CATERPILLAR CAT EP10KRT EP12KRT EP15KRT FORKLIFT LIFT TRUCKS CHASSIS, MAST AND OPTIONS Service Repair Manual

1
Service Manual
Chassis, Mast Options
EP10KRT EP12KRT EP15KRT
ETB10-00011-up ETB10-20001-up ETB10-50001-up
99759-65110
2
FOREWORD
This service manual is a guide to servicing of
Cat lift trucks of 1.0 ton, 1.25 ton and 1.5
ton models. The instructions are grouped by
systems to serve the convenience of your ready
reference. Long productive life of your lift
trucks depends to a great extent on correct
servicing the servicing consistent with what
you will learn from this service manual. We hope
you read the respective sections of this manual
carefully and know all the components you will
work on before attempting to start a test, repair
or rebuild job. The descriptions, illustrations
and specifications contained in this manual were
of the trucks of serial numbers in effect at the
time it was approved for printing. Cat lift truck
reserves the right to change specifications or
design without notice and without incurring
obligation. Safety Related Signs The following
safety related signs are used in this service
manual to emphasize important and critical
instructions
Indicates a specific potential hazard resulting
in serious bodily injury or death.
! WARNING
Indicates a specific potential hazard resulting
in bodily injury, or damage to, or destruction
of, the machine.
!
CAUTION
Indicates a condition that can cause damage to,
or shorten service life of, the machine.
NOTE
Pub. No. 99759-65110
3
HOW TO READ THIS MANUAL Disassembly diagram
(example)
Each disassembly diagram is followed by
Disassembly sequence and Suggestion for
disassembly.
Disassembly sequence

• Cover, Bolt, Washer (part name)
• Output shaft (part name)
• Suggestion for disassembly
• (1) Output shaft removal

Unit mm
Clearance between cylinder and piston A 0.020 to 0.105
Clearance between cylinder and piston B 0.15
A Standard value B Repair or service limit
4
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! WARNING
SAFETY
! WARNING
! WARNING
The proper and safe lubrication and maintenance
for this lift truck, recommended by Cat lift
truck, are outlined in the OPERATION
MAINTENANCE MANUAL for these trucks. Improper
performance of lubrication or maintenance
procedures is dangerous and could result in
injury or death. Read and understand the
OPERATION MAINTENANCE MANUAL before performing
any lubrication or maintenance.
Do not operate this truck unless you have read
and understand the instructions in the OPERATION
MAINTENANCE MANUAL. Improper truck operation
is dangerous and could result in injury or death.

1. Lower the forks or other implements to the ground
   before performing any work on the truck. If this
   cannot be done, make sure the forks or other
   implements are blocked correctly to prevent them
   from dropping unexpectedly.
2. Use steps and grab handles (if applicable) when
   mounting or dismounting a truck. Clean any mud
   or debris from steps, walkways or work platforms
   before using. Always face truck when using steps,
   ladders and walkways. When it is not possible to
   use the designed access system, provide ladders,
   scaffolds, or work platforms to perform safe
   repair operations.
3. To avoid back injury, use a hoist when lifting
   components which weigh 23 kg (50 lb.) or more.
   Make sure all chains, hooks, slings, etc., are in
   good condition and are of the correct capacity.
   Be sure hooks are positioned correctly. Lifting
   eyes are not to be side loaded during a lifting
   operation.
4. To avoid burns, be alert for hot parts on trucks
   which have just been stopped and hot fluids in
   lines, tubes and compartments.
5. Be careful when removing cover plates. Gradually
   back off the last two bolts or nuts located at
   opposite ends of the cover or device and pry
   cover loose to relieve any spring or other
   pressure, before removing the last two bolts or
   nuts completely.
6. Be careful when removing filler caps, breathers
   and plugs on the truck. Hold a rag over the cap
   or plug to prevent being sprayed or splashed by
   liquids under pressure. The danger is even
   greater if the truck has just been stopped
   because fluids can be hot.

The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or
components is important before the removal or
disassembly of any component. Because of the
size of some of the truck components, the
serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting
procedures when removing any components. Followin
g is a list of basic precautions that should
always be observed.

1. Read and understand all warning plates and decals
   on the truck before operating, lubricating or
   repairing the product.
2. Always wear protective glasses and protective
   shoes when working around trucks. In particular,
   wear protective glasses when pounding on any
   part of the truck or its attachments with a
   hammer or sledge. Use welders gloves,
   hood/goggles, apron and other protective
   clothing appropriate to the welding job being
   performed. Do not wear loose-fitting or torn
   clothing. Remove all rings from fingers when
   working on machinery.
3. Do not work on any truck that is supported only
   by lift jacks or a hoist. Always use blocks or
   jack stands to support the truck before
   performing any disassembly.

