each terminal using contact cleaner as shown in Figure 1.

Cleaner and lubricant are provided in the terminal maintenance kit SE000003. Fretting occurs during microscopic movement at the contact points of the connection. This movement exposes the base metal of the connector pin which, when oxygen is present, allows oxidation to occur. Sufficient build up of the oxidation can cause intermittent contact and intermittent vehicle operation. This can occur at any similar type of connection, whether at the control or in any associated vehicle wiring, and the resultant intermittent contact can provide the same fault indication as actual component failure. The addition of lubricant will prevent the oxidation process by eliminating the access of oxygen to the contact point. Add this lubricant to the 12 pin and 23 pin plugs of all new SX controls at the time of their installation into a vehicle

t ac

t cl

ean

r ane C le

c on

Figure 1 4. Lubricate each terminal using lubricant as shown in figure 2. Apply enough lubricant to each terminal opening to completely fill each opening to a depth of .125" minimum.

A IC R T N

New and re-manufactured control plugs are cleaned and lubricated prior to shipment from the factory. However, in applications where severe vibration or high temperature cycling and excessive humidity, such as freezers are present, it is recommended that the plug terminals be cleaned and lubricated every year, per these instructions. In normal applications, plug maintenance should be performed every two years, unless intermittent problems arise with the plugs, requiring more immediate attention. Warning: Do not use any other cleaners or lubricants other than the ones specified.

B LU

When servicing existing vehicles exhibiting symptoms of intermittent mis-operation or shutdown by the control, add this lubricant to all 12 and 23 pin plugs, after proper cleaning of the connectors, as a preventative measure to insure fretting is not an issue before control replacement. Also, for long term reliable control operation, the plug terminals must be maintained per these instructions with the recommended contact cleaner and lubricant which provides a high degree of environmental and fretting protection.

Figure 2 5. Reconnect plugs.

1-23

General Troubleshooting Instructions

Tools and test equipment required are: clip leads, volt-ohm meter (20,000 ohms per volt) and basic hand tools.

Trouble-shooting the SX control should be quick and easy when following the instructions outlined in the status code instruction sheets.

BDI Operation: BDI is only monitored by the GE Traction controller, not the pump controller. The separate pump controller has no way of tracking the charge of battery. In order to tell the truck display what the state of charge of the battery is so that it can show the operator, the traction controller uses a specific algorithm to more accurately determine the voltage on the battery. The information that is sent to the display is just a percentage value, but this percentage is linked to a specific battery voltage by the controller.

! WARNING Before trouble-shooting, jack up the drive wheels, disconnect the battery and discharge the capacitors. Capacitors should be discharged by connecting a 150 ohm, 25 watt resistor (Part No 358280) between the positive and negative terminals on the control panel for at least 20 seconds. Reconnect the battery as needed for specific checks. If mis-operation of the vehicle occurs, a status code will be displayed on the Dash Display or made available by plugging a Handset into the plug P2 location, and then reading the status code. Note: Status code numbers from 00 to 99 are traction control status codes. Status codes with the prefix 1 (101 to 199) are pump control status codes. With the status code number, follow the procedures outlined in the status code instruction sheets to determine the problem. Important Note: Due to the interaction of the controller with all vehicle functions, almost any status code or control fault could be caused by the controller. After all other status code procedures have been followed and no problem is found, the controller should then be replaced as the last option to correct the problem. The same device designations have been maintained on different controls but the wire numbers may vary. Refer to the schematic for your specific control. The wire numbers shown on the schematic will have identical numbers on the corresponding wiring diagrams for a specific vehicle. Check resistance on R x 1000 scale from frame to power and control terminals. A resistance of less than 20,000 ohms can cause misleading symptoms. Resistance less than 1000 ohms should be corrected first. Before proceeding, visually check for loose wiring, mis-aligned linkage to the accelerator switch, signs of overheating of components, etc.

The GE controller uses a value of 2.14 volts per cell or higher to indicate a fully charged battery (100%) and a value of 1.94 volts per cell or lower to indicate a fully discharged battery (0%). As an example, a 36V battery with 18 cells would have a fully charged voltage of 38.52V and a fully discharged voltage to a percentage value that is then sent to the display. The controller must know how many cells are present to properly make this association, so there is a setting (setting number 15) that can be adjusted to do this. Because the voltage difference is great enough between a 36V and 48V battery, there is a value that setting number 15 can be set to that allows the controller to determine which of these two voltages is connected. If this setting is used, the controller can sometimes be fooled by a 36V battery with a high surface voltage (generally present just after the battery is unplugged from the charger) or an over discharged 48V battery. Another problem can arise if a battery is plugged into the truck that has a different voltage than the previous battery, without letting the head capacitors in the controller discharge. Until the capacitors completely discharged, the controller still holds memory of the voltage of the first battery and will not automatically adjust to the new particular voltage of the battery to be used in the truck. Whenever the controller is powered up and the key switch is turned on after having the capacitors completely discharged, the controller must start with a new battery discharge level based on the voltage that is measured at that time. This discharged voltage is stored and sent to the display to be shown to the operator.

1-24

Once the controller knows how many cells the battery should have and the current discharge state of the battery, it must then start taking samples of the battery voltage to monitor any changes in the battery’s state of charge. These samples are taken only during operation of the traction motor by the traction controller and only when the current in the traction motor is between 50 amps and 400 amps. Each sample is at least 4 seconds apart. As the values of the sample voltages start changing, the controller waits until the measured voltage value is lower than the stored voltage value 6 times in a row before it will decrement the stored battery state of charge by 1%. This means that it will take a minimum of 4 minutes for the BDI to drop 10% Function 14 Setting: In order for the controller to know what the true state of discharge of the battery is by measuring the voltage while the battery is supplying current, there must be a relationship established that will give the static voltage of the battery based on the voltage of the battery under a load. This relationship is based on the internal resistance of the battery and can vary between different batteries based on battery quality, capacity and voltage. This compensation factor can be adjusted using setting 14 in the GE traction controller.

are at least 100 amps apart and extrapolate. The voltage drop that is given in the function 14 table is based on how much the voltage with battery current is assumed to be linear, so once the current and voltage are known for any 2 points, any third point on the same line can be calculated. If the third point is chosen as being exactly 100 amps above or below one of the other points, then the voltage difference between should work for the function 14 table. Example: Operated unloaded lift>36.5V on the battery with 120 amps out of the battery Operated loaded lift>34.4V on the battery with 275 amps out of the battery Find the voltage difference (X) for a current difference of 100 amps. Slope= voltage difference / current difference = (36.534.4)/(275-120) = 0.0135 = X / 100 X = 0.0135 * 100 = 1.35 Since 1.35 is between a setting of 16 (1.43) and 17 (1.34), choose the higher setting (17) to be sure that the battery is not over-discharged.

See Function 14 in the Handset section, there is a table titled Internal Resistance Compensation Table. This table gives the appropriate setting for a given voltage drop. This voltage drop value is the difference between the voltage on the battery while providing 0 amps of current (static voltage) and the voltage on the battery while providing 100 amps of currents. From this given voltage, the logic in the controller can determine the static voltage of the battery when the traction motor current is at any value between 50 amps and 400 amps.

The setting for function 14 should be adjusted for each different battery that is used in a truck to insure the proper amount of discharge per cycle. If a battery is still not being discharged properly (over or under discharged), even after properly adjusting function 14, the function 14 setting can be raised to decrease the depth of discharge or lowered to increase the depth of discharge.

To obtain the correct voltage drop for the function 14 table, the battery voltage when the battery current is 100 amps can be subtracted from the static battery voltage. A true static voltage of the battery can be difficult to obtain if there is some surface charge still on the battery right after charging or if the battery voltage is still rising after heavy usage. In addition, getting the current to be exactly 100 amps out if the battery can be difficult as well. Because getting this information is difficult, it can sometimes cause the voltage measurement to be off by as much as a couple of volts. A simpler method of obtaining the correct values that 1-25

PROGRAMMING 2. PROGRAMMING Handset .............................................................................................................................. 2-1 Operation ............................................................................................................................. 2-2 GE Sentry Set-up Procedures ............................................................................................. 2-2 Function Settings ................................................................................................................. 2-4 Controller Setup...................................................................................................................2-15 Traction Controller Settings ................................................................................................2-16 Accelerator Setup ................................................................................................................2-23 Pump Controller Settings.....................................................................................................2-25 Memory Maps ......................................................................................................................2-30 Speedometer Setup.............................................................................................................2-34

PROGRAMMING

Handset — General Information NOTE: The vehicle will operate with the Handset connected, however, the adjustment knob MUST BE SET FULLY CLOCKWISE to make sure the control can operate at maximum speed. This section has the control card checks and adjustments that can be made using the Handset. The control card checks and adjustments are usually made with the controller installed in the lift truck. Bench checks and adjustments can also be made with the control card connected. The checks show the stored setting numbers that have been stored for the different controller functions. This section also includes a description of each of the different functions. Use the adjustment knob on the Handset to adjust the function settings. See FIGURE 1. The Handset with a cord is available through your lift truck dealer under part #97E57-00100. The handset is the same for all GE controls, however, the cord is different for the SX series motor controllers. The SX controller Handset cord is available from MCFA under part # 97E57-00111.

Handset Functions The purpose of the Handset is to permit authorized personnel to perform checks and adjustments: 1. Adjustment Knob 2. LED Display 3. Keypad

4. Coil Cord 5. Plug P2 or P4 (12 Pin) 6. Modular Plug (8 Pin Hand Set)

FIGURE 1. Handset The Handset is a multifunctional tool to be used with the SX series motor controllers. The Handset is used to access the memory elements called “Registers” which have electronic data stored in them to control an operation. There are 128 Registers in the SX series of Control Cards. The Handset will access the registers for the traction or pump motor functions, indicate Status Codes (possible faults) and make adjustments to the operating limits set in the Control Cards. Some of the registers in the “SX” series of control cards can not be accessed with the Handset. The Handset can access the registers that control the operation of the lift truck. The values for the limits on the control card functions must be set with either the Handset or a PC. The Handset has a Light Emitting Diode (LED) display, a keypad for data entry and an adjustment knob for changing function values. See FIGURE 1. 2-1

✦ Monitor existing system fault codes for both traction and pump controllers. ✦ Monitor intermittent random status codes ✦ Monitor battery state of charge ✦ Monitor hourmeter reading on traction and pump controllers. ✦ Monitor or adjust the following control functions: ✧ Creep speed ✧ Controlled acceleration and 1A time ✧ Armature and field current limit. ✧ Steer pump time delay and define signal input (seat switch or directional switch) ✧ Regenerative braking current limit ✧ Speed limit points (SL1, SL2, and SL3) ✧ Truck management fault speed limit ✧ Internal resistance compensation for battery state of charge indication ✧ Battery voltage (36/48 volts can be auto ranging) ✦ Selection of card operation type: ✧ Standard traction card selection: ✧ 1A enabled/disabled ✧ Auto braking enabled/disabled

PROGRAMMING

Handset — Operation

! WARNING

Before connecting or disconnecting the Handset tool, 1) Jack up the drive wheels of the vehicle, 2) Turn off the key switch, 3) Unplug the battery and 4) Discharge the capacitors.

Before making any adjustments to the control, consult the function settings on page 4. Failure to use the proper settings could result in misoperation or damage to the control system.

At the Traction Controller, unplug the P2 plug” and plug in the Handset to the plug location P2 on the controller. After installing the Handset tool, plug in the battery and turn on the key switch. The following is the start-up display sequence that will occur:

Function Set-Up Procedures With the Handset connected, hold down the CONT button while turning on the Key Switch. The Handset will now show the segment checking display. This accesses the set up mode, ready to monitor or adjust control function settings. If a fault code is displayed simply push the CONT button to clear.

START-UP DISPLAY SEQUENCE

Push down one of the function numbers on the keypad to check that setting. For example, push down on function key ➄ : the corresponding function code will be displayed.

Key Switch On Verify each LED Segment 8888 If Maintenance Code is active

Example:

After one second we will see the value which is stored under this function:

If Maintenance Code is not active

Example:

Now turn the adjustment knob to the desired setting (the values will continue to blink). When the desired setting is reached, push STORE. This value will be displayed but will no longer be blinking. Next push the ESC button and get the Segment Check display again. This indicates the programming mode is still accessed.Continue this process to check or set all the functions. Each time a value is changed, go back and verify that the setting is correct. The value adjustment range available on the Handset is 0 to 255. However, some functions do not use the entire range.

Diagnostics override with fault Run Mode

Diagnostics override with fault

BDI Display

105

If this value needs to be reset, push again on the CONT button and the value will blink. The number on the Handset will no longer be the original value but will correspond to the position the adjustment knob was left.

Display Code -99 for four seconds and activate speed limit (if selected)

BDI Display

U 05

There are 15 numbers on the keypad but many more functions available. For the first 15 functions on the keypad simply press the appropriate number. To access functions 16 through 30 press the CONT button and the appropriate number on the keypad at the same time. For the traction controller, the seat switch must be open and for the pump controller, the key switch must be on.

Key Switch Off Display steer pump hourmeter for four seconds Display traction Hourmeter for four seconds Display pump Hourmeter for four seconds

FIGURE 2. Start up display 2-2

Example for function 16:

CONT and keypad #1

Example for function 18:

CONT and keypad #3

PROGRAMMING To access functions 48 and up, the seat switch must be closed. for the traction controller, and turn the key switch off for the pump controller. Then press the CONT button and the appropriate number on the keypad at the same time. Example for function 48:

CONT and keypad #1

NOTE: For bench checks and adjustments, please see the GE Sentry for Windows section

When programming is finished, press the ESC button when the (8888) is showing and press it again for 1 second. The display now shows the battery state of charge. This means the control is in run mode.

Accessing Stored Fault Codes The SX Traction and Pump Motor Controllers have function registers (31 through 47) that store the last 16 Status Codes that caused the operation of the lift truck to stop, the battery charge and the power steer hours at the time the fault occurred. A PMT fault is reset by turning the key to the OFF position and then to the ON position. The first of the 16 status codes will be overwritten each time a new status code occurs. The stored status can be cleared from the register by using the Handset. Use the procedure in FIGURE 3 to access and clear the fault code registers for the traction and pump controllers with the Handset. Key to OFF position

Push ESC and CONT at the same time

Release ESC and CONT

Status Code Displayed

Push ESC to erase stored data

Push CONT Key Displays Battery Stare-of Charge When Fault occurred

Push ESC to erase stored data

Push CONT Button

Display hourmeter reading when fault occurred

Push ESC to erase stored data

Push CONT Button FIGURE 3. Accessing Fault Codes 2-3

hold both the ESC and CONT Keys down to erase all 16 Stored codes

PROGRAMMING

! WARNING FUNCTION 3

Please contact MCFA before making changes to any function settings. Failure to properly adjust the settings could result in misoperation or damage to the motor and/or controller.

LX g

HANDSET

ARMATURE CONTROLLED ACCELERATION (Push 3)

This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100% applied battery voltage to the motor on hard acceleration. This function can be changed by the dash display mode selection button.

EVC

Range Set Resolution Example:

FUNCTION 4

CON T

ST ORE

ESC

+ FUNCTION 5

CREEP SPEED (Push 2)

This function allows for the adjustment of the creep speed of the vehicle. Creep speed can add 13 % to the percent on time at the slowest speed range. Range Set Resolution Example:

2% to 15% on time 0 to 255 0.05% per set unit Setting of 20 = 3% on time

COUNTER EMF TRIP POINT FOR AUTO BRAKING (Push 5)

This function allows for the adjustment of the speed at which the truck will activate auto braking, after the accelerator pedal is released. The truck speed correlates to the amount of voltage produced by the traction motor when it is coasting. The setting of this function represents the motor voltage. Range Set Resolution Example:

MILE PER HOUR SCALING (Push 1)

This function is not used on a Standard Display. If the premium display option is used, the speedometer should be adjusted through the display. Factory Default Value 16

FUNCTION 2

ARMATURE CURRENT LIMIT (Push 4)

This function should always remain set at 255 (maximum current limit) for this family of controls.

Setup Functions for Traction Controller FUNCTION 1

0.025 to 6.3 seconds 0 to 255 0.025 seconds per set unit Setting of 20 = 0.5 seconds

FUNCTION 6

0 to 100 volts 0 to 255 0.392 volts per set unit Setting of 20 = 7.84 volts

AUTO CALIBRATION OF ACCELERATOR POTENTIOMETER (Push 6)

This function allows for the auto calibration of the accelerator potentiometer. This function should be left set to a value of zero during normal truck operation. To activate accelerator the auto calibration routine, set this function to a value between 15 and 20, and refer to accelerator setup of this manual for detailed instructions covering the auto calibration procedure, on page 2. IMPORTANT NOTE: This function must be used to recalibrate the accelerator every time the traction controller or accelerator is replaced. The GE Sentry cannot be used to calibrate the accelerator. 2-4

PROGRAMMING FUNCTION 7

MIN FIELD CURRENT (Push 7) This function allows the adjustment of the field weakening level in order to set the top speed of the motor. Volts 36/48 72/80

Min 0 0

Resolution Example Max Set Per unit value If set at 71 20 51 to 115 0.314 amps 6.28A 17 51 to 114 0.269 amps 5.38A

MIN IF = (VAL-51) X 0.314 (at 36/48 VOLTS) MIN IF = (VAL-51) X 0.269 (at 72/80 VOLTS) Important Note: This function is used to optimize motor and control performance, and this setting was determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

FUNCTION 8

MAX FIELD CURRENT (Push 8)

REGEN BRAKING CURRENT LIMIT (Push 9)

This function allows for the adjustment of the maximum current seen by the motor during regenerative braking; the higher the current, the shorter the stopping distance. This function can be changed by the dash display mode selection button. Resolution Example Volts Min Max Set Per unit value If set at 100 36/48 182A 591A 0 to 255 1.625 344 amps 72/80 52A 409A 32 to 255 1.625 162 amps REGEN BRAKE IA = (VAL X 1.625) + 182 REGEN BRAKE IA = (VAL X 1.625)

This function allows for the adjustment of the motor speed limit (maximum battery volts to the motor) based on the state of pin P1-12 of the controller. If pin P1-12 is pulled to battery volts, the speed limit is deactivated. If pin P1-12 is allowed to float, the speed limit will be active. Range Set Resolution Example

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts

FUNCTION 12 TOP SPEED LIMIT (Push 12) This function allows for the adjustment of the motor speed limit (maximum battery volts to the motor). This speed limit is the same as function 11, however it is always active. This function can be changed by the dash display mode selection button. Range Set Resolution Example

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts

Factory Default Value 0 SPEED LIMIT = 100% - ((VAL-46) x 0.75%)

at 36/48 volts at 72/80 volts

FUNCTION 10 MAX FIELD CURRENT DURING REGEN (Push 10) This function allows for the adjustment of the maximum field current attainable during the regenerative braking mode. Resolution Example Volts Min Max Set Per unit value If set at 220 36/48 0 64 51 to 255 0.314 53 amps 72/80 0 55 51 to 255 0.269 45 amps IF = (VAL-51) x 0.314 (at 36/48 volts) IF = (VAL-51) x 0.269 (at 72/80 volts)

FUNCTION 11 AUXILIARY SPEED LIMIT (Push 11)

Factory Default Value 0 SPEED LIMIT = 100% - ((VAL-46) x 0.75%)

This function allows for the adjustment of the maximum field current in order to obtain the maximum torque of the motor. This function should always be set to 255.