6

1. Always use tools that are in good condition and
   be sure you understand how to use them before
   performing any service work.
2. Reinstall all fasteners with same part number. Do
   not use a lesser quality fastener if
   replacements are necessary. Do not mix metric
   fasteners with standard nuts and bolts.
3. If possible, make all repairs with the truck
   parked on a level, hard surface. Block truck so
   it does not roll while working on or under
   truck.
4. Disconnect battery and discharge any capacitors
   (electric trucks) before starting to work on
   truck. Hang Do not Operate tag in the
   Operators Compartment.
5. Repairs, which require welding, should be
   performed only with the benefit of the
   appropriate reference information and by
   personnel adequately trained and knowledgeable
   in welding procedures. Determine type of metal
   being welded and select correct welding
   procedure and electrodes, rods or wire to provide
   a weld metal strength equivalent at least to
   that of parent metal.
6. Do not damage wiring during removal operations.
   Reinstall the wiring so it is not damaged nor
   will it be damaged in operation by contacting
   sharp corners, or by rubbing against some object
   or hot surface. Do not connect wiring to a line
   containing fluid.
7. Be sure all protective devices including guards
   and shields are properly installed and
   functioning correctly before starting a repair.
   If a guard or shield must be removed to perform
   the repair work, use extra caution.
8. Always support the mast and carriage to keep
   carriage or attachments raised when maintenance
   or repair work is performed, which requires the
   mast in the raised position.

1. Loose or damaged fuel, lubricant and hydraulic
   lines, tubes and hoses can cause fires. Do not
   bend or strike high pressure lines or install
   ones which have been bent or damaged. Inspect
   lines, tubes and hoses carefully. Do not check
   for leaks with your hands. Pin hole (very small)
   leaks can result in a high velocity oil stream
   that will be invisible close to the hose. This
   oil can penetrate the skin and cause personal
   injury. Use cardboard or paper to locate pin
   hole leaks.
2. Tighten connections to the correct torque. Make
   sure that all heat shields, clamps and guards are
   installed correctly to avoid excessive heat,
   vibration or rubbing against other parts during
   operation. Shields that protect against oil spray
   onto hot exhaust components in event of a line,
   tube or seal failure, must be installed
   correctly.
3. Relieve all pressure in air, oil or water systems
   before any lines, fittings or related items are
   disconnected or removed. Always make sure all
   raised components are blocked correctly and be
   alert for possible pressure when disconnecting
   any device from a system that utilizes pressure.
4. Do not operate a truck if any rotating part is
   damaged or contacts any other part during
   operation. Any high speed rotating component
   that has been damaged or altered should be
   checked for balance before reusing.

7
GROUP INDEX
GROUP INDEX Items involved
GENERAL INFORMATION Serial Number Locations, Dimensions, Technical Data
VEHICLE ELECTRICAL COMPONENTS Console Box, Key Switch, Lamp Specification Chart
MAIN CONTROLLER Outline, Controller Components, Logic Card Components, Controller Models, Operation Outline, Drive System, Hydraulic System, Fail-safe System, Malfunction Detection, Malfunction Data Record, Setting, Self-diagnosis, etc.
TROUBLESHOOTING FOR CONTROL CIRCUITS Faulty Central Vehicle Monitor System, Faulty Diagnosis Indication, or Other Abnormalities
MOTORS Motor Installation Positions, Specifications, Structures, Tightening of High-power Cable Terminals, Inspection of Brushes for Wear and Brush Replacement, Procedures and Key Points for Removal and Installation, etc.
FRONT AXLE Structure and Functions, Disassembly and Reassembly of Front Axle Assembly, Service Data
REAR AXLE Rear Axle, Rear Wheels, Removal and Installation, Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data
BRAKE SYSTEM Specifications, Structure and Functions, Procedures and Key Points for Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
STEERING SYSTEM Specifications, Structure and Functions, Procedures and Key Points for Removal and Installation, Steering Control Valve, Hydraulic Circuit, Troubleshooting, Service Data
HYDRAULIC SYSTEM Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve
MASTS AND FORKS Simplex Mast, Duplex Mast, Triplex Mast
SERVICE DATA Inspection Standards, Periodic Replacement of Parts, Lubrication Standards, Main Component Weights, Tightening Torque for Standard Bolts and Nuts, Special Tools
OPTIONS Amber Strobe Kit, Back Buzzer Kit, Working Lamp Kit, Tire Kit
1 2 3 4 5 6 7 8 9 10 11 12 13
8
GENERAL INFORMATION
1
Vehicle Exterior ....................................................................................... 1 1
Models ....................................................................................................... 1 1
Serial Number Locations ...................................................................... 1 2
Chassis and Mast Model Identification ............................................ 1 3
Dimensions .............................................................................................. 1 4
Technical Data ......................................................................................... 1 5
9
GENERAL INFORMATION
Vehicle Exterior
103378
Models This manual applies to EP10KRT, EP12KRT
and EP15KRT.
Truck Model Serial Number
EP10KRT ETB10-00011-up
EP12KRT ETB10-20001-up
EP15KRT ETB10-50001-up
10
GENERAL INFORMATION Serial Number Locations
Mast number
Chassis number
Nameplate
209010
11
GENERAL INFORMATION
Chassis and Mast Model Identification
Chassis EP
10 KRT
Generation designator and truck type Rated
capacity 10 1000 kg 12 1250 kg 15 1500
kg Battery type GP gasoline engine DP diesel
engine
Mast 2
G
15
CA
33
Maximum lifting height 33 stands for 3300
mm Order of the minor change (CA for the
original, CB for the first change, CC for
the second change, and so on) Applicable truck
model designation 15 1.0 ton class Kind of
mast G simplex mast H duplex mast J triplex
mast Major change (2 for the original, 3 for
the first change, and so on up to 9)
12
GENERAL INFORMATION Dimensions
209011
13
GENERAL INFORMATION
Technical Data
Truck model EP10KRT EP12KRT EP15KRT
Mast tilt, forward/backward A (deg) 5/7 5/7 5/7
Height with mast lowered B (mm) 2110 2110 2110
Standard free lift C (mm) 120 120 120
Standard lift height D (mm) 3300 3300 3300
Overall height with mast raised (without backrest) E (mm) 3895 3895 3895
Overall length F (mm) 2500 2500 2575
Length to fork face (includes fork thickness) G (mm) 1700 1700 1775
Overall width H (mm) 997 997 997
Forks dimensions (thickness ? width ? length) I (mm) 35 ? 80 ? 800 35 ? 80 ? 800 35 ? 80 ? 800
Turning circle radius J (mm) 1370 1370 1445
Fork carriage width K (mm) 920 920 920
Ground clearance under mast, with load L (mm) 80 80 80
Ground clearance center of wheelbase, with load M (mm) 100 100 100
Travel speed, with/without load km/h 11.5/13.5 11.2/13 11/12.5
Lifting speed, with/without load m/s 0.29/0.48 0.27/0.48 0.26/0.48
Lowering speed, with/without load m/s 0.52/0.50 0.52/0.50 0.52/0.50
Rated drawbar pull, with/without load (60 min. short duty) N 1569/1667 1520/1669 1470/1670
Maximum drawbar pull, with/without load (5 min. short duty) N 4217/4315 4168/4315 4119/4314
Gradeability, with/without load 5.5/8 4.5/7.5 3.5/6.5
Maximum gradeability, with/without load 13/20 11/18 10/16
Battery to DIN 43531/35/36A/B/C/No. DIN43535A DIN43535A DIN43535A
Battery voltage/capacity at 5-hour discharge V/Ah 24/600, 720 24/600, 720 24/720, 840
Battery weight kg 445, 540 445, 540 540, 620
Truck weight, without load/including battery kg (Maximum battery) 2333 2568 2778
Drive motor capacity (60 min. short duty) kW 4.8 4.8 4.8
Pump motor output _at_15 duty factor kW 8.8 8.8 8.8
Drive motor control method Mosfet-chopper Mosfet-chopper Mosfet-chopper
Pump motor control method Chopper Chopper Chopper
1-5
14
VEHICLE ELECTRICAL COMPONENTS
Console Box ............................................................................................. 2 1
Functions of Vehicle Monitor System ........................................................ 2 1
Electrical Components .............................................................................. 2 3
Disassembly and Reassembly .................................................................. 2 4
Direction Lever ........................................................................................ 2 5
Accelerator Control ............................................................................... 2 6
Key Switch ............................................................................................... 2 7
Lighting Switch ....................................................................................... 2 7
Fuses ......................................................................................................... 2 8
Lamp Specification Chart .................................................................... 2 8
Electrical System Diagram (Type Chopper) ................................... 2 9
Electrical Schematic (Type Chopper) .............................................. 2 11
Electrical Schematic (Type Chopper) .............................................. 2 13
2
15
VEHICLE ELECTRICAL COMPONENTS
Console Box
103380