FUNCTION 9

Important Note: This function is used to optimize motor and control performance and this setting was determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

FUNCTION 13 MAINTENANCE AND TRUCK MANAGEMENT SPEED LIMIT (Push 13) This function is the same as function 11, however it is active based on maintenance hours (function 19 and 20), or traction motor overheating (Status Code 90) or on low BDI value. Range Set Resolution Example

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts SPEED LIMIT = 100% - ((VAL-46) x 0.75%) 2-5

PROGRAMMING FUNCTION 14 INTERNAL RESISTANCE COMPENSATION (Push 14)

The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions. Push the CONT key and the number shown in the following instructions at the same time. THE SEAT SWITCH MUST BE OPEN.

This function is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI. In order to determine this setting the voltage drop of the battery under load must first be calculated by the following method.

FUNCTION 16 STALL PROTECTION % ON-TIME TRIP POINT (Push CONT 1)

1. On a fully charged battery, record the open circuit voltage (Vo) by measuring the voltage at the control positive and negative power terminals. 2. Load the traction motor to 100 amps in the battery cable and record the voltage (VL) at the control positive and negative power terminal. 3. Calculate voltage drop (VDrop) as follows: VDrop = VO - VL 4. Use the table below to determine the appropriate setting using the calculated VDrop as a reference. (See Function 14 settings in General Information & Features)

This function allows for the adjustment of the stall motor protection, as well as the display and storing of an 82 fault code. This function adjusts the percent on time at which the fault occurs when the accelerator is calling for greater than 50% speed and the armature current is above 500 amps at 36/48V (or above 370 amps at 72/80V). Range 100% to 0% battery volts Set 46 to 180 Resolution 0.75% per set unit Example Setting of 125 = 41% on-time

INTERNAL RESISTANCE COMPENSATION TABLE Setting 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

VDrop 11.44 07.60 05.72 04.57 03.81 03.27 02.86 02.54 02.28 02.08 01.90 01.76 01.63 01.52 01.43

Setting 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

VDrop 01.34 01.27 01.20 01.14 01.09 01.04 00.99 00.95 00.91 00.88 00.85 00.82 00.79 00.76 00.74

% ON TIME = 100% - ((VAL-46) x 0.75%) Important Note: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

FUNCTION 17 CARD TYPE SELECTION (Push CONT 2) This function allows the user to enable or disable the vehicle’s auto braking routine by setting the function within the ranges outlined below. Control 740A, 36/48V 740A, 36/48V 740A, 36/48V 740A, 36/48V 600A, 36/48V 600A, 36/48V 450A, 72/80V 450A, 72/80V

FUNCTION 15 BATTERY VOLTS (Push l5) This function allows for the adjustment of voltage range. In order for the BDI to operate properly, the setting as shown in the table must be entered: Battery volts 36 volts 48 volts 72 volts 80 volts 36/48 volts No BDI

Set units Between 32 and 44 FACTORY DEFAULT Between 45 and 69 Between 70 and 80 Between 81 and 183 Between 184 and 250 Between 251 and 255 2-6

Function 1A enabled, auto braking enabled 1A enabled, auto braking disabled Without 1A, auto braking enabled Without 1A, auto braking disabled Auto braking enabled Auto braking disabled Auto braking enabled Auto braking disabled

Setting 128 to 255 64 to127 50 to 63 0 to 49 50 to 255 0 to 49 50 to 255 0 to 49

PROGRAMMING FUNCTION 18 STEER PUMP TIME DELAY (Push CONT 3)

FUNCTION 21 AUTO REGEN BRAKING CURRENT LIMIT (Push CONT 6)

This function allows for the selection of steer pump contactor pick up input, either seat switch or directional switch closing, as well as the adjustment of the time delay for the contactor drop out. •

Pick up steer pump contactor on seat switch closure and drop out steer pump contactor on seat switch opening, after a delay determined by the following: Range Setting Resolution

This function allows for the adjustment of the braking torque applied when the start or directional switch is opened, and the counter EMF is above the setting of Function 5. A higher current correlates to a shorter stopping distance. This function can be changed by the dash display mode selection button. Current = (Value of Setting /4) x 6.5

1.5 to 65 seconds Between 0 and 127 0.5 seconds per set unit

Note, if the result is less than 52 amps, the control will default to 52 amps.

Example: Setting of 20 = (20 x 0.5) + 1.5 = 11.5 seconds •

Pick up steer pump contactor on directional switch closure and drop out steer pump contactor on directional switch opening, after a delay determined by the following: Range Setting Resolution

FUNCTION 22 NOT APPLICABLE This value changes with operating mode selected, and should not be adjusted in the field.

0.5 to 63 seconds Between 128 and 255 0.5 seconds per set unit

FUNCTION 23 REGEN CANCEL CURRENT (Push CONT 8)

Example: Setting of 149 = ((149-128) x 0.5) + 1.5 = 11.5 seconds

This function allows for the adjustment of the armature current at which regenerative braking cancels, and is specific to each motor design.

Note: If the seat switch opens, the steer pump contactor will open immediately. If a foot directional control option is installed on a truck, only the settings for the seat switch input should be used.

Important Note: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

FUNCTION 19 MAINTENANCE CODE TENS AND UNITS HOURS SET (Push CONT 4) This function allows for the adjustment of the tens and units hours of the maintenance code activation time. If the replacement of the SX controller is required, record this value. Range Set Example Disabled

0 to 99 0 to 99 9999 Hours 255

FUNCTION 24 FIELD WEAKENING START (Push CONT 9) This function allows for setting the armature current at which minimum field current will be achieved. Range Setting Resolution Example

FUNCTION 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS HOURS SET (Push CONT 5) This function allows for the adjustment of the thousands and hundreds hours of the maintenance code activation time. Same as Function 19. Range Set Example Disabled

0 to 240 0 to 240 9999 Hours 255

0 to 414 Amps 0 to 255 1.625 per set unit Setting of 20 = 32.5 amps

I motor FWS = VAL. x 1.625 Important Note: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

2-7

PROGRAMMING FUNCTION 25 MONITOR (Push CONT 10)

the Memory Map, match the “stored status code pointer number” [the number shown in the HS (Handset) number column] on the memory map, with the number obtained from Function 28. This will be the last stored status code recorded.

This function is not used. To ensure optimum operation of the control, this function must be left with zero stored in this register.

Note: When scrolling through the stored status code register, the register always starts at status code 1 and scrolls to status code 16.

FUNCTION 26 FIELD TO ARMATURE CURRENT RATIO (Push CONT 11) This function sets the ratio between armature and field current when operating below the maximum field current and above the Field Weakening Start point. The setting represents the quantity of field current changed for each 1 amp of armature current changed. For a 36/48V control: Range 0 to 0.314 field amps/armature amp Setting 0 to 13 Resolution 0.024 field amps/armature amp Example Setting of 10 = 0.24 field amps/armature amp For a 72/80V control: Range 0 to 0.269 field amps/armature amp Setting 0 to 13 Resolution 0.021 field amps/armature amp Example Setting of 10 = 0.20 field amps/armature amp Important Note: This function is used to optimize motor and control performance, and this setting will be determined by MCFA engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of MCFA Service Engineering.

FUNCTION 27 MINUTES REGISTER (Push CONT 12) This register is only intended for storage of the minutes value for proper operation of the hour meter and should not be adjusted.

FUNCTION 28 STORED STATUS CODE COUNT POINTER (Push CONT 13)

FUNCTION 29 POWER STEERING HOURS (ONES AND TENS) (Push CONT 14) This register is only intended for storage of the ones and tens values of the hours of operation of the power steering motor and should not be adjusted.

FUNCTION 30 POWER STEERING HOURS (HUNDREDS AND THOUSANDS) (Push CONT 15) This register is only intended for storage of the hundreds and thousands values of the hours of operation of the power steering motor and should not be adjusted. DASH DISPLAY MODES The following functions (functions 48 through 63) are mode settings that are activated from the Dash Display. No mode should be set to values lower than the preceding mode.

FUNCTION 48 MODE 1 ARMATURE CONTROLLED ACCELERATION (Push CONT 1) This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100% applied battery voltage to the motor on hard acceleration.

This register contains the location of the last stored status code recorded of the 16 stored status codes. These stored status codes have caused a PMT controller shutdown and/or disruption of normal vehicle operation. To determine which stored status code was the last one recorded, read the number stored in Function 28. Using

Range Set Resolution Example:

1.0 to 25.5 seconds 10 to 255 0.10 seconds per set unit Setting of 20 = 2.0 seconds

This C/A takes effect when the Mode 1 settings are called for by the Dash Display. 2-8

PROGRAMMING FUNCTION 49 MODE 1 REGEN CURRENT LIMIT (Push CONT 2) This function allows for the adjustment of the maximum current seen by the motor during regenerative braking; the higher the current, the shorter the stopping distance. Resolution Example Volts Min Max Set Per unit value If set at 100 36/48 182A 591A 0 to 255 1.625 344 amps 72/80 52A 409A 32 to 255 1.625 162 amps REGEN BRAKE IA = (VAL X 1.625) + 182 at 36/48 volts REGEN BRAKE IA = (VAL X 1.625) at 72/80 volts

FUNCTION 52 MODE 2 ARMATURE CONTROLLED ACCELERATION (Push CONT 5) Same as Function 48. This C/A takes effect when the Mode 2 settings are called for by the Dash Display.

FUNCTION 53 MODE 2 REGEN CURRENT LIMIT (Push CONT 6) Same as Function 49.

This REGEN CURRENT LIMIT takes effect when the Mode 1 settings are called for by the Dash Display.

FUNCTION 50 MODE 1 AUTO REGEN CURRENT LIMIT (Push CONT 3) This function allows for the adjustment of the braking torque applied when the start or directional switch is opened, and the counter EMF is above the setting of Function 5. A higher current correlates to a shorter stopping distance.

This REGEN CURRENT LIMIT takes effect when the Mode 2 settings are called for by the Dash Display.

FUNCTION 54 MODE 2 AUTO REGEN CURRENT LIMIT (Push CONT 7) Same as Function 50. This AUTO REGEN CURRENT LIMIT takes effect when the Mode 2 settings are called for by the Dash Display.

Current = (Value of Setting /4) x 6.5 Note, if the result is less than 52 amps, the control will default to 52 amps.

FUNCTION 55 MODE 2 SPEED LIMIT (Push CONT 8) Same as Function 51.

This AUTO REGEN CURRENT LIMIT takes effect when the Mode 1 settings are called for by the Dash Display.

This SPEED LIMIT 2 takes effect when the Mode 2 settings are called for by the Dash Display.

FUNCTION 51 MODE 1 SPEED LIMIT (Push CONT 4) This function allows for the adjustment of the motor speed limit (maximum battery volts to the motor. Range Set Resolution Example

100% to 0% battery volts 46 to 180 0.75% per set unit Setting of 80 = 75% of battery volts

SPEED LIMIT = 100% - ((VAL-46) x 0.75%) This speed limit takes effect when the Mode 1 settings are called for by the interactive Dash Display.

FUNCTION 56 MODE 3 ARMATURE CONTROLLED ACCELERATION (Push CONT 9) Same as Function 48. This C/A takes effect when the Mode 3 settings are called for by the Dash Display.

FUNCTION 57 MODE 3 REGEN CURRENT LIMIT (Push CONT 10) Same as Function 49. This REGEN CURRENT LIMIT takes effect when the Mode 3 settings are called for by the Dash Display.

2-9

PROGRAMMING FUNCTION 58 MODE 3 AUTO REGEN CURRENT LIMIT (Push CONT 11) Same as Function 50. This AUTO REGEN CURRENT LIMIT takes effect when the Mode 3 settings are called for by the Dash Display.

FUNCTION 59 MODE 3 SPEED LIMIT 2 (Push CONT 12) Same as Function 51. This speed limit takes effect when the Mode 3 settings are called for by the Dash Display.

FUNCTION 60 MODE 4 ARMATURE CONTROLLED ACCELERATION (Push CONT 13) Same as Function 48. This C/A takes effect when the Mode 4 settings are called for by the Dash Display.

FUNCTION 61 MODE 4 REGEN CURRENT LIMIT (Push CONT 14) Same as Function 49. This REGEN CURRENT LIMIT takes effect when the Mode 4 settings are called for by the Dash Display.

FUNCTION 62 MODE 4 AUTO REGEN CURRENT LIMIT (Push CONT 15) Same as Function 50. This AUTO REGEN CURRENT LIMIT takes effect when the Mode 4 settings are called for by the Dash Display.

FUNCTION 63 MODE 4 SPEED LIMIT 2 (Push CONT ESC) Same as Function 51. This speed limit takes effect when the Mode 4 settings are called for by the Dash Display.

2-10

PROGRAMMING

The "maximum field current " setting is adjusted by Function 8. This function, along with the "armature current limit" , Function 4, sets the maximum torque of the motor.

MAXIMUM

FIELD CURRENT

The " ratio " setting is adjusted by Function 26. This function sets the ratio between armature and field current when operating, IMOTOR is above FWS and less than the full load transistion point. Setting is the value of field current changed for each 100 amps of armature current changed.

The " minimum field current " setting is adjusted by Function 7. The function sets the top speed of the motor. The " field weakening start " setting is adjusted by Function 24. This function sets the armature current at which minimum field current will be achieved .

ARMATURE CURRENT

The "full load transition point

The "armature current limit " setting is adjusted by Function 4. The function along with the "maximum field current", Function 8, sets the maximum torque of the motor.

2-11

MAXIMUM

ZERO

PROGRAMMING Setup Functions for Hydraulic Pump Control FUNCTION 1

Example: Setting of 20 = 0.032 seconds For example, if you had selected 2.08 volts from Function 16 to be added to the motor, it would take 0.18 seconds to add a total of 2.08 volts. (2.08/0.375)=0.032

NOT APPLICABLE

This function is not applicable to this type of control and should not be adjusted.

FUNCTION 2

FUNCTION 11 AUX 1/AUX 2 SPEED LIMIT 1 (SL1) (Push 11)

INTERNAL RESISTANCE COMPENSATION START (Push 2)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 limit switch input signal is received by the control card at pin P1-12. SL1 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

This function allows for the adjustment of the current level at which the internal resistance compensation feature (Function 16) will take effect. Range Setting Resolution

0 to 1325 amps 52 to 255 6.5 amps per set unit

Range Setting Resolution

0 volts to 96 volts 0 to 255 0.375 volts per set unit

Example: Setting of 72 = (72-52) x 6.5 = 130 amps Example: Setting of 50=18.75 volts FUNCTION 3

CONTROLLED ACCELERATION (Push 3)

FUNCTION 12 LIFT 1 SPEED LIMIT 2 (SL2) (Push 12)

This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration.

Same as Function 11 except using SL2 limit switch for input to control card at pin P1-19.

Range Setting Resolution

FUNCTION 13 TILT SPEED LIMIT 3 (SL3) (Push 13)

0.1 to 5.5 seconds 0 to 255 0.021 seconds per set unit

Example: Setting of 20 = 0.52 seconds C/A

FUNCTION 4

Same as Function 11 except using SL3 limit switch for input to control card at pin P1-20.

ARMATURE CURRENT LIMIT (Push 4)

FUNCTION 14 LIFT 2 SPEED LIMIT (SL4) (Push 14)

This function allows for the adjustment of the current limit of the control. The setting for this function should always remain at 255 for this family of controls to achieve maximum current limit.

Same as Function 11 except using SL4 limit switch for input to control card at pin P1-21.

FUNCTION 15 NOT APPLICABLE FUNCTION 7

INTERNAL RESISTANCE COMPENSATION RATE (Push 7) This function allows for the adjustment of the rate of time it takes for the control to add the internal resistance compensation voltage that is applied to the motor. This function will add 0.375 volts to the motor at the rate of time adjusted until the total IR compensation voltage has been added. Range Setting Resolution

This function is not applicable to this type of control and should not be adjusted.

Note: The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time. THE KEY SWITCH MUST BE ON.

0.0015 to 0.383 seconds 0 to 255 0.0015 seconds per set unit 2-12

PROGRAMMING FUNCTION 16 SPEED / TORQUE COMPENSATION (Push CONT 1) This function is used to stabilize pump speed at heavy loads. The voltage selected will be added to the motor at each 100 amp increment starting at the value set in Function 2. The voltage compensation selected will be added in increments of 0.375 volts until the entire voltage is added. For example, a setting of 2 will be added in 30 steps of 0.375 volts each whereas, a setting of 4 will be added in 15 steps of 0.375 volts each.

SETTING 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

SPEED / TORQUE VOLTAGE DROP SETTING 11.44 17 7.60 18 5.72 19 4.57 20 3.81 21 3.27 22 2.86 23 2.54 24 2.28 25 2.08 26 1.90 27 1.76 28 1.63 29 1.52 30 1.43 31

VOLTAGE DROP 1.34 1.27 1.20 1.14 1.09 1.04 0.99 0.95 0.91 0.88 0.85 0.82 0.79 0.76 0.74

COMPENSATION TABLE

control panel used and the supporting electromechanical devices. Failure to comply with proper application standards could result in mis-operation or damage to the control and/or motors.

FUNCTION 28: FAULT COUNT POINTER (Push CONT 13) This register contains the location of the last stored status code recorded of the 16 stored status codes. These stored status codes have caused a PMT controller shutdown and/or disruption of normal vehicle operation. To determine which stored status code was the last one recorded, read the number stored in Function 28. Using the Memory Map, match the “stored status code pointer number” in the HS (Handset) number column) on the memory map, with the number obtained from Function 28. This will be the last stored status code recorded. Note: When scrolling the stored status code register, the register always starts at status code 1 and scrolls to status code 16. DASH DISPLAY MODES: The Following functions (functions 48 through 63 are mode settings that are activated from the Dash Display. Note: The following functions have function numbers larger than the numbers on the Handset keyboard. To access these functions, push the CONT key and the number shown in the following instructions at the same time. THE KEY SWITCH MUST BE OFF.

FUNCTION 17 CARD TYPE SELECTION (Push CONT 2) This function should be set in accordance with the control type in use in the vehicle: Function

Setting

No BDI

Std C/L BDI Lockout High C/L BDI Lockout

54 to 62 63 to 71

36 to 44 45 to 53

BDI Lockout means that the BDI signal from the traction control must be present in order for the pump control to operate. This control will stop operation when the battery state of charge reaches 9%.

FUNCTION 48 MODE 1 - CONTROLLED ACCELERATION (Push CONT 1) This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration. Range Setting Resolution

0.1 to 22.0 seconds 0 to 255 0.084 seconds per set unit

Example: Setting of 20 = 1.8 seconds C/A

Settings for these functions should be made in between the values shown. Warning: This setting must be changed by authorized personnel only, following instructions supplied by MCFA Service Engineering. Card type selection must be made within the capabilities of the TRANSISTOR 2-13

PROGRAMMING FUNCTION 49 MODE 1 – LIFT 1 SPEED LIMIT (SL2) (Push CONT 2)

FUNCTION 54 MODE 2 – TILT SPEED LIMIT (SL3) (Push CONT 7)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL2 limit switch input signal is received by the control card. SL2 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

Same as Function 50.

Range Setting Resolution

Same as Function 51.

0 volts to 96 volts 0 to 255 0.375 volts per set unit

FUNCTION 56 MODE 3 - CONTROLLED ACCELERATION (Push CONT 9)

Example: Setting of 50=18.75 volts FUNCTION 50 MODE 1 – TILT SPEED LIMIT (SL3) (Push CONT 3)

Same as function 48.