1. Vehicle monitoring system (VMS)
2. Steering tilt knob
3. Key switch
4. Lighting switch

Functions of Vehicle Monitor System (VMS)
Operations 209140C Operations 209140C Operations 209140C Operations 209140C Operations 209140C
No. Monitor name When OFF When ON or flashing Remarks
1 Service indicator Wrench-symbol warning lamp turns on when error has occurred. Wrench-symbol warning lamp turns on when error has occurred. Wrench-symbol warning lamp turns on when error has occurred.
2 Worn motor brush lamp Drive motor and pump motor brushes in operable condition Worn brushes After brushes are replaced, lamp turns OFF.
3 Service indicator Controller, drive motors and pump motor in normal temperature Overheat Error code is indicated on display 8 when overheating condition has occurred.
4 Remaining battery charge warning lamp Normal battery condition Red LED turns on. Drive 1 Lifting function operates in restricted mode.
5 Brake fluid level lamp Normal fluid level Low fluid level
6 Parking lamp Parking brake disengaged Parking brake engaged
2-1
16
VEHICLE ELECTRICAL COMPONENTS
No. Monitor name When OFF When ON or flashing Remarks
7 Malfunction lamp Normal Vehicle malfunction
8 Error indicator Error code is displayed as follows when an error is present. A L ? ? ? Error code is displayed as follows when an error is present. A L ? ? ?
9 Battery discharge indicator (BDI) Any of four green LEDs turns on when corresponding battery is discharged.
10 Hourmeter time display
11 Truck mode indicator Power mode (Mode B) Economy mode (Mode A)
Error indicator
Indication Condition
A L 0 7 9 ON Key switch turned ON with direction lever in F or R position
A L 0 6 5 ON Drive motor overheated
A L 0 1 7 ON Pump motor overheated
A L 0 6 2 ON Traction controller overheated
A L 0 0 6 ON Data communication error
A L 0 3 5 ON Pump motor overcurrent
A L 0 6 4 ON Hydraulic controller overheated
A L 0 7 2 ON Drive motor stall timer
A L 0 7 9 ON Faulty setting of tilt lever
A L 0 7 9 ON Faulty setting of attachment lever 1
A L 0 7 9 ON Faulty setting of attachment lever 2
A L 0 3 2 ON Regeneration diode error
A L 0 3 2 ON Drive motor armature diode error
A L 0 2 8 ON Pump motor armature diode error
A L 0 6 9 ON Drive motor armature overcurrent
A L 0 5 7 ON Drive motor field overcurrent
2-2
17
VEHICLE ELECTRICAL COMPONENTS
Electrical Components
209141

1. Key switch
2. Display
3. Horn
4. Controller

1. Contactor
2. Fuse holder
3. Plate
4. Rivet

2-3
18
VEHICLE ELECTRICAL COMPONENTS Disassembly and
Reassembly Disassembly
209142

• Sequence
• Console box (front panel)
• Forward/reverse lever

1. Console box (rear panel)
2. Steering column assembly

• Disassembly procedure
• Remove the rear panel and front panel from the
  steering column assembly.
• Disconnect the harness connector at the direction
  lever.
• Disconnect the harness connector at the horn.
• Remove the steering tilt knob from the rear panel
  of the console box.
• Remove the steering column assembly.

209143
Reassembly Follow the disassembly procedure in
reverse.
2-4
19
VEHICLE ELECTRICAL COMPONENTS
Direction Lever Structure
209144

1. Knob
2. Lever
3. Harness

1. Connector
2. Screw, Spring washer

2-5
20
VEHICLE ELECTRICAL COMPONENTS Accelerator Control
206805A

• Adjustment procedure
• Disconnect the battery plug.
• Adjust the stopper bolt to a fixed position of 32
  to 34 mm from the floor to the top head of the
  bolt.
• Adjust the mounting angle of the position meter
  using the adjusting screws so the switch inside
  the position meter turns on when the accelerator
  pedal is depressed
• 1.5 to 2.6 mm.
• Make sure the inside switch turns ON by checking
  the continuity between terminals 143 and 144
  with an ohmmeter.
• Perform the accelerator self-diagnostics
  according to the table on page 3-13. The display
  should read OFF and Speed 0 without the
  accelerator depressed. The display should change
  to ON before the speed changes from 0 to 1. If
  not, then readjust accelerator switch.
• Make sure when the accelerator is fully depressed
  when the display reads Speed 16. If not,
  readjust the stop per bolt.