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL3 limit switch input signal is received by the control card. SL3 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit. Range Setting Resolution

FUNCTION 55 MODE 2 – LIFT 2 SPEED LIMIT (SL4) (Push CONT 8)

0 volts to 96 volts 0 to 255 0.375 volts per set unit

FUNCTION 57 MODE 3 – LIFT 1 SPEED LIMIT (SL2) (Push CONT 10) Same as Function 49.

FUNCTION 58 MODE 3 – TILT SPEED LIMIT (SL3) (Push CONT 11)

Example: Setting of 50=18.75 volts

Same as Function 50.

FUNCTION 51 MODE 1 – LIFT 2 SPEED LIMIT (SL4) (Push CONT 2)

FUNCTION 59 MODE 3 – LIFT 2 SPEED LIMIT (SL4) (Push CONT 12)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL4 limit switch input signal is received by the control card. SL4 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit.

Same as Function 51.

Range Setting Resolution

0 volts to 96 volts 0 to 255 0.375 volts per set unit

FUNCTION 60 MODE 4 - CONTROLLED ACCELERATION (Push CONT 13) Same as function 48.

Example: Setting of 50=18.75 volts

FUNCTION 61 MODE 4 – LIFT 1 SPEED LIMIT (SL2) (Push CONT 14)

FUNCTION 52: MODE 2 - CONTROLLED ACCELERATION (Push CONT 5)

Same as Function 49. FUNCTION 62 MODE 4 – TILT SPEED LIMIT 3 (SL3) (Push CONT 15)

Same as function 48. Same as Function 50. FUNCTION 53: MODE 2 – LIFT 1 SPEED LIMIT (SL2) (Push CONT 6)

FUNCTION 63 MODE 4 – LIFT 2 SPEED LIMIT (SL4) (Push CONT ESC)

Same as Function 49.

Same as Function 51. 2-14

SETUP PROCEDURES Controller Setup Every controller has a basic number of settings that come with the controller. These basic settings are generic and will not allow the truck to operate properly. After the controller is installed into a truck, the settings must be changed to match the voltage of the truck, the size of the truck and the type of motor in the truck. All trucks will have a traction controller that must be setup. Some trucks will have an optional pump controller that will also need to be setup. Before setting up any controller, the configuration of the truck must be determined. For the traction and pump controller setup, 4 things must be determined; UL type (E or EE), truck voltage, truck size and motor size. The UL type, truck voltage and size should be available on the build paperwork that comes with the truck. The motor information is available in the serial number of the truck. The number in the sixth position of the serial number (e.g. A3BC220053) gives the motor combination of the truck per the following table.

SN PREFIX FBC15K FBC18K FBC18KL FBC20K FBC25K

FBC25KE FBC25KL FBC30K

FBC30KL

A3BC11 A3BC12 A3BC13 A3BC14 A3BC21 A3BC22 A3BC23 A3BC24 A3BC28 A3BC31 A3BC32 A3BC33 A3BC34 A3BC38 A3BC44

MOTORS

VOLTAGE

TRACTION

PUMP

8" 9" 8" 9" 9" 11” 9" 11" 11" 9" 11" 9" 11" 11" 11"

6.6" 6.6" 8" 8" 8" 8" 9" 9" 9" 8" 8" 9" 9" 9" 9"

36/48V 36/48V 36/48V 36/48V 36/48V 36/48V 36/48V 36/48V 72/80V 36/48V 36/48V 36/48V 36/48V 72/80V 36/48V

Once the configuration of the truck is known, the correct settings will need to be input into the traction and pump controller (if the truck has a pump controller). Inputting the settings into the traction or pump controller will require a GE controller handset with the proper cable.

2-15

TRACTION CONTROLLER SETTINGS FOR FBC15K AND FBC18K SN PREFIX: A3BC11 OR A3BC13 TRACTION MOTOR DIAMETER: 8" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12]

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

*Valve changes to zero after calibration.

2-16

FBC15K (36V ONLY) FBC18K (36V ONLY) 16 16 87 87 24 24 255 255 20 20 See Page 2-33 See Page 2-33 86 86 255 255 45 30 170 170 0 0 0 0 113 113 24 24 36 36 130 130 57 57 149 149 255 255 255 255 25 35 183 183 30 30 64 64 0 0 6 5 0 0 0 0 0 0 0 0 36 36 0 0 0 0 80 83 36 36 23 15 0 0 0 0 24 24 45 30 25 35 0 0 18 18 90 60 50 70 0 0

TRACTION CONTROLLER SETTINGS FOR FBC15K, FBC18K AND FBC18KL SN PREFIX: A3BC12 OR A3BC14 TRACTION MOTOR DIAMETER: 9" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-17

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 87 87 24 33 255 255 15 25 See Page 2-33 88 88 255 255 0 0 201 201 0 0 0 0 113 113 24 16 36 48 120 120 57 57 149 149 255 255 255 255 0 10 183 183 30 30 100 100 0 0 6 6 0 0 0 0 0 0 0 0 36 50 0 0 0 0 80 80 36 50 0 0 0 0 0 0 24 33 0 0 0 10 0 0 18 25 0 0 0 20 0 0

TRACTION CONTROLLER SETTINGS FOR FBC20K, FBC25K AND FBC25KE SN PREFIX: A3BC21, A3BC23, A3BC31 OR A3BC33 TRACTION MOTOR DIAMETER: 9" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-18

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 87 87 24 33 255 255 13 13 See Page 2-33 90 90 255 255 7 7 240 240 0 0 0 0 113 113 24 16 36 48 130 130 57 57 149 149 255 255 255 255 25 25 183 183 50 50 70 60 0 0 5 5 0 0 0 0 0 0 0 0 36 50 0 0 0 0 80 80 36 50 3 3 0 0 0 0 24 33 7 7 25 25 0 0 18 25 13 13 50 50 0 0

TRACTION CONTROLLER SETTINGS FOR FBC20K, FBC25K AND FBC25KE SN PREFIX: A3BC22, A3BC24, A3BC32 OR A3BC34 TRACTION MOTOR DIAMETER: 11" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-19

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 60 60 20 27 255 255 15 15 See Page 2-33 79 80 255 255 35 25 255 255 0 0 0 0 113 113 24 16 36 48 130 130 57 57 149 149 255 255 255 255 30 25 183 183 50 50 100 100 0 0 3 5 0 0 0 0 0 0 0 0 30 40 0 0 0 0 80 80 30 40 18 13 0 0 0 0 20 27 35 25 30 25 0 0 15 20 70 50 60 50 0 0

TRACTION CONTROLLER SETTINGS FOR FBC25KL, FBC30K AND FBC30KL SN PREFIX: A3BC32, A3BC34 OR A3BC44 TRACTION MOTOR DIAMETER: 11" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-20

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 60 60 20 27 255 255 15 15 See Page 2-33 80 80 255 255 35 35 255 255 0 0 0 0 113 113 24 16 36 48 130 130 135 135 149 149 255 255 255 255 30 25 183 183 50 50 100 100 0 0 5 5 0 0 0 0 0 0 0 0 30 40 0 0 0 0 80 80 30 40 18 18 0 0 0 0 20 27 35 35 30 25 0 0 15 20 70 70 60 50 0 0

TRACTION CONTROLLER SETTINGS FOR FBC25KL AND FBC30K SN PREFIX: A3BC31 OR A3BC33 TRACTION MOTOR DIAMETER: 9" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-21

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 87 87 13 29 255 255 13 20 See Page 2-33 90 95 255 255 40 33 240 240 0 0 0 0 113 113 24 16 36 48 130 130 57 57 149 149 255 255 255 255 35 35 183 183 50 50 80 70 0 0 5 5 0 0 0 0 0 0 0 0 20 44 0 0 0 0 80 80 20 44 20 16 0 0 0 0 13 29 40 33 35 35 0 0 10 22 80 65 70 70 0 0

TRACTION CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION FBC15K, FBC18K AND FBC18KL SN PREFIX: A3BC12 OR A3BC14 TRACTION MOTOR DIAMETER: 9" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-22

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 87 87 27 33 255 255 20 25 See Page 2-33 88 88 255 255 25 0 170 170 0 0 110 110 113 113 24 16 36 48 160 160 57 0 149 149 255 255 255 255 35 0 183 183 30 30 112 100 0 0 8 9 0 0 0 0 0 0 0 0 100 0 0 0 0 0 130 130 100 0 18 0 0 0 0 0 67 0 35 0 55 55 0 0 20 25 50 0 70 0 110 110

TRACTION CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30K AND FBC30KL SN PREFIX: A3BC22, A3BC24, A3BC32, A3BC34 OR A3BC44 TRACTION MOTOR DIAMETER: 11" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-23

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V 48V 16 16 60 60 27 27 255 255 20 20 See Page 2-33 80 90 255 255 25 0 255 255 0 0 80 90 113 113 24 16 36 48 160 160 57 0 149 149 255 255 255 255 35 0 183 183 50 50 100 100 0 0 8 7 0 0 0 0 0 0 0 0 40 40 0 0 0 0 100 110 40 40 13 0 0 0 80 90 27 27 25 0 35 0 80 90 20 20 50 0 70 0 80 90

TRACTION CONTROLLER SETTINGS FOR FBC20K, FBC25K, FBC25KE, FBC25KL AND FBC30K SN PREFIX: A3BC28 OR A3BC38 TRACTION MOTOR DIAMETER: 11" SETTING DESCRIPTION MPH Scaling Creep Speed Controlled Acceleration Armature Current Limit Counter EMF Trip Point for Auto Regen Auto Calibration of Accel. Potentiometer* Min Field Current Max Field Current Regen Current Limit Max Field Current for Regen Speed Limit from Pin 12 on Negative (SL1) Max Armature % On (SL2) Speed Limit from Trac Mtr Temp/Maint/BDI Internal Resistance Compensation Battery Voltage Traction Motor Stall Protection Card Type Selection Steer Motor Time Delay Maint Code Hrs Tens and Ones Maint Code Hrs Thousands and Hundreds Auto Regen Current Limit Truck Mode Set by Display Regen Cancel Current Field Weakening Start Monitor Field to Armature Current Ratio Minutes Register for Hourmeter Stored Fault Count Pointer P/S Hourmeter Storage Register P/S Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Regen Current Limit [#9] MODE 1 - Auto Regen Current Limit [#21] MODE 1 - Max Armature % On (SL2) [#12] MODE 2 - Controlled Acceleration [#3] MODE 2 - Regen Current Limit [#9] MODE 2 - Auto Regen Current Limit [#21] MODE 2 - Max Armature % On (SL2) [#12] MODE 3 - Controlled Acceleration [#3] MODE 3 - Regen Current Limit [#9] MODE 3 - Auto Regen Current Limit [#21] MODE 3 - Max Armature % On (SL2) [#12] MODE 4 - Controlled Acceleration [#3] MODE 4 - Regen Current Limit [#9] MODE 4 - Auto Regen Current Limit [#21] MODE 4 - Max Armature % On (SL2) [#12] *Valve changes to zero after calibration.

2-24

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

72V 80V 16 16 87 87 24 27 255 255 20 20 See Page 2-33 84 84 255 255 90 90 255 255 0 0 0 0 113 113 16 16 75 90 130 130 57 57 149 149 255 255 255 255 25 25 183 183 105 105 90 90 0 0 5 5 0 0 0 0 0 0 0 0 36 40 0 0 0 0 80 80 36 40 45 45 0 0 0 0 24 27 90 90 25 25 0 0 18 20 180 180 50 50 0 0

PUMP CONTROLLER SETTINGS FOR FBC15K, FBC18K AND FBC18KL SN PREFIX: A3BC13 OR A3BC14 PUMP MOTOR DIAMETER: 8" SETTING DESCRIPTION N/A Internal Resistance Compensation Start Controlled Acceleration Armature Current Limit N/A N/A Internal Resistance Compensation Rate N/A N/A N/A Aux1/Aux2 Speed Limit (SL1) Lift 1 Speed Limit (SL2) Tilt Speed Limit (SL3) Lift 2 Speed Limit (SL4) N/A Speed Torque Compensation Card Type Selection (500A/600A) N/A N/A N/A N/A Truck Mode Set by Display minutes minutes seconds N/A Monitor N/A Stored Fault Count Pointer Pump Hourmeter Storage Register Pump Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Lift 1 Speed Limit (SL2) [#12] MODE 1 - Tilt Speed Limit (SL3) [#13] MODE 1 - Lift 2 Speed Limit (SL4) [#14] MODE 2 - Controlled Acceleration [#3] MODE 2 - Lift 1 Speed Limit (SL2) [#12] MODE 2 - Tilt Speed Limit (SL3) [#13] MODE 2 - Lift 2 Speed Limit (SL4) [#14] MODE 3 - Controlled Acceleration [#3] MODE 3 - Lift 1 Speed Limit (SL2) [#12] MODE 3 - Tilt Speed Limit (SL3) [#13] MODE 3 - Lift 2 Speed Limit (SL4) [#14] MODE 4 - Controlled Acceleration [#3] MODE 4 - Lift 1 Speed Limit (SL2) [#12] MODE 4 - Tilt Speed Limit (SL3) [#13] MODE 4 - Lift 2 Speed Limit (SL4) [#14] 2-25

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V/48V 0 66 20 255 255 255 100 255 255 255 50 45 38 96 255 20 58 255 255 255 255 183 0 0 0 0 255 0 0 0 27 34 31 67 27 45 38 80 20 45 38 96 20 67 50 255

PUMP CONTROLLER SETTINGS FOR FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30KAND FBC30KL SN PREFIX: A3BC23, A3BC24, A3BC33, A3BC34 OR A3BC44 PUMP MOTOR DIAMETER: 9" SETTING DESCRIPTION N/A Internal Resistance Compensation Start Controlled Acceleration Armature Current Limit N/A N/A Internal Resistance Compensation Rate N/A N/A N/A Aux1/Aux2 Speed Limit (SL1) Lift 1 Speed Limit (SL2) Tilt Speed Limit (SL3) Lift 2 Speed Limit (SL4) N/A Speed Torque Compensation Card Type Selection (500A/600A) N/A N/A N/A N/A Truck Mode Set by Display minutes minutes seconds N/A Monitor N/A Stored Fault Count Pointer Pump Hourmeter Storage Register Pump Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Lift 1 Speed Limit (SL2) [#12] MODE 1 - Tilt Speed Limit (SL3) [#13] MODE 1 - Lift 2 Speed Limit (SL4) [#14] MODE 2 - Controlled Acceleration [#3] MODE 2 - Lift 1 Speed Limit (SL2) [#12] MODE 2 - Tilt Speed Limit (SL3) [#13] MODE 2 - Lift 2 Speed Limit (SL4) [#14] MODE 3 - Controlled Acceleration [#3] MODE 3 - Lift 1 Speed Limit (SL2) [#12] MODE 3 - Tilt Speed Limit (SL3) [#13] MODE 3 - Lift 2 Speed Limit (SL4) [#14] MODE 4 - Controlled Acceleration [#3] MODE 4 - Lift 1 Speed Limit (SL2) [#12] MODE 4 - Tilt Speed Limit (SL3) [#13] MODE 4 - Lift 2 Speed Limit (SL4) [#14] 2-26

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V/48V 0 66 20 255 255 255 100 255 255 255 50 45 38 96 255 20 67 255 255 255 255 183 0 0 0 0 255 0 0 0 27 34 31 67 27 45 38 80 20 45 38 96 20 67 50 255

PUMP CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION FBC15K, FBC18K AND FBC18KL SN PREFIX: A3BC14 PUMP MOTOR DIAMETER: 8" SETTING DESCRIPTION N/A Internal Resistance Compensation Start Controlled Acceleration Armature Current Limit N/A N/A Internal Resistance Compensation Rate N/A N/A N/A Aux1/Aux2 Speed Limit (SL1) Lift 1 Speed Limit (SL2) Tilt Speed Limit (SL3) Lift 2 Speed Limit (SL4) N/A Speed Torque Compensation Card Type Selection (500A/600A) N/A N/A N/A N/A Truck Mode Set by Display minutes minutes seconds N/A Monitor N/A Stored Fault Count Pointer Pump Hourmeter Storage Register Pump Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Lift 1 Speed Limit (SL2) [#12] MODE 1 - Tilt Speed Limit (SL3) [#13] MODE 1 - Lift 2 Speed Limit (SL4) [#14] MODE 2 - Controlled Acceleration [#3] MODE 2 - Lift 1 Speed Limit (SL2) [#12] MODE 2 - Tilt Speed Limit (SL3) [#13] MODE 2 - Lift 2 Speed Limit (SL4) [#14] MODE 3 - Controlled Acceleration [#3] MODE 3 - Lift 1 Speed Limit (SL2) [#12] MODE 3 - Tilt Speed Limit (SL3) [#13] MODE 3 - Lift 2 Speed Limit (SL4) [#14] MODE 4 - Controlled Acceleration [#3] MODE 4 - Lift 1 Speed Limit (SL2) [#12] MODE 4 - Tilt Speed Limit (SL3) [#13] MODE 4 - Lift 2 Speed Limit (SL4) [#14] 2-27

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36V/48V 0 66 40 255 255 255 100 255 255 255 50 45 38 96 255 20 58 255 255 255 255 183 0 0 0 0 255 0 0 0 53 34 31 67 53 45 38 80 40 45 38 96 40 67 50 255

PUMP CONTROLLER SETTINGS FOR UL EE CLOSED MOTOR OPTION FBC20K, FBC25K, FBC25KE, FBC25KL, FBC30K AND FBC30KL SN PREFIX: A3BC24, A3BC34 OR A3BC44 PUMP MOTOR DIAMETER: 9" SETTING DESCRIPTION N/A Internal Resistance Compensation Start Controlled Acceleration Armature Current Limit N/A N/A Internal Resistance Compensation Rate N/A N/A N/A Aux1/Aux2 Speed Limit (SL1) Lift 1 Speed Limit (SL2) Tilt Speed Limit (SL3) Lift 2 Speed Limit (SL4) N/A Speed Torque Compensation Card Type Selection (500A/600A) N/A N/A N/A N/A Truck Mode Set by Display minutes minutes seconds N/A Monitor N/A Stored Fault Count Pointer Pump Hourmeter Storage Register Pump Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Lift 1 Speed Limit (SL2) [#12] MODE 1 - Tilt Speed Limit (SL3) [#13] MODE 1 - Lift 2 Speed Limit (SL4) [#14] MODE 2 - Controlled Acceleration [#3] MODE 2 - Lift 1 Speed Limit (SL2) [#12] MODE 2 - Tilt Speed Limit (SL3) [#13] MODE 2 - Lift 2 Speed Limit (SL4) [#14] MODE 3 - Controlled Acceleration [#3] MODE 3 - Lift 1 Speed Limit (SL2) [#12] MODE 3 - Tilt Speed Limit (SL3) [#13] MODE 3 - Lift 2 Speed Limit (SL4) [#14] MODE 4 - Controlled Acceleration [#3] MODE 4 - Lift 1 Speed Limit (SL2) [#12] MODE 4 - Tilt Speed Limit (SL3) [#13] MODE 4 - Lift 2 Speed Limit (SL4) [#14]

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 2-28

36V/48V 0 66 40 255 255 255 100 255 255 255 50 45 38 96 255 20 67 255 255 255 255 183 0 0 0 0 255 0 0 0 53 34 31 67 53 45 38 80 40 45 38 96 40 67 50 255

PUMP CONTROLLER SETTINGS FOR FBC20K, FBC25K, FBC25KE, FBC25KL AND FBC30K SN PREFIX: A3BC28 OR A3BC38 PUMP MOTOR DIAMETER: 9" SETTING DESCRIPTION N/A Internal Resistance Compensation Start Controlled Acceleration Armature Current Limit N/A N/A Internal Resistance Compensation Rate N/A N/A N/A Aux1/Aux2 Speed Limit (SL1) Lift 1 Speed Limit (SL2) Tilt Speed Limit (SL3) Lift 2 Speed Limit (SL4) N/A Speed Torque Compensation Card Type Selection (500A/600A) N/A N/A N/A N/A Truck Mode Set by Display minutes minutes seconds N/A Monitor N/A Stored Fault Count Pointer Pump Hourmeter Storage Register Pump Hourmeter Storage Register MODE 1 - Controlled Acceleration [#3] MODE 1 - Lift 1 Speed Limit (SL2) [#12] MODE 1 - Tilt Speed Limit (SL3) [#13] MODE 1 - Lift 2 Speed Limit (SL4) [#14] MODE 2 - Controlled Acceleration [#3] MODE 2 - Lift 1 Speed Limit (SL2) [#12] MODE 2 - Tilt Speed Limit (SL3) [#13] MODE 2 - Lift 2 Speed Limit (SL4) [#14] MODE 3 - Controlled Acceleration [#3] MODE 3 - Lift 1 Speed Limit (SL2) [#12] MODE 3 - Tilt Speed Limit (SL3) [#13] MODE 3 - Lift 2 Speed Limit (SL4) [#14] MODE 4 - Controlled Acceleration [#3] MODE 4 - Lift 1 Speed Limit (SL2) [#12] MODE 4 - Tilt Speed Limit (SL3) [#13] MODE 4 - Lift 2 Speed Limit (SL4) [#14] 2-29

SET# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

72V/80V 0 66 20 255 255 255 100 255 255 255 100 77 75 255 255 20 58 255 255 255 255 183 0 0 0 0 255 0 0 0 27 58 63 179 27 77 75 217 20 77 75 255 20 116 100 255

MEMORY MAPS Traction Control E2 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

Func No. HS No. 44 46 47 48 49 (26) 50 51 52 53 (28) 54 55 56 57 (30) 58 59 60 61 (32) 62 63 64 65 (34) 66 67 68 69 (36) 70 71 72 73 (38) ; 74 75 76 77 (40) 78 79 80 . 81 (42) 82 83 84 85 (44) 86 87 88 89 (46) 90 91

Traction Control Function Hours (Thou/Hun) 3 BDI 4 Hours (Tens/Ones) 4 Hours (Thou/Hun) 4 Stored Status Code #5 BDI 5 Hours (Tens/Ones) 5 Hours (Thou/Hun) 5 Stored Status Code #6 BDI 6 Hours (Tens/Ones) 6 Hours (Thou/Hun) 6 Stored Status Code #7 BDI 7 Hours (Tens/Ones) 7 Hours (Thou/Hun) 7 Stored Status Code #8 BDI 8 Hours; (Tens/Ones) 8 Hours (Thou/Hun) 8 Stored Status Code #9 BDI 9 Hours (Tens/Ones) 9 Hours (Thou/Hun) 9 Stored Status Code #10 BDI 10 Hours (Tens/Ones) 10 Hours (Thou/Hun) 10 Stored Status Code #11 BDI 11 Hours (Tens/Ones) 11 Hours (Thou/Hun) 11 Stored Status Code #12 BDI 12 Hours (Tens/Ones) 12 Hours (Thou/Hun) 12 Stored Status Code #13 BDI 13 Hours (Tens/Ones) 13 Hours (Thou/Hun) 13 Stored Status Code # 14 BDI 14 Hours (Tens/Ones) 14 Hours (Thou/Hun) 14 Stored Status Code # 15 BDI 15 Hours (Tens/Ones) 15 2-30

Access By

Restrictions

PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only

Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only

MEMORY MAPS Traction Control E2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Func No. HS No. 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 31 32 33 (18) 34 35 36 37 (20) 38 39 40 41 (22) 42 43

Traction Control Access By Function MPH Scaling HS or PC Creep HS or PC Controlled Acceleration HS or PC Armature Current Limit HS or PC Counter EMF Trip Point for Auto Braking HS or PC Auto Calibration of Accelerator Pot HS or PC Minimum Field Current HS or PC Maximum Field Current HS or PC Regen Current Limit HS or PC Field Current for Regen HS or PC Speed Limit 1 HS or PC Top Speed Limit HS or PC Maintenance & Truck Mgmt Speed Limit HS or PC IR Compensation HS or PC Battery Volts Select HS or PC Stall Protection and % ON-Time Trip HS or PC Card Type Select HS or PC Steer Pump Time Delay HS or PC Maintenance Code HM (Tens/Units) HS or PC Maintenance Code HM (Thou/Hun) HS or PC Auto Regen Braking Current Limit HS or PC Mode Storage HS or PC Regen Cancel Current HS or PC FW Start HS or PC Monitor HS or PC Ratio HS or PC Steer Pump Minutes HS or PC Fault Count Pointer HS or PC Steer Pump Hours (Tens/Ones) HS or PC Steer Pump Hours (Thou/Hun) HS or PC Traction Hours (Tens/Ones) PC Only Traction Hours (Thou/Hun) PC Only Stored Status Code #1 PC Only BDI 1 PC Only Hours (Tens/Ones) 1 PC Only Hours (Thou/Hun) 1 PC Only Stored Status Code #2 PC Only BDI 2 PC Only Hours (Tens/Ones) 2 PC Only Hours (Thou/Hun) 2 PC Only Stored Status Code #3 PC Only BDI 3 PC Only Hours (Tens/Ones) 3 PC Only

2-31

Restrictions None None None None None None Contact service Engineering

None None None None None None None None None None None None None None For DD on power up None Contact service Engineering

Temporary Storage Contact service Engineering

Temporary Storage None None None None None Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only

MEMORY MAPS Traction Control E2 90 91 92 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

Func No. HS No. 91 92 93 (48) 95 96 67 48 98 49 99 50 100 51 101 52 102 53 103 54 104 55 105 56 106 57 107 58 108 59 109 60 110 61 111 62 112 63 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

Traction Control Function Hours (Tens/Ones) 15 Hours (Thou/Hun) 15 Stored Status Code #16 Hours (Tens/Ones) 16 Hours (Thou/Hun) 16 Dash Display CA-1 Dash Display Regen C/L-1 Dash Display Auto Regen C/L-1 Dash Display Speed Limit 2 - 1 Dash Display CA-2 Dash Display Regen C/L-2 Dash Display Auto Regen C/L-2 Dash Display Speed Limit 2 - 2 Dash Display CA-3 Dash Display Regen C/L -3 Dash Display Auto Regen C/L-3 Dash Display Speed Limit 2 - 3 Dash Display CA-4 Dash Display Regen C/L-4 Dash Display Auto Regen C/L-4 Dash Display Speed Limit 2 - 4 Secure HM (Tens/Ones) Steer Pump Secure HM (Thou/Hun) Steer Pump Secure Aux HM (Tens/Ones) Secure Aux HM (Thou/Hun) Reserved Reserved Reserved Reserved Truck Minutes Pump Minutes Pump Hours (Tens/Ones) Pump Hours (Thou/Hun) OEM Use OEM Use Accelerator Auto Calibration Slope Accelerator Auto Calibration Y-Intercept

2-32

Access By

Restrictions

PC Only PC Only PC Only PC Only PC Only HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC HS or PC PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only PC Only

Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only Reset to Zero Only None None None None None None None None None None None None None None None None Read Only Read Only Read Only Read Only GE Future Use GE Future Use GE Future Use GE Future Use None None None None None None None None

Accelerator Setup

The purpose of this setup procedure is to make the GE SX Traction controller learn the range of the accelerator potentiometer. If this procedure is not done after new settings are installed into the controller, the display will show a fault code – 08. The default settings are designed to require the accelerator setup every time new settings are installed. Because of this, the accelerator setup should ALWAYS be done right after inputting the settings into the traction controller. This setup should be done any time the accelerator or traction controller is replaced for the production trucks. This procedure can also be performed any time the accelerator appears to be out of adjustment. This adjustment is possible only on traction software version M and higher. 1. 2. 3. 4.

Unplug the battery and blow the horn to discharge the capacitor. Unplug the small black connector from the traction control and plug in the GE handset. Make sure the battery is plugged in and the key switch is OFF. Turn on the Key and while holding down the CONT key on the handset, then release the CONT key after 8888 appears on the handset. (The seat switch must be open) 5. Push 6 on the handset and change the value to 18 by pushing CONT, (the display will start flashing), turn the knob when you see the 18, push store to save setting. 6. Sit on the seat to close the seat switch. 7. Leave the handset plugged in. 8. Make sure the directional lever is in neutral position and the seat switch is closed, Press the ESC key on the handset. 9. If a – 83 appears, one of the above conditions has not been met. You will need to start over. ‘AAAA’ should appear on the handset display. 10. With your foot off of the accelerator pedal, the start switch in the “ON” position, push the directional lever into forward and ‘AAA’ should now appear on the handset display. 11. Put the directional lever back into neutral and ‘AA’ should now appear on the handset display. 12. Depress the accelerator all the way down and hold it. 13. Push the directional lever into forward and ‘A’ should now appear on the handset display. 14. Put the directional lever back into neutral and – 11 should now appear on the handset display. 15. Release the accelerator and the truck should operate normally. If during this procedure a fault code – 86 appears, there may be something wrong with the output of the accelerator or there was just a glitch in the setup. Turn the key switch OFF then back ON to reset the procedure and try again. If the procedure is unsuccessful more than 3 times, then there may be something wrong with the output of the accelerator. The voltage output for the accelerator must not exceed 4.3V and the difference between the output voltage in the OFF position and the output voltage at full activation of the accelerator must be between 2.5V and 4.2V. If any of these criteria are not met, a fault code – 86 will appear. One possible cause for this is the incorrect adjustment of the accelerator pedal stop bolt. The distance from the top of the threaded bolt to the flat surface of the floor plate should be 22 ± 2 mm X (26 ± 2 mm for foot direction control). If the accelerator range is set properly, function 6 will automatically change back to a value of 0. Because the value of function 6 is defaulted to 255 when a controller is initially set up, the accelerator must also be set up every time new settings are installed into the controller.

2-33

Premium Display Speedometer Setup (For Premium Display Option Only)

• • • • • • • • • • •

The premium display has the ability to show the speed of the truck. Since the gear ratio is different between a 1 ton truck and a 2-3 ton truck, the display must be set to show the right speed for the right size truck. Plug the battery into the truck with the key switch OFF and make sure the display is blank. Once the display is blank, press and hold down both gray buttons on the display for 15 seconds. While holding down the buttons, the display will first show a blinking speed unit for 10 seconds, then it will show nothing for 5 seconds. After 15 seconds a number will appear blinking on the right side of the display. At this time, release both buttons. Now you are in the speed setup mode. The value of this setting can be changed from 1 to 25. If the truck is a 1 ton truck set the value to 18. If the truck is a 2 or 3 ton truck, set the value to 5. To set the value, press and hold down the right button. The number will start counting up. Once the correct number is shown, release the right button. To input this value, press and release the left button once. The number should stop blinking if it is set. To exit this setup mode, press and release both buttons once. If the number does not seem like it is being set, exit this setup mode and reenter to try again.

2-34

CHECKS & REPAIRS 3. CHECKS & REPAIRS General Information ............................................................................................................. 3-1 Fuses .................................................................................................................................. 3-2 Exploded View of Contactor ................................................................................................ 3-3 Contactor Repair.................................................................................................................. 3-4 Truck Management Module ................................................................................................ 3-5 Thermal Transfer ................................................................................................................. 3-6 Traction Control ...................................................................................................................3-10 Trouble Shooting Tips (Motors) ..........................................................................................3-11 Unsatisfactory Brush Performance .....................................................................................3-12 Commutator Surfaces Conditions........................................................................................3-18

CHECKS & REPAIRS

General Information

Pump fuse (350 Amperes)

Traction Fuse (350 Ampere for 600 Amp control) (500 Ampere for 740 Amp control) Traction and Pump Ampere rating is identified by the 11th, 12th and 13th digit of the GE part number example: 606 = 600 and 746 = 740 marked on the bottom of the controller by the buses or bus bars.

! WARNING Some adjustments in this section must be done with the battery connected and power applied to the controller. When making these adjustments, make sure the drive wheels are raised from the floor. Some voltage measurements must be made with the SRO circuit complete. Make sure the drive wheels are raised from the surface before doing troubleshooting. If working alone, put a weight in the seat to close the seat switch. Put the voltmeter so that you can see it from the operator area. This will allow the controls to be operated while taking voltage measurements.

3-1

CHECKS & REPAIRS

General Information

! WARNING Make sure to disconnect the battery and separate the connector before disassembling any part of the controller. The capacitor stores electrical energy and can cause injury if a person discharges a capacitor through parts of the body. AFTER the battery is disconnected, make sure to also discharge the capacitor by using a p/n 358-280 Resistor across the positive and negative terminals on the control panel for a least 20 seconds.

☞ NOTICE ☞ The electronic controller in these lift trucks can not be seen from the operator area. Some checks and adjustments are difficult to do unless another person can operate the controls.

☞ NOTICE ☞ The bolts and screws connected to the electronic components are normally metric sizes. Make sure that the correct fastener for the part that has been disassembled is used.

Fuses The fuses are found on the SX control panel. The value of the power fuse for the traction controller is 350 amps for the 600 amp controller and 500 amps for the 740 amp controller. The value of the power fuse for the hydraulic pump controller is 350 amps and the value for the hydraulic pump contactor is 500 amps. The value of the power fuse for the power steering motor is 60 amps. The condition of the fuses can be determined by looking at them or checking with an ohmmeter.

3-2

CHECKS & REPAIRS Contactor Line 1 CONTACTOR 2 WASHER,PLAIN 3 TIP,SPRING TOP 4 TIP,SPRING 5 TIP, SPRING SEAT 6 TIP,MOVABLE 7 CLAMP,BUS 8 SCREW 9 WASHER, LOCK 10 TIP,CARRIER 11 BUSHING, PLUNGER 12 TIP, STATIONARY 15 BASE,BUS 16 ARMATURE 17 SPRING, ARMATURE 18 FRAME 19 COIL 20 MAGNET BASE ASSY 21 KIT,SERVICE TIP 22 NUT

Contactor Repair Make a location identification for the wires and cables then disconnect from the contactor assembly. Remove the mounting screws and remove the contactor assembly. Contactor Contacts. The contacts in a contactor are made of special silver alloy. The contacts will look black and rough from normal operation. This condition does not cause problems with the operation of the lift truck. Cleaning is not necessary. DO NOT USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE CONTACTS.

! WARNING ALWAYS replace all of the contacts in a contactor at the same time. Replace the contacts in the contactor for the hydraulic pump after 1000 hours of operation. Replace the contacts in the other contactors when the thickness of any area of a contact is less than 30% of the thickness of a new contact or if there is any transfer of contact material.

Typical Contactor Assembly

3-3

CHECKS & REPAIRS

Contactor Repair Coil. Check the coil with an ohmmeter for an open circuit or a short-circuit. Replace if damaged. The coils in the contactors for the hydraulic pump and 1A have an external suppressor. The coil and the suppressor can be checked separately with an ohmmeter. A suppressor diode (and sometimes a resistor in series) is part of the coil. The diode will cause the ohmmeter to indicate a difference in resistance in one direction. Reverse the probes of the ohmmeter to the opposite terminals and measure the resistance. Use the highest resistance.

COIL RESISTANCE TEST SPECIFICATIONS Line, Traction Line and Pump Line (36/48V)

59 ohms ± 10%

Line and Power Steering (72/80V)

161 ohms ± 10%

Power Steering (36/48V)

77 ohms ± 10%

Pump and 1A Bypass (36/48V)

33 ohms ±10%

Brush Wear Indicators

Motor Thermal Switches

The brush wear indicator will illuminate on the premium display only, when the motor brushes must be replaced. The sensor is located on the brush carrier and will come in contact with the brush holder when the brushes have passed a serviceable limit. When the brush wears within approximately 1.5 mm (0.060 in) of the brush lead, the connection between the brush and the sensor causes the indicator to illuminate on the premium display

The motor thermal switch will illuminate on both displays. The switch is located in the motor and the over temperature action light will illuminate when the motor overheats. The thermal switch cannot be replaced if it is damaged. The thermal switch can only be replaced by replacing the motor fields.

The operation of the brush wear indicators can be checked during periodic maintenance. The battery must be removed from the lift truck for access to the motors.

! WARNING

Use a jumper cable so that the battery can be connected for operation of the motors. See FIGURE 11. Disconnect the sensor wires from the outside of the motor case. Touch the ends of each sensor wire to the A1 terminal of the motor while it is in operation. The warning light will illuminate if the

1. RAISE DRIVE WHEELS 2. REMOVE BATTERY 3. INSTALL JUMPER

To prevent damage and injury if the lift truck moves. Raise the drive wheels from the floor during these tests.

Use a jumper cable so that the battery can be connected for operation of the motors. See FIGURE 11. Disconnect the sensor wires from outside of the motor case. Touch the ends of the sensor wire together. The warning light will illuminate if the circuit is operating correctly.

Connect the battery so that the motor can be operated. The battery must be removed for access to the motor. Use a jumper cable to connect the battery to the lift truck. Raise the drive wheels. See “Before Servicing Forklift Truck” in the GENERAL INFORMATION Section.

FIGURE 11. Connect Battery to Operate Motor 3-4

CHECKS & REPAIRS

☞ NOTE ☞

Truck Management Module

The microprocessor only checks for TMM status codes 94 and 95 when a neutral signal is present (i.e. open start switch or open F/R switch), the status code is displayed and the speed limit enabled when the control is returned to the run mode.

The Truck Management Module is a multi-function accessory card or an auxiliary function of the SX Pump control used with the SX series Traction controls. The TMM card provides the status codes or operator warning codes, that will be displayed on the dash display whenever a normally open switch or sensor wire provides a signal to. The TMM is used to display overtemperature of motors, hydraulic systems or any other device or system than can activate a thermostat type switch that closes at the desired temperature. Status code 90 not only displays the status code to the dash display but when activated can be programmed with the Handset to reduce the speed of the truck from 100% to 0% percent on time. The TMM is also used to monitor and display motor brush wear warnings on the premium display when the motor brushes require replacement.

The TMM is also used as a Brush Wear Indicator (BWI) when the truck is equipped with a premium display. The Brush Wear Indicator is designed to detect a worn-out brush and display a fault code on the dash display to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface. The BWI is a sensor that short circuits to the motor armature to signal limits of brush wear. NOTE: Motor armature must be in the positive side of the battery circuit.

Operation The TMM card utilizes up to 6 input points and 3 output points (See Wiring Section for connections). The 3 output points connect to the “P2” plug on the traction Controller. The input to the TMM card is a switch wire closure to battery negative or positive.

! WARNING Before adjusting, servicing or making contact with working components, raise the truck wheels off the floor, disconnect the battery and discharge the capacitor in the traction and pump controls

The instructions for adjustment of the speed limit function of status code 90 is described in detail in the instructions for the Handset. The speed limit function will be enabled when the input switch supplies a negative signal to TB1.