208081
2-6
21
VEHICLE ELECTRICAL COMPONENTS
Key Switch
206806A
Terminal B B M1, M2 M1, M2
Connection destination Main fuse battery Main fuse battery Logic card Logic card
(OFF)
I (ON)
I (ON)
Lighting Switch
103042 209145
Terminal B B W W W H H
Connection destination Battery Battery Working lamp Working lamp Working lamp Head lamps Head lamps
1st position
1st position
2nd position
2nd position
2-7
22
VEHICLE ELECTRICAL COMPONENTS Fuses
Capacity (A) Location Main connecting device
500 Contactor assembly Battery Refer to Group 3 Main Controller.
325 Contactor assembly Loading hydraulic motor Refer to Group 3 Main Controller.
15 Fuse holder Electric parts 103402
10 Fuse holder Controller 103402
NOTE Refer to Parts Manual for proper
replacement fuses.
Lamp Specification Chart
Item Lamp Quantity Bulb color Bulb Bulb Remarks
Item Lamp Quantity Bulb color 24 V External diagram Remarks
Head lamps 2 Clear 70 W Option
Working lamp 1 Clear 70 W Option
205833
2-8
23
MAIN CONTROLLER
Variation....................................................................................... 3 1
Outline of Controller .................................................................... 3 3
Outline of Contactor Module....................................................... 3 4
Operation Outline ........................................................................ 3 5
Drive System ............................................................................... 3 5
Neutral Position ........................................................................................ 3 5
Powering ................................................................................................... 3 5
Regeneration System ............................................................................... 3 6
Hydraulic System ........................................................................ 3 9
Fail Safe System.......................................................................... 3 10
Output Power Control at Low Battery Voltage ........................................... 3 10
Overheat ................................................................................................... 3 10
Maximum Vehicle Speed Control .............................................................. 3 10
Output Power Control During Braking ....................................................... 3 10
Chat Timer ................................................................................................ 3 10
Seat Switch Timer ..................................................................................... 3 10
Stall Timer ................................................................................................. 3 11
Malfunction Detection (Run Time Diagnostics) .......................... 3 11
Malfunction Data Record (History Folder) .................................. 3 11
Data Storage ............................................................................................ 3 11
Review of Stored Data .............................................................................. 3 11
Setting ......................................................................................... 3 11
Self-diagnostics .......................................................................... 3 11
Safety Function ........................................................................... 3 12
Display ........................................................................................ 3 16
Combination Display ................................................................................. 3 16
Action Lights ............................................................................................. 3 16
3
24
Removal and Installation..........................
................................... Removal and
Installation of Controller .......................
............................... Removal and
Installation of Logic Card .......................
.............................. Basic Check
..................................................
.............................. Testing Tools
..................................................
...........................................
Measurement of Logic Card Voltage
..................................................
....... Check Contactor Coil .....................
..................................................
......... Check Contactor Tip ....................
..................................................
........... System Construction
..................................................
............................... Controller
Interface Pin Assign ............................
..................................... Digital
Console ..........................................
.................................. Programming
and Adjustments Using Digital Console
.............................. Combisem
Diagnostic .......................................
........................................ Digital
Console Function Diagram .........................
....................................
3 17 3 17 3 19 3 20 3 20 3 20 3
22 3 22 3 23 3 24 3 25 3 25 3 35 3
45
25
MAIN CONTROLLER
Variation (1) There is one controller model, as
shown in the table below.
Voltage Controller Configuration
DC24 V Chopper
(2) There is one controller and one contactor
module.
Item Item Remarks
Controller Traction 24 V 500 A max.
Controller Hydraulic 24 V 550 A max.
Contactor Contactor Line contactor, fuse (drive and pump) and switches
(3) The maximum vehicle speed varies depending on
load weight, as shown in the table below. Unit
km/h
Truck model EP10KRT EP12KRT EP15KRT
Travel speeds with load 11.5 11.2 11.0
3-1
26
MAIN CONTROLLER
Outline of Controller The controller is the
heart of the truck operating system. The logic
card contains decision making functions, and is
equipped with a battery discharge indicator and a
malfunction diagnostic function. The controller
is used to operate the drive motor and hydraulic
motor.
209026

1. Controller
2. Logics assembly
3. Cover
4. Screw

1. Washer
2. Spring washer
3. Connector

27
MAIN CONTROLLER Outline of Contactor Module The
contactor module controls the function of the
main switch and circuit protector. The contactor
is operated by the controller.
209027

1. Bracket
2. Contactor
3. Bar
4. Terminal, Nut

1. Pump fuse (350 A)
2. Main fuse (500 A)
3. Screw, Washer

28
MAIN CONTROLLER
Operation Outline
Drive System Neutral position If the truck runs
and the direction lever is in the neutral
position, then the regeneration function is
activated. If the truck is powered by turning the
key switch to ON and the direction lever is in
the neutral position, the controller checks
whether the drive motor is turning or not.
(1) Power ON, default condition Turning on the
key switch supplies power to the controller.
When power is ON, the controller checks all
switches and sensor input conditions the
combination display indicates the vehicle
condition. Next, the line contactor turns ON and
provides battery power to the main circuit. The
pump motor starts rotating (idle revolution is
500 to 600 rpm). Seat switch ON Forward/reverse
lever Neutral Hydraulic lever OFF Accelerator N
eutral With the line contactor in the ON
condition, the hourmeter indicates cumulative
hours.
Powering

• Outline
• Accelerator is a combination of the digital
  signal (accelerator idle switch) and the analog
  signal (accelerator input). Digital signals
  relationship to analog signal.
• Analog signal range is from 0 to 5 V.
• Digital signal voltage change (open ? close) is
  typically 0.94V 0.47V.
• During vehicle operation the signal voltage
  ranges from where the accelerator idle switch is
  closed (typically 0.94 V 0.47 V) to about 4 V.
• Its signal range can be adjusted by using the
  console. The controller uses this signal as
  continuous input data.
• Accelerator signal is a torque demand data.
• Motor torque is determined by accelerator signal
  and vehicle speed.
• Power selection can be selected by using the
  console. Current rise rate can be adjusted by
  using console.