3-5

CHECKS & REPAIRS

Thermal Transfer Why is Thermal Transfer important? Solid-state electronic devices are often considered “lossless” as compared to their electro-mechanical counterparts. However, these devices are not entirely 100% efficient and losses exist in the form of generated heat which must be dissipated properly to insure long-term reliability and performance. The Control incorporates solid-state devices throughout. It also incorporates heat sinking to provide proper dissipation of the generated heat through these heat sinks to the control base to be eventually dissipated in the vehicle control mounting structure (i.e. bulkhead). The Control heat sinks are designed to provide relief from short-term thermal peak overloads, but long-term cooling is dependent on proper thermal transfer from the heat sink to the vehicle frame.

What determines “Good” Thermal Transfer? The primary factor for insuring “good” thermal transfer is a good mechanical surface-to-surface interfacing for flat and threaded surface mating. The effectiveness of the thermal transfer is a function of the amount of actual surface contact there is between a heat “source” and a properly selected heat “sink”. While most commercially prepared surfaces appear flat and smooth, good thermal transfer of the heat generated in solid-state devices requires the optimum in surface contact. The smallest amount of surface irregularity can be detrimental as it adds to the thermal resistivity between the two surfaces and limits thermal transfer. “Good” thermal transfer is thus dependent on 3 factors: 1. Proper heat sinking. 2. Proper mechanical mating (mounting). 3. Optimum surface contact.

3-6

CHECKS & REPAIRS Insuring Proper Thermal Transfer Mounting Instructions for Motor Controls In the design of this family of motor controls, performance assumptions were made based on heat transfer between the control and the ambient environment. The vehicle mounting surface acts as a heat sink, which increases the effective surface area for heat dissipation. If this assumed heat transfer is not achieved during control installation and operation, the controllers will fall short of their anticipated performance. It should be noted that the condition of the mounting surface, and the quality of the resulting interface between the control and the vehicle, can significantly hinder heat transfer from the control.This why each control has a thin sheet of copper between the control and the frame of the truck. The presence of contaminants, or of air voids created by surface inconsistencies in either the vehicle or the control, degrade the control’s capacity for heat transfer. The control’s performance is de-rated proportionally as its own thermal sensors reduce its operation to protect it from damage due to excessive heating. Contained within the software of the controls are several diagnostic status codes related to controller thermal performance. Failure to follow these mounting recommendations increases the likelihood of encountering these status codes. Careful surface preparation, including adequate application of thermal compound, as detailed in the following paragraphs, must be completed during the installation of the controls. There are many techniques for applying thermal compound, and one approach is outlined below that has shown to apply a consistent thickness of material. Necessary Tools Recommended use of the following components, or equivalent substitutions, during the control installation process: a) Thermal compound, (5P9837), maintained per the manufacturer’s recommendations and free of contaminants b) 3/32" notched trowel, such as a adhesive spreader, model SE000049 c) Calibrated torque wrench (0 – 15 ft-lbs) The Controls During the manufacture of the control, the surface flatness is maintained at 0.005" per linear inch (not to exceed 0.025" per 10.0 inches). The surface finish of the control has an Ra (average roughness) of 64 (microinches), or better. This finish is consistent with cold rolled or extruded aluminum. Care should always be taken in the handling and storage of controllers. The base of the control should be free from nicks, bumps, protrusions or any other foreign object that would prevent the control from sitting flush with the vehicle mounting surface. Examine the base of the control to verify that it is in good condition and free from damage or contamination. Vehicle Mounting Surface The quality of the vehicle mounting surface is critical for the optimum heat transfer between the control and the ambient environment. Conduction through the base of the control is the control’s only means of heat rejection. While the controls are highly efficient, a few percent of the electrical energy will be converted into heat. As previously mentioned, if this energy is not dissipated through the base of the control, a thermal protector will reduce the performance of the control until the temperature stabilizes. For optimal heat transfer from control to vehicle, the flatness of the vehicle mounting surface should be equivalent to the flatness of the control surface (0.005" per linear inch). Use a straight edge or dial indicator to verify the mounting surface. The biggest hindrance to heat transfer is the presence of rust, scale, weld splatter or paint on the vehicle mounting surface. If any of these items are noted, prepare the surface per the following guidelines: a) Clean the mounting surface with a rotary wire brush until the metal surface is exposed. b) Using 80-100 grit emery paper, sand the surface until the metal shines. c) Flush the surface clean with an appropriate liquid de-greaser or parts cleaner.

3-7

CHECKS & REPAIRS Application of Thermal Compound Due to the minute differences in the control mounting surface and the vehicle mounting surface, small pockets of air will be created. These air pockets will add to the overall thermal resistance of the interface. To avoid these air pockets and improve thermal conductivity, thermal compound must be applied between the control base plate and the vehicle mounting surface. The function of this compound is to conform to surface discrepancies, filling gaps and optimizing the metalto-metal contact of the control and the vehicle. a) Prepare the two mounting surfaces (control and vehicle) as indicated above. b) Using a triangular notched trowel of 3/32" (.09" ± .01), apply the grease to the vehicle mounting surface. c) Use straight, non-crossing strokes of the trowel to apply the compound. d) Make multiple vertical passes until a uniform consistency is achieved.

Adhesive spreader model SE000049

Vehicle surface after proper grease application

Mounting the Control a) After control mounting surface is prepared with heat sink grease, place the copper heat conducting pad on heat sink grease and align holes as positioned. b) After placing the copper pad, apply heat sink grease to the exposed side of the pad using the same method as before. c) Prepare mounting surface of truck. d) Place the control unit with desired orientation on mounting surface of truck with mounting holes aligned. e) Move the control slightly in all directions to eliminate voids and enhance the distribution of the thermal compound. f) Insert all of the mounting hardware (6 or 8 bolts, M6, necessary for the mounting of the respective control). g) Tighten these bolts (as per sequence shown in diagrams below) to half of the nominal torque value (4 ft-lb). h) Lastly, tighten the bolts to the nominal torque value (8 ft-lb), following the same sequence.

Calibrated torque wrench for hardware installation

3-8

CHECKS & REPAIRS Traction 8

Hydraulic 4

Proper sequence for use in tightening hardware during control mounting

Maintenance If it is necessary to remove the control, careful consideration must be given to removing the old thermal compound from the control and mounting surface, prior to replacement of the unit. Never re-use thermal compound. Use a putty knife or similar straight edge to carefully remove all thermal compound residue without damaging either mounting surface. Flush the surfaces with a liquid de-greaser or parts cleaner and allow them to dry, before re-applying the thermal compound and mounting the control. Take care not to contaminate the surfaces with hydraulic fluid or battery acid. If the copper heat conducting pad between the control and the truck shows signs of corrosion that cannot be cleaned,, then the copper pad must be replaced. otherwise, carefully remove the old thermal compound and reapply it before installing the new control.

3-9

CHECKS & REPAIRS Traction Control

1 2 3 4

Traction Control Pad, TR Heats Bolt, Washer Assembly Washer, Plain

5 6 7 8

3-10

Bolt, Lockwasher Assembly Washer, Plain Fuse Washer, Spring

CHECKS & REPAIRS

Trouble Shooting Tips (Motors) SUCCESSFUL ☞ COMMUTATION ☞ REQUIREMENTS

☞ INSULATION SYSTEM ☞ • Insulation resistance - 0.10 Mega-ohm (or greater)

• Good contact between commutator and brush

• Less than 0.10 Mega-ohm, investigate: – Excessive dirt – Moisture – Insulation break down

• Mechanically true commutator • Brushes free to move in holders • Copper-Oxide-Carbon film (as opposed to pure copper surface) noted by color variations

For moisture, bake in an oven at 90 degrees C (190F)

• Commutator surface should be clean and smooth

• 600V - 60HZ - 1 minute

• Clean commutator

• Test older motors at 75% of above values

NOTE: Refer to the next following pages for charts on “Unsatisfactory Brush Performance” and illustrations of “Commutator Surfaces” which show the main patterns of film build-up on commutators, and indicate the type of brush/commutator interaction which give rise to each pattern.

☞ ARMATURE WINDING PROBLEMS ☞ • Open Circuit – Thin red sparks encircling commutator – Blackens or flattens commutator bars, especially at edges

☞ SPARKING AT BRUSHES ☞

• Short Circuit – Blue spark in vicinity of brush holder – Commutator bars oxidize or burn

• Commutator in poor condition • Eccentric or rough commutator

• Grounded – High current draw – Rapid brush wear

• Excessive vibration • Broken or sluggish spring • Brushes to short • Machine overloaded • Short circuit in armature

Notes:

3-11

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE ONE Primary Sources of Unsatisfactory Brush Performance

Preparation and Care of Motor

Mechanical Fault in Motor

Electric Fault in Motor

Load or Service Condition

Disturbing External Condition

• Poor operation of commutator surface • High mica • Side mica • Need for periodic cleaning • Clogged ventilating ducts • Brushes tight in holders • Brushes too loose in holders • Brush holders loose at mounting • Loose pole pieces • Loose or worn bearings • Dynamic imbalance • Variable angular velocity • Open or high resistance connection at commutator • Connection at series terminal • Short circuit in field or armature winding • Ground in field or armature winding • Reversed polarity on main pole • Overload • Dynamic braking • Low average current density in brushes • Contaminated atmosphere • “Contact positions” • Oil on commutator or oil mist in air • Abrasive dust in air • Humidity too high • Humidity too low • Silicone contamination • Loose or damaged motor mounting • External source of vibration • External short circuit • Contact drop of brushes too high • Contact drop of brushes too low • Lack of film-forming properties in brush • Lack of polishing action in brush • Brushes too abrasive • Lack of carrying capacity 3-12

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE TWO Indications Appearing at Brushes INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Sparking

Commutator surface condition

• Poor operation of commutator surface • High mica • Side mica • Low average current density in brushes • Contaminated atmosphere • Contact positions • Oil on commutator or oil mist in air • Humidity too low • Lack of film-forming properties in brush • Lack of polishing action in brush

Mechanical fault in motor

• Clogged ventilating ducts • Brushes tight in holders • Brushes too loose at mounting • Loose pole pieces • Loose or worn bearings • Dynamic unbalance • Incorrect spring tension

Electrical fault in motor

• Open or high resistance connection at commutator

• Short circuit in field or armature winding • Ground in field or armature winding • Reversed polarity on main pole Bad load condition

• Overload • Rapid change of load

Vibration

• Loose or damaged motor mountings • External source of vibration

Chattering of brushes

• See Chattering or Noisy Brushes

Wrong brush grade for

• Lack of film-forming properties in brush application

Other

• Silicone contamination

Etched or Burned Bands on Brush Face

Embedded copper

• See Copper in Brush Face

Rapid Brush Wear

Commutator surface condition

• See specific surface fault in evidence • Silicone contamination

Severe sparking

• See Sparking 3-13

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE TWO (cont’d) Indications Appearing at Brushes INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Rapid Brush Wear (cont’d)

Imperfect contact w/commutator

• Incorrect spring tension • Brushes tight in holders • Brushes too loose in holders • Brushes holders loose at mounting • Loose or damaged motor mountings • External source of vibration

Wrong brush grade f/application

• Lack of film-forming properties in brush

Commutator surface condition

• High mica • Side mica

Bad service condition

• Oil on commutator or oil mist in air • Abrasive dust in air • Humidity too high • Humidity too low

Wrong brush grade f/application

• Lack of film-forming properties in brush • Brushes too abrasive

Commutator surface condition

• Raised Commutator Bars

Looseness in motor

• Brushes too loose in holders • Brushes holders loose at mounting • Incorrect spring tension

High friction

• Clogged ventilating ducts • Contact poisons • Humidity too low • External source of vibration

Wrong brush grade f/application

• Lack of film-forming properties in brush

Copper in Brush Face

Chattering or Noisy Brushes

3-14

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE THREE Indications Appearing as Heating INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Heating in Windings (Field or Armature)

Severe load condition

• Overload • External short circuit • Stalled motor

Unbalanced magnetic field

• Loose or worn bearings • Short circuit in field or armature winding

Lack of ventilation Heating at Commutator

Heating at Brushes

Severe load condition

• Overload

Severe sparking

• Contact positions • See Sparking

High friction

• Incorrect spring tension • Contact poisons • Humidity too low • Lack of film-forming properties in brush

Poor commutator surface

• See specific surface fault in evidence

Depreciation

• Clogged ventilating ducts

High contact resistance

• Contact drop of brushes too high

Severe load condition

• Overload

Faulty motor adjustment

• Incorrect spring tension

Severe sparking

• See Sparking

Raw streaks on commutator

• See Streaking or Threading of Surface

Embedded copper

• See Copper in Brush Face

Wrong brush grade f/application

• Contact drop of brushes too low • Lack of film-forming properties in brush • Brushes too abrasive • Lack of carrying capacity

3-15

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE FOUR Indications Appearing at Commutator Surface INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Brush Chipping or Breakage

Commutator surface condition

• See specific surface fault in evidence

Looseness in motor

• Brushes too loose in holders • Brushes holders loose at mounting

Vibration

• External source of vibration

Chattering

• See Chattering or Noisy Brushes

Sluggish brush movement

• Brushes tight in holders

Rough or uneven surface

• Poor operation of commutator surface • High mica • Side mica

High Commutator Bar

Sparking

• Stalled motor

Low Commutator Bar

Sparking

• High mica • Open or high resistance connection at commutator

• Stalled motor Sparking

• Low average current density in brushes • Contaminated atmosphere • Contact positions • Oil on commutator or oil mist in air • Humidity too low • Lack of film-forming properties in brush

Copper or foreign material in brush face

• High mica • Side mica • Oil on commutator or oil mist in air • Abrasive dust in air • Humidity too high • Brushes too abrasive

Bar Etching or Burning

Sparking

• High mica • Side mica

Bar Marking at Pole Pitch Spacing

Sparking

• Open or high resistance connection

Streaking or Threading of Surface

at commutator 3-16

CHECKS & REPAIRS

Unsatisfactory Brush Performance TABLE FOUR (cont’d) Indications Appearing at Commutator Surface INDICATION

IMMEDIATE CAUSES

PRIMARY FAULTS

Bar Marking at Slot Pitch Spacing

Sparking

• Lack of polishing action in brush • Lack of film-forming properties in brush

Flat Spot

Sparking

• Open or high resistance connection at commutator

• Stalled motor Discoloration of Surface

High temperature

• See Heating at Commutator

Atmospheric condition

• Contaminated atmosphere • Oil in commutator or oil mist in air

Wrong brush grade for application • Lack of polishing action in brush • Lack of film-forming properties in brush Raw Copper Surface

Embedded copper

• See Copper in Brush Face

Bad service condition

• Contact positions • Abrasive dust in air • Humidity too low

Wrong brush grade for application • Lack of film-forming properties in brush • Brushes too abrasive Rapid Commutator Wear with Blackened Surface

• High mica • Side mica • Incorrect spring tension • Brushes tight in holders • See Sparking

Burning

Severe sparking Rapid Commutator Wear with Bright Surface

Foreign material in brush face

• Contact positions • Abrasive dust in air • Humidity too low • Brushes too abrasive

Wrong brush grade for application • Brushes too abrasive • Lack of film-forming properties Copper Dragging

• External source of vibration • Lack of film-forming properties in brush

Brush Vibration 3-17

CHECKS & REPAIRS

Commutator Surfaces GOOD CONDITION

UNSATISFACTORY CONDITION

LIGHT FILM

UNEVEN FILM

Uniform coloring indicates satisfactory operation of machine and brushes. Film color is largely an effect of thickness, therefore provided the film is uniform it is perfectly acceptable.

Patchy colors of varying densities and shape. Due to unclean operating conditions or incorrect physical condition of commutator.

SATISFACTORY CONDITION

UNSATISFACTORY CONDITION

LIGHT AND DARK PATTERN This is not a good condition but in our experience it is known that machines having this commutator pattern have operated with satisfactory results for long periods of time. This condition can appear in alternating bars as shown or every 3rd or 4th bar, etc. This is related to the winding design of the armature. Difficulty caused from split windings crossing in the same slot.

FILM WITH DARK AREAS

UNSATISFACTORY CONDITION

STREAKY FILM WITH NO COMMUTATOR WEAR

EXAMPLE OF POOR COMMUTATOR MACHINING

These areas can be isolated or regular. Commutator out of round. This can be caused by vibration or mechanical deficiencies in equipment operation, bearings, couplings, etc.

Frequently due to under-loaded operation, machine grossly over-brushed or brush grade incorrect for particular machine application. Atmosphere and environmental conditions can contribute.

Bars are low on entry and leaving edges giving rise to the brushes riding on the middle of the bars.

3-18

CHECKS & REPAIRS

Commutator Surfaces UNSATISFACTORY CONDITION

UNSATISFACTORY CONDITION

EXAMPLE OF POOR COMMUTATOR MACHINING

BRUSH CONTACT MARK Storage of machines, for lengthy periods, with brushes in position. This can also result from operation of machine in prolonged stall conditions.

Bars are low in the middle giving rise to the brushes riding on entry and leaving bar edges. This and the previous illustration indicate the need for better maintenance.

UNSATISFACTORY CONDITION

STREAKY FILM WITH COMMUTATOR WEAR

BAR EDGE BURNING CAUSE HIGH MICA

This is a further development of the third example, previous page. Brush grade, machine applications and working environment all suspect. Earlier corrective action should have been taken.

Illustration shows high mica in every slot. Same effect can occur on one bar only. Similar conditions can be caused by a high or low bar.

UNSATISFACTORY CONDITION

DOUBLE POLE PITCH

SMALL BRIGHT SPOTS

Darkening of commutator in sequences two pole pitches apart is due to armature fault, defective coil, riser bars or equalizer connections.

Related to over-loaded machines and low brush pressure. Due to sparking under brush which gives rise to spots being of a random distribution. If not corrected, will result in scored commutator.

3-19

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM 4.

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

SX Control F2

Neg

GE Name Plate and Part Number P1

A1 Positive

Note: The settings for the controller must be set after installation. See Controller Setup in the Handset section for the proper procedure.

These troubleshooting instructions are intended as a method to check all outside devices and eliminate them as the source of the problem in order to conclude that the SX Control is faulty. Instructions for Removal of SX Control 1. Disconnect Battery, Discharge Cap, Raise drive wheels. 2. Unplug main and Y plugs by pressing down on tab and pulling straight out on connector. Never use wires to pull out connector. 3. Remove power fuse and all Bus or cable connections from control.

4-1

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM The primary method of diagnosing SX Control System 1st Check is for Shorts to frame. Voltage on frame faults is to use the diagnostic features of the display and handset. These, along with the preceding fault code tables, may cause many problems and codes. aid in the resolution of the majority of faults encountered. 2nd Checks are always loose/dirty connections at If a problem is readily identified through the built-in diagcontroller and harness connections. nostics feature, use the following tables as a secondary guide to aid in the identification of the fault.

TABLE ONE Failures that Cause Reduced or No Motor Torque

☞ NOTE ☞

Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1a. Line Contactor does not pick up. No control voltage from positive to negative.

• Check power and control fuses. • Check battery for low specific gravity and connections for looseness or broken connector.

1b. Line Contactor does not pick up. with control voltage positive to negative

• Check PTC (Positive Temperature Coefficient) for heating. If hot to touch, check for proper battery polarity to control panel.

• Plug in the battery with the key switch OFF. Voltage on should be battery volts at P1-1.

• Close key switch and check volts at P1-2; voltage should be battery volts. If not check control fuse FU2

• With key switch and seat switch closed, check for battery volts at P1-6. If zero, check control fuse, wiring or faulty key switch. If low check for volt drop across circuit from battery pos to P1-6.

• With key switch and seat switch closed, check for battery volts at P1-2. If zero, check control wire #10 between key switch and seat switch and control card or fault seat switch. If low check for volt drop across circuit to P1-2.

• Check for positive at line contact coil. P10-2 connection. If not battery volts check line coil for open or possible loose connections.

• Static Return to Off Fault. If monitoring system warning light on display (!) comes on, once the key switch and seat switch are closed:

• Check for fault in directional control switch. • Check for fault in wiring to directional control switch

4-2

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

TABLE ONE (cont’d) Failures that Cause Reduced or No Motor Torque

☞ NOTE ☞

Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1c. Line contact closes, truck doesn’t move

• Check power fuse at positive on control. Should be battery volts. If not, check power fuse by volt drop check across fuse

• Check for over temperature condition on traction motor or traction control.

• Check voltage at A1 and A2, should be battery volts. If not, check motor cables and volts at A1 and A2 to locate open circuit. Check motor brushes for sticking

• Check F1 to F2 for open field circuit. (loose connections) • Check for voltage on F1 and F2, it should increase and decrease by pressing accelerator and releasing.

• Check voltage at P1-7. Should be 0.5 volts with accelerator at creep speed, increasing to 3.5 volts or more as the accelerator is pressed down to top speed. If P1-7 remains at about 0.5 or less volts, check start switch and accelerator potentiometer.

• Check circuit from accelerator start switch and potentiometer to traction control for open wires.

• Check motor A1 to A2 for open circuit in motor armature. • Check motor F1 to F2 for open circuit in motor fields. • Check for direction switch inputs to control at P1-5 and P1-6 for forward and reverse. If voltage not present, check circuit to accelerator. Positive at P7-A and check for circuit through switch at P7-B and P7-C.

• Replace the SX Traction control.

4-3

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

TABLE ONE (cont’d) Failures that Cause Reduced or No Motor Torque

☞ NOTE ☞

Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1d. Line contactor closes, display powers up, Power steering contactor does not close.

• Check for direction switch positive to control at P1-4 and P1-5. If not present check direction switch and voltage to switch.

• With direction switch input voltage to P1-4 or P1-5. Check for positive voltage to power steering coil at P10-3 wire 21. If voltage is not present check coil for open by resistance check. If Low voltage check for volt drop across wire 10 from key switch and across key switch.

• If battery voltage is correct at P10-3 and all other voltage are correct to traction control. The power steering driver in the control has failed and SX controller must be replaced.

4-4

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

TABLE TWO Mis-operation of Other Features

☞ NOTE ☞

Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1a. 1A Bypass contact does not close (If equipped)

• Check accelerator voltage to control at P1-7. Voltage should start at below 0.5v and increase to above 3.5 volts as accelerator is depressed

• Voltage from accelerator must go above 3.5V at P1-7 to achieve 1A By Pass operation.

Warning: Do Not use jumper wire on coil driver with motor in static condition or Severe damage may occur to motor armature. However controller protects against this action and should produce a code

• Check Battery position voltage at 1A bypass coil to PID driver terminal 3 wire 30.

• Check for Battery Neg at PID driver terminal 2. • Check for signal voltage from control at P1-11 to PID driver terminal 1. Voltage should be less than 12.

• If voltage is 12 or higher at P1-11 or PID driver terminal 1 then check for open PID driver.

• If voltage is 2 or less and terminal 2 and 3 do not complete the circuit the PID driver may be shorted or open and should be replaced.

4-5

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

TABLE THREE Mis-operation of Other Features

☞ NOTE ☞

Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

1a. 1A Bypass contactor close with key.

• Check for short to negative on wire 45 from coil to driver terminal 3.

• Check for signal voltage at P1-11 if present. Replace SX controller

1b. Power Steering contact closes with key switch

• Check for voltage short to battery neg on wire 21 between P10-3 and P1-18.

• Check Negative voltage at P10-3. If present replace SX controller.

4-6

SX CONTROL CONNECTIONS & TROUBLESHOOTING BY SYMPTOM

TABLE THREE (cont’d) Mis-operation of Other Features

☞ NOTE ☞

Conduct all testing with drive wheels raised off the floor.

Symptom

Probable Cause

3a. 1A Bypass contactor will not close at stall. (If equipped)

• Check voltage. • Check Bypass contactor and driver and wiring. • Replace SX Controller.

3b. 1A will not open until start switch is opened.

• Check voltage at P1-7. Should be near 0.5 volts, or below

3c. Stiff Regen (severe reversal).

• Check Regen adjustment setting on Controller.

when accelerator is released. If not, check accelerator output.

• Check controller type setting. • Check traction motor brushes. • Check traction motor commotator for raised bars or out of round..

• Replace SX Controller. 3d. Very soft reversal during regen braking mode.

• Check for proper adjustment of regen. • Check controller type setting • Replace SX Controller.

4-7

NOTES

4-8

WIRING 5. WIRING Traction Bypass with Pump Contactor Schematic ............................................................... 5-1 Pump Contactor Schematic.................................................................................................. 5-3 Traction Bypass with Pump Contactor Schematic ............................................................... 5-5 Traction Bypass with Pump Control Schematic ................................................................... 5-7 Pump Control Schematic...................................................................................................... 5-9 Traction Motor Controller with Pump Motor Controller and Bypass.....................................5-11 Voltage Checks.....................................................................................................................5-13 TMM7A (Truck Management Module) .................................................................................5-16 Pump Driver..........................................................................................................................5-18 Pump Time Delay ................................................................................................................5-19

WIRING Connections to Main Traction Plug P1 with Controller Hydraulics Pin Wire 1 2 2 10 3 15 4 6 5 8 6 7 7 29 8 9

28 56

11 12 13 14 15 16 17

COLOR Blue Yellow Yellow / Black Green Green / Black Red White

PUMP INPUT/OUTPUT NORMAL Battery volts from battery B + Battery volts from key 0 Accelerator Start Switch 0 Forward Switch 0 Reverse Switch 0 Seat Switch 0 Accelerator Input .3 - .8 V Voltage Signal Black Accelerator Negative 0 Black Accelerator Pot + 4–5V 5 Volt Supply Black / White BDI Interrupt for .5 V Lift Lockout Blank Blank Blank Blank Blank Blank Black /Red LINE CONTACTOR B+ DRIVER AND SUPPRESSION Black / Green STEER PUMP CTR B+ DRIVER AND SUPPRESSION Blank Blank Yellow HOURMETER INPUT 0V FOR PUMP CONTACTOR Blank Blank

19 20 21 10 K 22 23

ACTIVE B+ B+ B+ B+ B+ B+ 3.4 – 4.2 v B4.2 V

TEST PROCEDURE Plug in Battery Key on Push Accelerator Move F/R to Forward Move F/R to Reverse Close Seat Switch Push Accelerator to floor Checked to Battery + Battery Plugged in

12 V 0V

Seat switch closed Low Battery (lift Lockout)

0-1 V

Line Contactor Closed

0-1 V

Steer Contactor Closed

B+

Key on

Pins 1 & 2 Normal Voltage is Battery plugged in Key and Seat Switch open. Pins 3 – 8 Normal Voltage is Battery plugged in Key Closed and Seat Switch open. Pins 9 –23 Normal Voltage is Battery plugged in Key and Seat Switch Closed.

2 9

3 10

4 11

5 12

6 13

6 14

Input Pins 1-8

Outputs & Signal Voltage Pins 9-23

15 22

WIRE HARNESS VIEW- MAIN PLUG

5-13

WIRING Connections to Main Hydraulic Plug P5 with Controller Hydraulics Pin Wire 1 2A 2 10A 3 4 5 85 6 86 7 8 87 9 88 10 17

COLOR Blue Yellow Blue / White Yellow / White Violet / White Green / Black Black / White

PUMP INPUT/OUTPUT NORMAL ACTIVE Battery volts from battery B + B+ Battery volts from key 0 volts B+ Blank Blank BWI Traction Motor 0 volts BWI Traction Motor 0 volts Blank BWI Pump 0 volts BWI Pump 0 volts Hyd. Enable signal 12 volts 0 volts

11 12

82 52

Red / White Yellow / Blue

Pump Temperature Pump Aux 1 & 2 Switch

5 volts 5 volts

13 14 15 16 17 18 19

24 23 80 53

Green Green Brown / White Yellow / Black

To Plug 2 – 8 To Plug 2 – 9 Blank Traction Temperature Blank Blank Hyd lift Switch # 2

5 volts 5 Volts

20 21

51 54

Yellow / Green Tilt Switch Yellow / Red Hyd lift Switch #1

22 23

2 9

3 10

4 11

Blank Blank

5 12

6 13

6 14

8 15

WIRE HARNESS VIEW- MAIN PLUG

5-14

0 volts 0 volts

TEST PROCEDURE Plug in battery Key switch on

Brushes worn Brushes worn Brushes worn Brushes worn Low Battery (lift cutout) Seat switch closed Over Temp light on Handle pulled (switch closed)

5 Volts

0 Volts

Over temp light on

5 Volts

0 Volts

5 Volts 5 Volts

0 Volts 0 Volts

Pull lift lever full (High Speed lift) Push tilt lever Pull lift lever back (Low speed lift)

WIRING CONNECTIONS TO MAIN PLUG (23 PIN) AND P2 or P4 PLUG (12 PIN) PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

TRACTION INPUT/OUTPUT (P1) Battery volts from battery Battery volts from key Battery volts from start switch Battery volts from forward switch Battery volts from reverse switch Battery volts from seat switch Accelerator input voltage signal Accelerator negative Accelerator pot +5 volts supply BDI interrupt for lift lockout 1A Driver signal Optional switched speed limit set by function 11 Not used Hydraulic switch sensor Not used Not used Line contactor driver and suppression Steer pump control driver and suppression 1 TMM +5 volt supply Not used Hourmeter input for pump contactor Not used Not used

PUMP INPUT/OUTPUT (P5) Battery volts from battery Battery volts from key Status code 93 input Status code 93 input Status code 94 input Status code 94 input Potentiometer input voltage signal Status code 95 input Status code 95 input Pump Enable signal 12v DC Status code 91 input Speed limit #1 input TMM brushwear indicator output TMM over temperature output Status code 92 input Status code 90 input Line contactor driver A contactor driver Speed limit #2 input Speed limit #3 input Speed limit #4 input Not used Not used

2 9

WIRE HARNESS VIEW P2 or P4

Pin 1 2 3 4 5 6 7 8 9 10 11 12

3 10

4 11

5 12

6 13

6 14

8 15

WIRE HARNESS VIEW- MAIN PLUG

Traction P2 “Y” Plug Input/Output Not used Not used Not used Negative +5 volt supply Cont/Store(in) Handset Not used Value Function Not used Serial Receive Serial Transmit

Pump “P4” Plug Input/Output Not used Not used Not used Negative +5 volt supply Cont/Store(in) Handset Not used Not used Not used Not used Serial Receive Serial Transmit

5-15

WIRING

TMM7A (Truck Management Module)

CONNECTOR WIRE TERMINAL #

DESCRIPTION

–

Traction Motor BWI

P2-9 Traction Card

Pump Motor BWI

P2-9 Traction Card

Pump Motor BWI

P1 19 Traction Card

–

CONDITION

Traction Motor Over Temperature

NOMINAL VOLTAGE

No Fault

Traction Motor Over Temperature

Not Used Pump Motor Over Temperature

No Fault

Traction Motor Over Temperature

Not Used No Fault

Traction Motor Brushes Worn

B+

No Fault

Traction Motor Brushes Worn

B+

– No Fault

Pump Motor Brushes Worn

B+

– No Fault

Pump Motor Brushes Worn

B+

–

+5V

Not Used Battery Negative

0V 0V

5-16

WIRING

P11 PIN # ERROR

TMM7A TERMINAL #

TMM7A WIRE #

2 3

None None

TB7 TB9

70 71

TRUCK HARNESS WIRE # 23 24

TRANSISTOR PUMP CONTROL PIN # P5-14 P5-13

None

TB13

25/17

P5-10

5 6 7 8 9 10

90 91 93 93 94 94

TB1 TB3 TB5 TB6 TB8 TB10

73 74 75 76 77 78

80 82 85 86 87 88

P5-16 P5-11

– – – –

94 94 95 95

– – – –

85 86 87 88

– – – – P5-5 P5-6 P5-8 P5-9

DESCRIPTION

P2-9 On Traction Control P2-8 On Traction Control P1-19 On Traction Control with pump contactor P1-10 on Traction Control with pump control Traction Motor Overtemp Pump Motor Overtemp Traction BWI Traction BWI Pump BWI Pump BWI Traction BWI

Traction BWI Pump BWI Pump BWI

NOTE: TMM7A wires are all black with numbers stamped in white. Truck harness wires are multi colored with wire numbers stamped 10mm from each terminal. Some TMM7A wire numbers are exactly the same as truck harness wire numbers, but the wires are not connected.

5-17

WIRING

Pump Driver FUNCTION: Controls the power supply to the contactor coil according to the control signal input.

TERMINAL TRUCK WIRE # HARNESS #

DESCRIPTION

CONDITION

VOLTAGE ON TERMINAL

WIRE #

50-1

Not Activated

Activated

Always

Contactor Not Activated

Control Signal Input

Battery Negative

Contactor Coil Input Contactor Activated

N/A

Not Used

BV = Battery Volt

5-18

0 - 0.5V

WIRING

Pump Time Delay FUNCTION: Controls the power supply to the pump driver according to the control signal input.

TERMINAL #

TRUCK WIRE HARNESS #

CONTACTOR PANEL HARNESS #

DESCRIPTION

CONDITION

VOLTAGE ON TERMINAL

Not Activated

Activated

Always

Contactor Not Activated

12V

Contactor Activated

11V

Control Signal Output

Battery Negative

Control Card Input to Delay

BV 4

Battery Positive

Key On BV

BV = Battery Volt

5-19

WIRING

Shorted or Open Field or Armature FET Test DESCRIPTION: If a problem is suspected with the SX controller, the following test procedure will assist you in diagnosing field and armature transistor (FET) failures in SX controllers. This test may be used for both the traction and pump controllers. NOTE: You must use a digital meter set to the DIODE TEST FUNCTION to perform these tests. ARMATURE FET TEST: 1. Remove all cables and wire harnesses from the SX controller. 2. Verify the digital meter is set to the diode test function. 3. Attach the RED lead to the NEG terminal and attach the BLACK lead to the A2 terminal. 4. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If an armature FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller. 5. Attach the RED lead to the A2 terminal and attach the BLACK lead to the POS terminal. 6. A properly function SX controller will have a reading between 0.3 and 0.6 volts. If an armature FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller. FIELD FET TEST: 1. Attach the RED lead to NEG and attach the BLACK lead to F1. 2. A properly function SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller. 3. Attach the BLACK lead to F2. 4. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller. 5. Attach the BLACK lead to POS and attach the RED lead to F1. 6. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller. 7. Attach the RED lead to F2. 8. A properly functioning SX controller will have a reading between 0.3 and 0.6 volts. If a field FET is shorted or open, the reading will be higher or lower than the normal 0.3 to 0.6 volts. Replace the Controller.

5-20

Traction Bypass with Pump Contactor

5-1

yp 1

2 4

1. Controller, Traction 2. Contactor, Hydraulic Pump Motor 3. Fuse (Traction Circuit) 4. Fuse (Hydraulic Pump Circuit) 5. Fuse Panel (FU 1, FU 2, FU 3) 6. Fuse 5 (Steering Circuit) 7. Contactor, Power Steering Motor

Pump Contactor

5-3

Controller, Traction Contactor, Hydraulic Pump Motor Fuse 4 (Traction Circuit) Fuse 6 (Hydraulic Pump Circuit) Fuse Panel (FU 1, FU 2, FU 3) Fuse 5 (Steering Circuit) Contactor, Power Steering Motor Contactor, 1-A Bypass Contactor, Line

1. 2. 3. 4. 5. 6. 7. 8. 9. 2

3 7

Traction Bypass with Pump Contactor

5-5

Traction Bypass with Pump Control

5-7

2 1

1. 2. 3. 4. 5. 6. 7. 8.

Controller, Traction Controller, Pump Contactor , Line Contactor, Power Steering Motor Fuse 4 (Traction Circuit) Fuse Panel (FU 1, FU 2, FU 3) Fuse 5 (Steering Circuit) Fuse 6 (Hydraulic Pump Circuit

8 6

87 5

4 3

Pump Control

5-9

Traction Motor Controller with Pump Motor Controller and Bypass

5-11

SX DIAGNOSTIC STATUS CODES 6. DIAGNOSTIC STATUS CODES Basic Checks ....................................................................................................................... 6-1 Status Codes ........................................................................................................................ 6-2

SX DIAGNOSTIC STATUS CODES

Basic Checks The biggest mistake technicians can make is to assume they know the problem before starting to work on a truck. Unfortunately while making our life easier self-diagnostics also make us more susceptible to this type of mistake. Never start to fix a truck based solely on the number on the dash or handset display. Always follow the basic troubleshooting steps.

•

Talk to the operator.

•

Confirm their description of the problem with an operational check.

•

Visually inspect cables, connectors, contactor tips, etc.

•

Perform basic battery cables to frame resistance tests. You should have at least 20,000 ohms.

•

Check for any voltage on the frame.

•

Check the battery condition.

Disconnect the battery and discharge the capacitor with the 150–25 watt resistor between the Pos & Neg terminals on controller.

•

Remove the P2 plug which connects the dash display to the card and insert the handset plug connector.

•

Plug in the battery.

•

While holding the CONT button down on the handset turn on the key switch to enter the programming mode.

When you get the 8888 on the handset push down on the key pad #1 button to double check the Status Code stored in the memory which should be the same as the dash display (if it showed one).

•

Before proceeding check the card’s programming.

Always check each function and write down the reading. If the programming fails to match the specifications reprogram the controller and check the truck operation before going any further. If repairs are required turn the key switch off, then push the CONT and ESC keys at the same time to enter the History Folder. These codes should only be zeroed out after the truck is repaired and running properly. Utilize the Status Codes in the following pages to find the component or area to check for a fault. Status Codes can be the result of a defective controller, but all voltage checks and testing should be performed before replacing.

Now we are ready to allow the self-diagnostics to give us a starting point to repair the truck. Turn the key switch on and check when the display goes through its boot up sequence to be sure all of the LEDs or LCD segments are functional. At this time note the status (fault) code (if any) and then turn the key switch off so you can note the hours on the meter. •

•

Display Codes Note – Shorts to frame may cause false codes. CCCC – No activity detected on communication line from display to controller. Check for shorts to frame by volts. C– –C – Activity detected on communication line to control, but does not make sense. PC – Pump controller information data cannot be read. Open in P4. DC – Drive controller information data cannot be read. Open in P2. “=” – Fault Code Data from controller is outside of range Please see Display Section for proper setup of speed sensor.