(2) Normal mode (RUN mode) When the direction
lever is operated and the accelerator pedal is
pressed, the vehicle moves forward or backward.
During deceleration, the motors conduct various
regenerative operations according to the
settings. When the vehicle is running, the
steering pump motor rotates at 700 to 800
rpm. Operating a hydraulic lever activates the
pump motor and provides hydraulic power. The
controller monitors operating conditions. When
an abnormality occurs, the display unit indicates
an error code and activates an appropriate
fail-safe function. The error code is stored in
the controller memory the combination display
indicates the error code.
(2) Truck mode The truck mode can be selected
from Power Mode (Mode B) and Economy Mode (Mode
A) by using the console. Each Mode has preset
values for drive speed, acceleration, lift
speed, tilt speed, and regen brake. For
reference, performance changes of 1.5 ton class
are shown below.
29
MAIN CONTROLLER
Truck Mode Item 1.5 ton class Economy Mode 1.5 ton class Power Mode
Drive speed (without load) 0 to 10.0 km/h 0 to 12.5 km/h
Acceleration Comfortable Fast
Lift speed (without load) 0 to 0.42 m/s 0 to 0.48 m/s
Tilt speed Fixed Fixed
Regen brake Moderate braking Hard braking
In the weakening region, the speed of the motor
can be reduced by increasing the flux.
Consequently EMF will be increased and current
direction will be in the opposite direction, so
the battery is charged by the dynamic energy of
the vehicle. This condition happens during
deceleration when the accelerator pedal is
depressed from 100 to 70. At 70, the speed
reaches o its nominal speed and the system comes
out from the weakening region. Nominal speed
means the motor speed at nominal flux and at
nominal voltage (equal to the battery
voltage). Once the motor reaches nominal speed,
more braking is needed (Ex. Accelerator pedal is
completely released), the controller should
reduce the applied voltage to the rotor from
100 down to 0. As soon as the rotor is
short-circuited, the EMF will be equal to 0 and
the rotation speed will be zero (or almost equal
to zero). By reducing the applied voltage to the
rotor, the controller should turn ON the drive
MOSFET (minus battery side) and turn off the
brake MOSFET (plus battery side) with the high
time ratio (the two changing conditions are
written below respectively). The direction of the
motor current during this phase is shown in Fig.
1 and 2 where the current into the motor is in
the opposite direction to the traction current
direction (battery plus to minus). It follows two
different conditions
Regeneration System Basic theory The Electro
Motive Force (EMF) on the rotor of a Separately
Excited Machine motor (SEM motor) is
proportional to the rotating speed of the rotor
and to the flux generated by the field current.
Rotating speed is dependent on truck speed and
field current which can be changed by the
controller. During traction, the Maximum EMF is
equal to or less than the ones applied to the
rotor current. Some rotor current losses are due
to external cables, bad connections and brushes.
Under the same flux volume, the rotating speed
will decrease when motor torque become high and
the rotating speed will reach the maximum value
with zero rotor current. When the motor is raced
at high speed, the EMF will be higher than the
applied voltage. Resulting in the rotor current
flowing in the opposite direction. In this
condition, the motor will brake automatically and
recharge the battery. SEM motor is able to
transform its function between motor and
generator (brake) behavior will depend on the
ratio between the required speed and the real
motor speed. At the right load condition, the
speed of the motor can be increased
automatically with reducing the flux. This
working condition is called the weakening region.
30
MAIN CONTROLLER
1) Regenerative condition The current comes from
minus battery, through the drive MOSFET and then
through the motor to recharge the battery.
Brake MOSFET OFF
Drive MOSFET ON
Rotor Drive motor
Stator
Fig.1 Regenerative condition
31
MAIN CONTROLLER 2) Short circuit condition The
current flows through the rotor via the closed
brake MOSFET. During regenerative condition, the
rotor current runs out rapidly and should be
incremented by changing to the short-circuit
condition (during the short-circuit condition
the rotor current increases rapidly by EMF). The
inductance of the system gives the necessary
inertia for the flow of constant current.
Brake MOSFET ON
Drive MOSFET OFF
Rotor Drive motor
Stator
Fig.2 Short circuit condition
32
MAIN CONTROLLER
(5) Anti roll-down When the vehicle is on a
downward grade with the key switch ON and
running over maximum speed, then regeneration is
activated.
Function

• Lever regeneration
• When the direction lever is shifted into the
  position opposite to the vehicle's traveling
  direction, the regeneration function is
  activated. The amount of regeneration is
  determined by the truck speed and the
  accelerator position.
• The regenerative characteristic can be selected
  by using the console. The degree of acceleration
  serves as the parameter. The harder the
  accelerator pedal is pressed, the amount of
  regeneration increases.
• The regeneration function is activated until the
  vehicle stops.
• The maximum current of regeneration must be less
  than the powering current.
• Neutral regeneration
• When the direction lever is shifted into the
  neutral position, the regeneration function is
  activated.
• The regenerative characteristic can be selected
  by using the console.
• The regeneration function is activated until the
  vehicle stops.
• The maximum current of regeneration must be less
  than the powering current.
• Accel regeneration (auto regeneration)
• When the direction lever position is the same as
  the vehicle's traveling direction and the
  accelerator is released, then the regeneration
  function is activated.
• The regeneration character is determined by auto
  regenerative characteristics and can be selected
  by using the console. The maximum current of
  regeneration must be less than the powering
  current.
• The regeneration function is activated until the
  vehicle stops.
• Anti roll-back
• When the vehicle runs with the key switch ON and
  the accelerator position is in neutral, then
  regeneration is activated.

Hydraulic System
When the hydraulic lever is operated, the pump
motor rotates. The motor is driven by a
specified chopping rate.
(1) Lift speed When the lift lever is operated,
the lift analog signal changes
continuously. Lift potentiometer is the stroke
sensor. In the operating condition, lift signal
range is from 1 V to 4 V. Signal range data can
be adjusted by using the console. The controller
uses this signal for continuous input data.
(2) Tilt speed Tilt speed is set by the
controller. This function cannot be adjusted by
using the console.
(3) Attachment 1 speed, attachment 2 speed The
attachment speed function is set by a priority
for each attachment. These functions can be
adjusted by using the console.
(4) Priority When two or more levers are operated
at the same time, the following priority order
is effective. Tilt lever (high priority),
Attachment 1 lever, Attachment 2 lever, lift
lever (low priority)
33
MAIN CONTROLLER
(3) Controller overheat When powering, the
controller restricts the drive motor operation
to the extent that the trucks can travel with a
full load. The output duty of lift and
attachment 1and 2 is cut by 50.
Fail Safe System Output Power Control at Low
Battery Voltage
(1) Battery discharge characteristic Available
for the different discharge characteristics of
the battery. It can be adjusted by using the
console.
Maximum Vehicle Speed Control Limits the maximum
vehicle speed.
(2) Output power control When the battery voltage
is lower than the setting data, this limits the
output power. Output power controls Traction
When powering, limits the output power. Under the
condition of full load, the vehicle can
run. Pump The operation of lift and attachment
1and 2 to cut their output duty ratio by 50.
Tilt operation remains the same. When operated
at the same time The pump motor can operate
only when the truck stops and the direction
lever is in neutral. Battery voltage ranges from
15 to 18 at this time. Output controls are as
follows. Output power control Traction When
powering, limits the output power. Under the
condition of full load, the vehicle can
run. Pump Doesn't control output. Line contactor
is OFF when battery voltage is under 15 V. Reset
the key switch to the ON position.
Output Power Control During Braking The maximum
current is controlled during the use of the
service brake and parking brake. (1) Service brake
Maximum field current 20A Maximum armature
current 125A (2) Parking brake
Maximum field current 20A Maximum armature
current 125A
Chat Timer When the following conditions remain
for the time duration setting, the pump motor
stops.

1. Accelerator
2. Forward/reverse lever

0 Neutral

1. Lift, tilt and attachment levers OFF
2. Steering Not operated

Operating any of the above, except (4), activates
the pump motor. Chat timer can be selected by
using the console (5 to 40 sec).
Seat Switch Timer When the operator leaves the
seat for the time duration setting, the line
contactor turns OFF. When the key switch is
turned on without the operator sitting in the
seat, the line contactor turns OFF. If
acceleration is 0, direction lever in in neutral
and the hydraulic levers are all OFF, turning on
the seat switch activates the line
contactor. Seat switch timer can be set by using
of console (3 to 15 sec).
Overheat
(1) Drive motor overheat When powering up, the
controller restricts the drive motor operation
to the extent that the trucks can travel with
full load.
(2) Pump motor overheat The output duty of lift
and attachment 1 and 2 is cut by 50.
34
MAIN CONTROLLER
Stall Timer Stall timer will be pre-set at 10 sec
to protect the motors from overheating. This
setting is adjustable by using the console.
Setting Use serial communication, and operate
console tool.
Truck mode The truck mode can be selected between
Power Mode (Mode B) and Economy Mode (Mode A)
using the console.
Malfunction Detection (Run Time Diagnostics)