6-1

SX DIAGNOSTIC STATUS CODES TABLE OF CONTENTS

STATUS DESCRIPTION PAGE CODE Blank Segments do not illuminate on the Dash Display and/or the Handset. .6-4 -01 No seat switch input (no voltage to P1-6) . . . . . . . . . . . . . . . . . . . . . . . .6-4 -02 Forward directional switch is closed on initial power up . . . . . . . . . . . . .6-5 -03 Reverse directional switch is closed on initial power up . . . . . . . . . . . . .6-5 -05 Start switch or brake switch fails to close . . . . . . . . . . . . . . . . . . . . . . . .6-6 -06 Accelerator depressed with no direction selected . . . . . . . . . . . . . . . . .6-6 -07 Accelerator input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 -08 Accelerator input speed too high on power up after initial key switch closure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 -09 Both the forward and reverse directional switches are closed at the same time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .6-8 -11 Start switch closed on power up after initial key switch closure . . . . . ..6-8 -15 Battery voltage is too low or control card is mis-adjusted . . . . . . . . . .. .6-9 -16 Battery voltage is too high or control card is mis-adjusted . . . . . . . . . .. 6-9 -21 Accelerator voltage is too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 -23 Motor field current is too high on start up in the reverse direction . . . .6-10 -24 Motor field current is too high on start up in the forward direction . . . .6-11 -27 Control’s internal power supply is less than 10 volts DC . . . . . . . . . . .6-11 -28 Motor field current is too high during the run mode . . . . . . . . . . . . . . .6-12 -41 Shorted thermal protector (TP) or armature transistor over temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 -42 Motor armature offset voltage is too high . . . . . . . . . . . . . . . . . . . . . . .6-13 -43 Motor armature offset voltage is too low . . . . . . . . . .. . . . . . . . . . . . .6-13 -44 Armature transistor did not turn off properly . . . . . . . . . . . . . . . . . . . .6-14 -45 Armature transistor did not turn on properly . . . . . . . . . . . . . . . . . . . . .6-14 -46 Look Ahead test for A2 volts less than 12% of battery volts. . . . . . . . .6-15 -49 Motor field current is too low during the run mode. . . . . . . . . . . . . . .. 6-15 -51 Capacitor volts are low before the line contactor closes . . . . . . . . . . ..6-16 -57 Controller “motor current sensor” input too low during running . . . . . ..6-16 -64 The line driver input (P2-17) is less than 12% of battery volts . . . . . ..6-17 -65 The line coil is too high during the run mode . . . . . . . . . . . . . . . . . . .. 6-17 -66 The field current exceeds the current limit on the field transistor . . . .. 6-18 -67 The armature current exceeds the armature transistor limit . . . . . . . .. 6-18 -69 The power steering coil current is too high during the run mode. . . . .6-19 -76 Capacitor (1C) voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-19 -77 Motor current is detected during regenerative braking . . . . . . . . . . . .. 6-20 -82 If the armature motor current is greater than a preset value for longer than 3.5 sec. The armature motoring current will be turned off . ..6-20 6-2

-83 -86 -89 -89 -90 -91 -94 -94 -95 -95 -99 -117 -127 -128 -141 -142 -143 -144 -145 -146 -150 -151 -157 -180 -181 -189

A switch position is incorrect during the accelerator potentiometer auto calibration routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-21 Accelerator pot values obtained during the auto calibration routine were not valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 Hydraulic lever is activated before the pump is enabled when key switch is initially enabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 Hydraulic lever is activated when truck is operating . . . . . . . . . . . . . ..6-22 Traction motor temperature has exceeded maximum temperature limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 Pump motor temperature has exceeded maximum temperature limit. .6-24 Traction motor brush wear indicator had detected a worn brush . . . . .6-25 Traction motor brush wear indicator had detected a worn brush . . . . .6-25 Pump motor brush wear indicator has detected worn brush . . . . . . . .6-26 Pump motor brush wear indicator has detected worn brush . . . . . . . .6-26 Maintenance alert and speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-27 “Card Type” selection is invalid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-27 Control logic card power supply is less than 10 VDC . . . . . . . . . . . . .6-28 Armature current is too high during the lift mode . . . . . . . . . . . . . . . ..6-28 Shorted thermal protector (TP1) or transistor is over temperature . . . .6-29 Pump Controller “motor current sensor” input is missing . . . . . . . . . . .6-29 Pump Controller “motor current sensor” input is too low . . . . . . . . . . ..6-30 Power Transistor (Q1) did not turn off properly. . . . . . . . . . . . . . . . . . .6-30 Power Transistor (Q1) did not turn o properly. . . . . . . . . . . . . . . . . . . ..6-31 “Look Ahead” test for pump motor circuit volts less than 12% of the battery volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 Capacitor volts are low after the line contactor closes . . . . . . . . . . . . .6-32 Capacitor volts are low before the line contactor closes. (Internal card function during pre-charge) . . . . . . . . . . . . . . . . . . . . . .6-32 Controller “motor current sensor” input voltage polarity check . . . . . ..6-33 Voltage at capacitor (1C) is less than 14 volts . . . . . . . . . . . . . . . . . . .6-33 Battery voltage is less than 14 volts . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 Input switch closed before pump enable signal is received. . . . . . . . .6-34

6-3

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

NONE MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Segments do not illuminate on the Dash Display and/or the Handset.

No input voltage to the Logic Card or the display unit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Display screen on Dash Display and/or Handset is blank. POSSIBLE CAUSE Positive or negative control voltage is not present. • Insure that the key switch is closed and voltage is present between P1-1 & battery negative. Also check for voltage between P1-2 and control negative. Open circuit between control card AND the Dash Display or Handset. • Check for an open circuit or loose connection going from the control and the Dash Display or Handset. Defective Dash Display or Handset. • Replace Dash Display or Handset.

TRACTION STATUS CODE

-01

DESCRIPTION OF STATUS

This status code will be displayed when P1-6 is less than 50% battery volts.

No seat switch input (no voltage to P1-6).

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Mis-adjusted or defective seat or deadman switch. • Check to see that the seat switch closes properly. Open circuit between battery positive and P1-6. • Check for loose connections or broken wires: -Between the seat switch and P1-6. -Between the key switch and the battery positive side of the seat switch. -Between the seat switch and P1-2. • On vehicles without a seat/deadman switch, check for a loose connection or broken wire from P1-2 and/or P1-6.

6-4

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-02

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Forward directional switch is closed on initial power up.

This status code will be displayed when P1-4 is greater than 60% of battery voltage at initial key switch on.

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate because of Static Return to Off (SRO) lock out. POSSIBLE CAUSE Forward directional switch is closed on initial start up (i.e. closure of battery, key switch or seat/deadman switch). • Return directional switch lever to neutral and then return lever to forward position. Forward directional switch is welded closed or mis-adjusted to be held closed. • Replace or adjust directional switch to insure that it opens when the directional switch is returned to neutral. Defective control. • Replace the controller unit.

TRACTION STATUS CODE

-03

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Reverse directional switch is closed on initial power up.

This status code will be displayed when P1-5 is greater than 60% of battery voltage at initial key switch on.

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate because of Static Return to Off (SRO) lock out. POSSIBLE CAUSE Reverse directional switch is closed on initial start up (i.e. closure of battery, key switch or seat/deadman switch). • Return directional switch lever to neutral and then return lever to reverse position. Reverse directional switch is welded closed or mis-adjusted to be held closed. • Replace or adjust directional switch to insure that it opens when the directional switch is returned to neutral. Defective control. • Replace the controller unit.

6-5

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-05 MEMORY RECALL

Circuits valid for Traction Controller

TRACTION STATUS CODE

-06

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Start switch or brake switch fails to close.

This status code will be displayed when P1-7 is calling for greater than 40% speed and P1-3 is less than 60% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective start switch circuit. • Check start switch to insure closure with accelerator pedal released. • Check for open circuit or loose connection in wiring from key switch to start switch and from P1-3 to start switch. Defective accelerator switch. • Check accelerator switch potentiometer for proper operation and ohmic value.

DESCRIPTION OF STATUS

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION This status code will be displayed when P1-4 & P1-5 are less than 60% of battery volts, and P1-7 is calling for greater than 40% speed.

Accelerator depressed with no direction selected.

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Accelerator pedal is depressed before closing forward or reverse directional switch. • Status code will disappear when directional switch is closed or when accelerator pedal is released. Defective directional switch. • Check forward or reverse switch to insure closure when direction is selected. Open circuit between directional switch(es) and battery positive or between directional switch(es) and P1-4 or P1-5. • Check all control wires and connections shown in Trouble Shooting Diagram.

6-6

SX DIAGNOSTIC STATUS CODES TRACTION STATUS CODE

DESCRIPTION OF STATUS

This status code will be displayed when the accelerator input voltage at P1-7 is 0.7 volts less than the zero speed auto calibration value for the accelerator.

Accelerator input voltage too high.

-07 CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate when accelerator pedal is depressed or status code -07 is displayed then disappears when the vehicle starts to accelerate. POSSIBLE CAUSE Accelerator input mis-adjusted or defective.

P1-9 P1-7 P1-8

Open circuit between battery negative and P1-7 in accelerator input circuit. • Check for broken wires or loose connections or open potentiometer / voltage supply.

28 P9-1

P9-4

Short circuit from battery positive to wiring in accelerator input circuit.

P9-3 ACC. POT

TRACTION STATUS CODE

-08

MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Accelerator input speed too high on power up after initial key switch closure.

This status code will be displayed when the accelerator input voltage at P1-7 is calling for greater than 20% speed, and any of the following connections are opened and closed: battery or key switch.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Accelerator input mis-adjusted or defective. • Input voltage at P1-7 should be more than 20% speed.. Adjust or replace accelerator unit to insure that the voltage at P1-7 is calling for less than 20% before depressing pedal. • Repeat the auto calibration routine outlined in Accelerator Controller Set-up Procedures of this manual. • P1-7 or the accelerator pot negative have an open circuit. • Defective Control

P1-9 P1-7 P1-8 56 P9-4

28 P9-1 P9-3

ACC. POT

6-7

SX DIAGNOSTIC STATUS CODES TRACTION STATUS CODE

-09 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Both the forward and reverse directional switches are closed at the same time.

This status code will be displayed when P1-4 and P1-5 are greater than 60% of battery volts at the same time.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Forward or reverse directional switch welded closed or mis-adjusted to be held closed. • Replace or adjust directional switches to insure that they open when directional switch is returned to neutral. Short circuit between battery positive and P1-4 and / or P1-5. • Disconnect wires from P1-4 and P1-5 and check wire for short circuit to positive side of directional switch. Defective card. • Disconnect wires and measure voltage at P1-4 and P1-5. Voltage should be less than 60% of battery volts.

TRACTION STATUS CODE

-11 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Start switch closed on power up after initial key switch closure.

This status code will be displayed when P3 is greater than 60% of battery voltage when the key switch is closed.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Start switch input mis-adjusted or defective. • Input voltage at P1-3 should be less than 60% of battery volts at key switch closing. Adjust or replace accelerator unit to insure that the voltage at P1-3 is less than 60% of battery volts before closing the start switch. Short circuit between battery positive and P1-3 in start switch input circuit. • Disconnect wire from P1-3. Check for short circuit from wire to battery positive. Defective card. • Disconnect wire from P1-3. Measure voltage from P1-3 to negative. Voltage should be zero, if not, replace card.

6-8

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-15 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Battery voltage is too low or control card is mis-adjusted.

This status code will be displayed when the battery volts are less than 1.95 volts per cell at initial key switch on. See table below.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Discharged battery. • Check battery for proper open circuit voltage as shown in “Trouble Shooting Diagram, charge battery, if required. Defective battery. • Check each battery cell for proper voltage (greater than 1.95 volts at cell). Replace or repair battery. Incorrect control card adjustment. • Check function 15 for proper adjustment for battery being used. See Handset instruction sheet for details. Adjust to proper settings. Check “minimum” battery volts at P1-1 and NEG.

TRACTION STATUS CODE

-16 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Battery voltage is too high or control card is mis-adjusted.

This status code will be displayed when the battery volts are greater than 2.40 volts per cell at initial key switch on. See table below.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Incorrect control card adjustment. • Check function 15 for proper adjustment for battery being used. See Handset instructions for details. Adjust to proper setting. Battery over-charged or incorrect battery used. • Check battery for proper open circuit voltage per table in trouble-shooting diagram. If voltage excessive, check battery charger for proper output voltage. Check “maximum” battery volts at P1-1 and NEG.

FU1 15A 5

NOMINAL BATTERY VOLTAGE

MAXIMUM LIMIT VOLTS AT 2.4 VDC PER CELL

24 36 48

28.8 43.2 57.6

72 80

86.4 100.8

P1-1

NEG

Traction Control N Terminal

6-9

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

DESCRIPTION OF STATUS

This status code will be displayed when the voltage at P1-7 is greater than 4.5 volts.

Accelerator voltage is too high.

-21 CORRECTIVE ACTIONS MEMORY RECALL

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Controller will not operate. POSSIBLE CAUSE • Verify wire connection between accelerator pot to P1-8.

Circuits valid for Traction Controller

P1-9 P1-7 P1-8

• Verify wire connection between P1-7 to accelerator pot.

56 • Verify that the accelerator pot is adjusted properly.

P9-4

28 P9-1 P9-3

ACC. POT

TRACTION STATUS CODE

-23 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Motor field current is too high on start up in the reverse direction.

This status code will be displayed when the current draw in the motor field is too high at start up in the reverse direction.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective control • Replace controller unit.

Circuits valid for Traction Controller

6-10

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-24

DESCRIPTION OF STATUS

This status code will be displayed when the current draw in the motor field is too high at start up in the forward direction.

Motor field current is too high on start up in the forward direction.

CORRECTIVE ACTIONS MEMORY RECALL

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control does not operate. POSSIBLE CAUSE Defective control. • Replace controller unit.

Circuits valid for Traction Controller

TRACTION STATUS CODE

-27

DESCRIPTION OF STATUS

This status code will be displayed when the control’s power supply is less than 10 volts.

Control’s internal power supply is less than 10 Volts DC.

CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Line contactor opens and closes, then can only be closed by opening and closing the key switch. POSSIBLE CAUSE Discharged Battery. • Check battery to insure proper state of charge. Voltage may be dropping below 10 Volts DC under load. Loose connection at P1-1. • Insure that the wire connection at P1-1 is tight. P1-1 should be at battery voltage.

FU2

KEY SWITCH

5 FU1 10

P1-1 NEG

Defective control. • Replace controller unit.

6-11

P1-2

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-28

DESCRIPTION OF STATUS

This status code will be displayed when the current in the motor field is sustained above a preset limit for longer than 70 seconds.

Motor field current is too high during the run mode.

CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Controller

TRACTION STATUS CODE

-41 MEMORY RECALL

YES

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Continued operation of vehicle in high motor current condition. • Operate vehicle at lower motor current condition for 70 seconds. Function 7 is mis-adjusted to allow higher than normal motor filed current. • Adjust function per OEM instructions.

THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A CONTROL ISSUE. IF FUNCTION 7 IS NOT MIS-ADJUSTED, THE STATUS CODE INDICATES AN APPLICATION ISSUE WHERE A MOTOR IS BEING STALLED, ETC. DISPLAY OF THIS STATUS CODE SHOULD NOT TRIGGER THE RETURN OF A CONTROL FOR REPAIR OR REPLACEMENT.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Shorted thermal protector (TP) or armature transistor over temperature.

This status code will be displayed when the voltage at the thermal protector is too low.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Reduced or no power to traction motor in transistor range. POSSIBLE CAUSE Control is in thermal cut-back. • Allow control to cool, status code should disappear. Defective control. • Replace controller unit. NOTE:

Thermal protector located in control is not serviceable.

6-12

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-42 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Motor armature offset voltage is too high.

This status code will be displayed when the voltage at the current sensor input is greater than 2.6 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective control. • Replace controller unit.

Circuits valid for Traction Controller

TRACTION STATUS CODE

-43 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Motor armature offset voltage is too low.

This status code will be displayed when the voltage at the current sensor input is less than 2.4 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective control. • Replace controller unit.

Circuits valid for Traction Controller

6-13

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-44 MEMORY RECALL

YES

Circuits valid for Traction Controller

TRACTION STATUS CODE

-45 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Armature transistor did not turn off properly.

This status code will be displayed when, during control operation, the armature transistor fails to turn off. This will result in a PMT condition.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Line contactor opens and then can only be closed by opening and closing the key switch. POSSIBLE CAUSE Defective control. • Replace controller unit.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Armature transistor did not turn on properly.

This status code will be displayed when, during control operation, the armature transistor fails to turn on properly. This will result in a PMT condition.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Truck will not operate. POSSIBLE CAUSE Defective control. • Replace controller unit.

Circuits valid for Traction Controller

6-14

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-46 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

“Look Ahead” test for A2 volts less than 12% of battery volts.

This status code will be displayed when the voltage at A2 is less than 12% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Line contactor will open. POSSIBLE CAUSE Check for short circuit from the motor armature to the frame of the vehicle.

Circuits valid for Traction Controller

TRACTION STATUS CODE

-49 MEMORY RECALL

YES

Check for welded 1A contactor (if used) Defective control. • Replace controller unit.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Motor field current is too low during the run mode.

This status code will be displayed when the current draw in the motor field is too low during the run mode.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Defective control or connection.

Circuits valid for Traction Controller

• Replace controller unit. • Open motor field winding.

6-15

SX DIAGNOSTIC STATUS CODES TRACTION STATUS CODE

-51 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Capacitor volts are low before the line contactor closes.

This status code will be displayed during “key on” when the capacitor volts is less than 85% of battery volts at initial key switch on.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Line contactor does not close when capacitor does not pre-charge. POSSIBLE CAUSE • Welded 1A contactor (if used) • Check PTC for open circuit on line contactor. • Check for conductivity across open 1A contactor. Wiring error • Insure that there is no device connected to load side of line contactor. Defective control. • Replace controller unit.

1A CTR 740Amp control only

TRACTION STATUS CODE

-57 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Controller “motor current sensor” input too low during running.

This status code will be displayed when the voltage input from the current sensor is too low during running.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE • Line contactor power tips did not close.

Circuits valid for Traction Controller

• Volt drop across contactor tips. Defective control. • Replace controller unit.

6-16

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-64 MEMORY RECALL

Circuits valid for Traction Controller

TRACTION STATUS CODE

-65 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

The line driver input (P2-17) is less than 12% of battery volts.

This status code will be displayed when the control detects that the line driver input (P2-17) is less than 12% battery volts when the key switch is turned on.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control does not operate. Line contactor does not close. POSSIBLE CAUSE • Open wire connection to Pin P1-17. • Shorted line Driver transistor in control. • Possible open circuit in line contactor coil Defective control. • Replace controller unit.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

The line coil is too high during the run mode.

This status code will be displayed when the current limit in the line coil driver is exceeded during the run mode. The line contactor will drop out and the key switch will have to be recycled to reset the control.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control does not operate. POSSIBLE CAUSE • Shorted line contactor coil. • Short between wires connected to line coil.

Circuits valid for Traction Controller

If line coil resistance is correct: (59Ω for 36-48) (161Ω for 80V) Defective control. • Replace controller unit.

6-17

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-66 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

The field current exceeds the current limit on the field transistor.

This status code will be displayed when the field transistor exceeds its specific current limit. The line contactor will drop out and the key switch will have to be recycled to restart the control.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. • Line contactor opens. POSSIBLE CAUSE • Shorted field F1 to F2

Circuits valid for Traction Controller

• Open FU4 fuse • F1 or F2 terminals shorted to battery positive (B+) • F1 or F2 Terminals shorted to battery negative (B-) (The controller looks for a high change in current over time to identify a short circuit in the field or cables.)

TRACTION STATUS CODE

-67

DESCRIPTION OF STATUS The armature current exceeds the armature transistor limit.

This status code will be displayed when the armature transistor exceeds its specific current limit. The control is reset by recycling the key switch.

CORRECTIVE ACTIONS MEMORY RECALL

YES

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE • Shorted motor armature A1 to A2

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

• Power cables may be shorted to each other (Measure at control terminals) • A1 to A2 terminals may be shorted to battery positive or negative.

6-18

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-69 MEMORY RECALL

YES

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

The power steering coil current is too high during the run mode.

This status code will be displayed when the current in the power steering driver circuit exceeds current limit during the run mode. The control is reset by recycling the key switch.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE • Shorted power steering control coil • Short between wires connecting to the power steering coil. • Open FU4 fuse

If the power steering coil resistance is correct (59Ω for 36-48volt) (161Ω for 80 volt) then: • Defective control. Replace control unit.

DESCRIPTION OF STATUS

This status code will be displayed when the voltage on the capacitor goes above limit voltage* during the regenerative braking cycle.

Capacitor (1C) voltage too high.

-76 CORRECTIVE ACTIONS YES

Circuits valid for Traction Controller

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Line contactor opens and closes, then opens and can only close by opening and closing the key switch. POSSIBLE CAUSE • Unplugging the battery connector during regenerative braking. • Line contactor bouncing open during regen. • Main power fuse opening during regen. • Intermittent battery plug connection.

LINE

FU4

Battery -

* Limit Voltage: Limit Batt. 50V 36V 70V 48V 96V 72/80V

6-19

POS

NEG

POWER CONNECTIONS

ARMATURE

MEMORY RECALL

CAUSE OF STATUS INDICATION

FIELD

TRACTION STATUS CODE

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-77

DESCRIPTION OF STATUS

This status code will be displayed when motoring current is detected during the regenerative braking cycle.

Motor current is detected during regenerative braking.

CORRECTIVE ACTIONS MEMORY RECALL

YES

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Truck will not operate. POSSIBLE CAUSE Defective control. • Replace controller unit

TRACTION STATUS CODE

-82 MEMORY RECALL

YES

Circuits valid for Traction Controller

FU1

Battery -

POS

NEG

POWER CONNECTIONS

FIELD

ARMATURE

LINE

Circuits valid for Traction Controller

ACC POT

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

If the armature motor current is greater than a preset value for longer than 3.5 sec the armature motoring current will be turned off.

This status code will be displayed when the armature motor current exceeds a preset value for 3.5 sec and the accelerator pedal is calling for maximum performance.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM The Control will not operate, and can only be reset by cycling the key switch.

*CODE WARNING*

POSSIBLE CAUSE: • Continued operation of vehicle in high motor current condition • Operating control at stall motor current for more than 3.5 seconds. • Function 16 is incorrectly adjusted for control % on time. Adjust function • Function 16 is adjusted a level of 130 for all controls except the 9"15K-18KL which is set to 120 and the EE’s are all set at 160. • Possible mechanical resistance to motor rotation.

THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A CONTROL ISSUE. IF FUNCTION 16 IS NOT MIS-ADJUSTED, THE STATUS CODE INDICATES AN APPLICATION ISSUE WHERE A MOTOR IS BEING STALLED, ETC. DISPLAY OF THIS STATUS CODE SHOULD NOT TRIGGER THE RETURN OF A CONTROL FOR REPAIR OR REPLACEMENT. *Continued occurrence of this code could lead to damage to motor assembly.

6-20

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-83

DESCRIPTION OF STATUS

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Traction Controller

TRACTION STATUS CODE

-86 MEMORY RECALL

Circuits valid for Traction Controller

CAUSE OF STATUS INDICATION

This status code will be displayed when the seat switch is A switch position is incorrect during the open, or the any of the forward, reverse or start switches accelerator potentiometer auto calibra- are closed at the beginning of the accelerator potentiometion routine. ter auto calibration routine.

TROUBLE-SHOOTING DIAGRAM

SYMPTOM The auto calibration routine outlined in Section 8 of this manual will not start. POSSIBLE CAUSE: • Seat switch is open • Confirm switch wiring, or replace switch, if required. • Any of the forward, reverse or start switches are closed • Confirm switch wiring, or replace switch, if required.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Accelerator pot values obtained during the auto calibration routine were not valid.

Refer to Section 8 of this manual for possible causes of this status code.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Accelerator potentiometer auto calibration routine was not successfully completed. POSSIBLE CAUSE: • Misadjusted or defective accelerator potentiometer assembly • Verify the accelerator potentiometer operation. • Open circuit on the accelerator potentiometer.

P1-9 P1-7 P1-8 56 P9-4

28 P9-1 P9-3

ACC. POT

6-21

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-89 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Hydraulic lever is activated before the pump is enabled when key switch is initially activated.

This status code will be displayed when the voltage at P14 is greater than 3 volts at pump enable (10ms).

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM The truck will not run or the pump will not operate.

POSSIBLE CAUSE: Shorted or welded hydraulic switch • Verify connections to hydraulic switches • Verify mechanical operation of hydraulic switches (check adjustment). • Check for short between wire 50 and 52. • Check for shorted switch.

TRACTION STATUS CODE

-89 MEMORY RECALL

Circuits valid for Traction Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Hydraulic lever is activated when truck is operating

This status code will be displayed when the voltage at P14 is greater than 3 volts at pump enable (10ms).

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Hydraulic functions do not operate.

POSSIBLE CAUSE: • Battery voltage has dropped to Lift Lockout conditions.

6-22

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-90 MEMORY RECALL

YES

Circuits valid for Traction Motor Temperature (Contactor Hydraulics)

TRACTION STATUS CODE

-90 MEMORY RECALL

YES

Circuits valid for Traction Motor Temperature (Pump Controller)

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Traction motor temperature has exceeded maximum temperature limit.

This status code will be displayed when the voltage at the respective terminal of the Pump Logic Card is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status code flashes “on and off”. Action Light flashes. POSSIBLE CAUSE User defined status code is displayed by switch closure to battery negative. • Defective temp switch (shorted). Traction motor. • Defective TMM card. • Wire 80 shorted to battery NEG. • Battery Neg @ TMM7A terminal 1 P11-5

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Traction motor temperature has exceeded maximum temperature limit. (with pump controller hyd.)

This status code will be displayed when the voltage at the respective terminal of the TMM is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status code flashes “on and off”. Action light flashes POSSIBLE CAUSE User defined status code is displayed by switch closure to battery negative. • Defective temp switch (shorted). Traction motor. • Defective pump card. • Wire 80 shorted to battery NEG. • Battery Neg @ pump control P5-16

6-23

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-91 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump motor temperature has exceeded maximum temperature limit.

This status code will be displayed when the voltage at the respective terminal of the TMM is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”. Action Light flashes POSSIBLE CAUSE User defined status code is displayed by switch closure to battery negative.

Circuits valid for Hydraulic Pump Temperature (Contactor Hydraulics)

TRACTION STATUS CODE

-91 MEMORY RECALL

YES

• Battery Neg at TMM7A terminal 3 P11-6. • Wire 82 shorted to battery NEG. • Defective Temp switch (shorted). • Defective TMM card.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump motor temperature has exceeded maximum temperature limit. (with pump controller hyd.)

This status code will be displayed when the voltage at the respective terminal of the TMM is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE User defined status code is displayed by switch closure to battery negative.

Circuits valid for Hydraulic Pump Temperature (Pump Controller)

• Defective temp switch (shorted). Pump motor. • Defective pump card. • Wire 82 shorted to battery NEG. • Battery Neg at P5-11

6-24

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-93 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Traction motor brush wear indicator had detected worn brush.

This status code will be displayed when the voltage at terminal 8 and 10 of the TMM is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE User defined status code is displayed by motor brush sensor closure to battery positive.

Circuits valid for Traction Motor Brush Wear Indicator (Contactor Hydraulics)

• Worn brushes. • Terminal 5 or 6 is shorted to positive on the TMM7A card. • Defective input switch (shorted) check for proper adjustment of the BWI T-bar on brush holder. • Wire 85 or 86 shorted to positive. • Defective TMM7A card.

TRACTION STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Traction motor brush wear indicator had detected worn brush.

This status code will be displayed when the voltage at the respective terminal of the Pump Logic Card is at zero volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-94 MEMORY RECALL

YES

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE User defined status code is displayed by motor brush sensor closure to battery positive.

Circuits valid for Traction Motor Brush Wear (Pump Controller)

• Worn brushes. • P5-5 or P5-6 is shorted to positive on pump control card. • Defective input switch (shorted) check for proper adjustment of the BWI T-bar on brush holder. • Wire 85 or 86 shorted to positive. • Defective pump control card.

6-25

SX DIAGNOSTIC STATUS CODES

TRACTION STATUS CODE

-94 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump motor brush wear indicator has detected worn brush.

This status code will be displayed when the voltage at the respective terminal of the TMM is at battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE User defined status code is displayed by motor brush sensor closure to battery positive.

Circuits valid for Pump Motor Brush Wear Indicator (Contactor Hydraulics)

TRACTION STATUS CODE

-95 MEMORY RECALL

YES

• Worn brushes.

NEG • Terminal 8 or 10 is shorted to positive on the TMM7A card. • Defective input switch (shorted) check for proper adjustment of the BWI T-bar on brush holder. • Wire 87 or 88 shorted to positive.

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump motor brush wear indicator has detected worn brush.

This status code will be displayed when the voltage at the respective terminal of the Pump Logic Card is at battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status Code flashes “on and off”. POSSIBLE CAUSE User defined status code is displayed by motor brush sensor closure to battery positive.

Circuits valid for Pump Motor Brush Wear Indicator (Pump Controller)

• Worn brushes. • P5-8 or 5-9 is shorted to positive. • Defective input switch (shorted) check for proper adjustment of the BWI T-bar on brush holder. • Wire 87 or 88 shorted to positive. • Defective pump control card.

NEG

6-26

SX DIAGNOSTIC STATUS CODES TRACTION STATUS CODE

DESCRIPTION OF STATUS

This status code will be displayed when the “normal” hour meter exceeds the “maintenance alert hours” setting for the vehicle.

Maintenance alert and speed limit.

-99 CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Traction Control

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Status code is displayed for 4 seconds when the key switch is first turned on, and/or the vehicle may run at a reduced speed. CUSTOMER SELECTED SETTING WITH THE HANDSET: User defined status code is displayed when the normal hour meter reading exceeds the programmed “maintenance alert hours” setting selected by the user • Maintenance Code Hour Meter, Functions 19 and 20, are programmed with the Handset and command the display of status code -99. • If desired, Maintenance Code Speed Limit, Function 13, can be programmed with the Handset.

NO DIAGRAM USER SHOULD PERFORM THE DESIRED MAINTENANCE FUNCTION

User should perform the desired maintenance function. Re-set maintenance alert hour meter after maintenance is performed. .

TRACTION STATUS CODE

DESCRIPTION OF STATUS

This status code will be displayed when the card type selection value is set to an invalid number.

“Card Type” selection is invalid.

-117 CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Invalid card type selection. • Review function 17 in the Handset Instruction sheets. Adjust and set card type value as instructed by Service Manual.

NO GRAPHIC FOR THIS STATUS CODE

6-27

SX DIAGNOSTIC STATUS CODES HYDRAULIC STATUS CODE

-127 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Control logic card power supply is less than 10 VDC.

This status code will be displayed when the logic card power supply is less than 10 volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Discharged battery • Check battery to insure proper state of charge.

Circuits valid for Pump Controller

• Check control fuse FU 11. Loose connection at P1-1. • Insure that the wire connection at P1-1 is tight. • Insure that wire connection at P5-1 is tight. • Check for Volt drop across wire 12 and wire 2. Defective logic card.. • Replace control.

HYDRAULIC STATUS CODE

-128 MEMORY RECALL

YES

Circuits valid for Pump Controller

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Armature current is too high during the lift mode

This status code will be displayed when the current in the armature circuit is sustained above 400A for 70 sec.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control will not operate. POSSIBLE CAUSE Continued operation of vehicle in high motor current condition. • Operate vehicle at lower motor current condition for 70 seconds.

NO GRAPHIC FOR THIS STATUS CODE

• Check hydraulic pressure adjustment.

6-28

SX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

DESCRIPTION OF STATUS

This status code is displayed when the voltage at the thermal protector is less than 3.8 volts.

Pump control is over Temperature

-141 CORRECTIVE ACTIONS MEMORY RECALL

YES

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Reduced or no power to pump motor in control range. POSSIBLE CAUSE Control is in thermal cut-back. • Allow control to cool, status code should disappear. • Check wire 23, P5-14 and P2-9 • Check hydraulic pressure adjustment. NOTE: Pump control thermal protection is located inside of pump control and is not serviceable

HYDRAULIC STATUS CODE

-142 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump Controller “motor current sensor” input is missing.

This status code is displayed when the voltage at the current sensor is greater than 1.6 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM No power to pump motor in control range. POSSIBLE CAUSE Control is defective. • Replace controller unit.

Circuits valid for Pump Controller

• Note: Pump motor current sensor is located inside of pump control and testing is not possible.

6-29

SX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

-143 MEMORY RECALL

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Pump Controller “motor current sensor” input is too low.

This status code is displayed when the voltage at the current sensor is less than 0.6 volts with no current flowing in the motor circuit.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM No power to pump motor in control range. POSSIBLE CAUSE Control is defective • Replace controller unit.

Circuits valid for Pump Controller

• Note: Pump motor current sensor is located inside of pump control and testing is not possible.

HYDRAULIC STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Power Transistor (Q1) did not turn off properly.

This status code is displayed when, during pump control operation, the transistor fails to turn off.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-144 MEMORY RECALL

YES

Circuits valid for Pump Controller

NOTE: Pump control thermal protection is located inside of pump control and is not serviceable

SYMPTOM Control may run continuously. POSSIBLE CAUSE Control is defective • Check switch adjustment. • Check for shorts to Neg on wires 51,52,53,54. • Replace controller.

6-30

SX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

-145 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Power Transistor (Q1) did not turn on properly.

This status code is displayed when, during pump control operation, the transistor fails to turn on.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Control may run continuously. POSSIBLE CAUSE Control is defective • Replace controller unit.

Circuits valid for Pump Controller

• Check for proper negative voltage at N terminal on control. • Check for shorts to Neg on wires 51,52,53,54. • Check for proper positive voltage to control at P5-1. 19-20, 21 and 12 • Check for proper positive voltage at P5-1 • Check for proper Neg voltage at N terminal on control

MEMORY RECALL

YES

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

“Look Ahead” test for Pump motor circuit volts less than 12% of battery volts.

This status code will be displayed when the voltage in the pump motor is less than 12% of battery volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump contactor will operate.

FU6

POSSIBLE CAUSE • Check for short circuit from the motor armature to the frame of the vehicle. • Check for open circuit from A1 to A2 on control through motor. A1

Control is defective • Replace controller.

A1 A1 P PUMP CONTROL POWER CONNECTION A2 N

A2 N

6-31

ARMATURE

-146

DESCRIPTION OF STATUS

FIELD

HYDRAULIC STATUS CODE

SX DIAGNOSTIC STATUS CODES

MEMORY RECALL

YES

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION

Capacitor volts are low after the line contactor closes.

This status code will be displayed when the capacitor voltage is less than 85% of the battery voltage in the run mode.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump control will not operate. POSSIBLE CAUSE Defective line contactor. • Check for open line contactor power tips. • Check for volt drop across line contactor. • Check for loose or open connections in cables from battery positive to control positive circuit.

-151 MEMORY RECALL

Circuits valid for Pump Controller

FU6

A1 A1 P PUMP CONTROL POWER CONNECTION A2 N

Defective power fuse. • Check power fuse for open circuit. No battery voltage at P5-1. • Check for battery voltage at POS and P5-1. • Check for loose connection at P5-1.

HYDRAULIC STATUS CODE

325 amps

ARMATURE

-150

DESCRIPTION OF STATUS

FIELD

HYDRAULIC STATUS CODE

A2 N

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Capacitor volts are low before the line contactor closes. (Internal card function during pre-charge)

This status code will be displayed during “key on” when the capacitor volts is less than 85% of battery volts at initial key switch on.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump control will not operate. POSSIBLE CAUSE Note: Repeated “charging/discharging” the capacitors during troubleshooting will cause status code 51. Also “do not” connect any loads to the load side of the line contactor. • Check battery voltage. • Check for open PTC resistor. • Check for battery voltage at P5-1 Defective control. • Replace controller unit. Note: PTC resistor is located across the line contactor that is serviceable. Note: There is also a PTC resistor that is in the controller and it is not serviceable.

6-32

SX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

-157 MEMORY RECALL

YES

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

“Controller motor current sensor” input voltage polarity check.

This status code will be displayed when the voltage input to motor current sensor is of the wrong polarity.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump control will not operate. POSSIBLE CAUSE Control is defective • Replace controller unit.

Circuits valid for Pump Controller

HYDRAULIC STATUS CODE

-180

DESCRIPTION OF STATUS

CORRECTIVE ACTIONS MEMORY RECALL

Circuits valid for Pump Controller

CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at P1 is less than 14 volts. This occurs typically in the run mode of operation.

Voltage at capacitor (1C) is less than 14 volts.

TROUBLE-SHOOTING DIAGRAM

SYMPTOM Pump Control will not operate. POSSIBLE CAUSE (Line contactor controlled by traction control). Line contactor opened up during run. •Check connection from P5-17 to Line coil (-) for loose connection. •Check connection from battery (+) to Line coil (+) for loose connection. •Check for failed power fuse at pump control. •Check for dirty contactor tips.

6-33

SX DIAGNOSTIC STATUS CODES

HYDRAULIC STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

Battery voltage is less than 14 volts.

This status code will be displayed when the battery voltage measured at P1 is less than 14 volts.

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

-181 MEMORY RECALL

YES

SYMPTOM Pump control will not operate. POSSIBLE CAUSE • Check connection from control fuse to pump P1 for loose connections.

Circuits valid for Pump Controller

HYDRAULIC STATUS CODE

-189

• Check for low battery volts under load. • Check for volt drop between pos. and P5-1.

DESCRIPTION OF STATUS Input switch closed before pump enable signal is received.

CORRECTIVE ACTIONS MEMORY RECALL

SYMPTOM Pump Control will not operate. POSSIBLE CAUSE • Hydraulic handle pulled before pump enable signal given.

Circuits valid for Pump Controller

• Shorted hydraulic switch. • Check Hydraulic switch adjustment. • Defective control.

6-34

CAUSE OF STATUS INDICATION This status code will be displayed when pin 12,19,20 or 21 is pulled to negative before pin 10 is greater than 5.0 volts.

TROUBLE-SHOOTING DIAGRAM

TECHNICAL PUBLICATIONS FEEDBACK (Please Print)

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The following discrepancy or omission has been discovered in: ❏

Operation & Maintenance Manual

❏

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Part List/Manual

❏

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❏

Service Manual

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Electronic Manual

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Other:

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(Please print)

Explanation of discrepancy or omission:

Please fax or mail completed form to: Mitsubishi Caterpillar Forklift America Inc. Attn: Technical Publications 2121 W. Sam Houston Parkway N. Houston, Texas 77043-2305 Fax: 713-365-1616

Mitsubishi Caterpillar Forklift Europe B.V. Attn: Service Engineering P.O. Box 30171 1303 AC, Almere, The Netherlands Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd. Attn: Service Engineering No. 2 Tuas Avenue 20 Singapore 638818 Republic of Singapore Fax: 65-861-9277

Mitsubishi Forklift Trucks

Service Manual

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