• Setup parameter
• Standard setup parameters, can be selected by
  using the console tool. Every parameter can be
  setup in 10 steps. Final definition of
  parameters are the result of prototype testing.
• Drive speed
• Acceleration
• Regen braking (auto-regen, direction regen,
  neutral regen)
• Lift speed
• Attachment speed 1
• Attachment speed 2
• Seat switch timer (5 to 40 sec)
• Chat timer (3 to 15 sec)

If a malfunction is detected, the red LED flashes
and the error code is indicated on the
combination display. The corresponding fail-safe
is activated at the same time. Refer to the
malfunction detection tables. Customer should
inform service of all malfunction error codes
and LED flash patterns.
Malfunction Data Record (History folder) Data
Storage Errors are automatically stored in the
memory. A maximum of 5 sets of data can be
stored.
Self-diagnostics
Review of Stored Data
Check the input and output status. Use serial
communication, and operate console.

• To review data
• Use serial communication, and operate console.
• To delete data
• Use serial communication, and operate console.

3-11
35

• MAIN CONTROLLER
• Safety Function
• The controller must meet the safety conditions
  below
• When the CPU is hanging up, the vehicle will stop
  functioning.
• When the accelerator condition is unusual, the
  vehicle should be stopped.
• It has a function that protects against motor and
  contactor short circuits.
• If forward and reverse signals turn on at the
  same time, the vehicle must stop.
• If something unusual happens, it indicates the
  status.
• Even if a terminal of the controller makes
  contact with a high voltage line or grounding
  line, the controller will not crash nor run out
  of control.
• When a different battery voltage is connected,
  the controller indicates the status.
• When the lift potentiometer signal is unusual,
  the lift function will stop.

3-12
36
MAIN CONTROLLER
Malfunction Detection
Malfunction Detection method/condition Display Display Display Display Display Display Fail-safe process Reset method
Malfunction Detection method/condition LED LED LED LED LED Error code Fail-safe process Reset method
Malfunction Detection method/condition Error Brake Battery Thermal Brush Error code Fail-safe process Reset method
Drive motor overheat Signal input AL065 Output power control Cooling
Pump motor overheat Signal input AL017 Output power control Cooling
Controller overheat Signal input AL062 Output power control Cooling
Drive motor brush wear
Pump motor brush wear
Brake fluid low

Drive motor transistor wire breakage Check the main circuit voltage level AL060 Line contactor OFF Power reset
Drive motor transistor shorting Check the main circuit voltage level AL032 Line contactor OFF Power reset
Drive motor stall timer Time duration elapsed AL072 Line contactor OFF Power reset
Drive motor transistor drive error Error detection signal from drive card AL060 Line contactor OFF Power reset
Drive motor current sensor error Check the current sensor output value AL053 Line contactor OFF Power reset
Drive motor armature over current 500 A AL069 Line contactor OFF Power reset
Drive motor field over current 50 A AL057 Line contactor OFF Power reset
Drive motor field error Compare the current instruction value and actual current valve AL058 Line contactor OFF Power reset
Drive motor field drive error Error detection signal from H bridge card AL015 Line contactor OFF Power reset

Pump motor transistor wire breakage Check the main circuit voltage level AL028 Line contactor OFF Power reset
Pump motor transistor shorting Check the main circuit voltage level AL028 Line contactor OFF Power reset
Pump motor transistor drive error Error detection signal from drive card AL028 Line contactor OFF Power reset
Pump motor current sensor error Check the current sensor output value AL056 Line contactor OFF Power reset
Pump motor over current 500 A AL035 Line contactor OFF Power reset

Line contactor error Check the main circuit voltage level AL037 Line contactor OFF Power reset
Regeneration diode error Check the main circuit voltage level AL032 Line contactor OFF Power reset
Drive motor armature diode error Check the main circuit voltage level AL032 Line contactor OFF Power reset
Pump motor armature diode error Check the main circuit voltage level AL028 Line contactor OFF Power reset
Drive motor armature breakage Check the main circuit voltage level AL032 Line contactor OFF Power reset
Pump motor armature breakage Check the main circuit voltage level AL028 Line contactor OFF Power reset
Accelerator error Input range exceeded AL078 Line contactor OFF Power reset
3-13
37
MAIN CONTROLLER
Malfunction Detection method/condition Display Display Display Display Display Display Fail-safe process Reset method
Malfunction Detection method/condition LED LED LED LED LED Error code Fail-safe process Reset method
Malfunction Detection method/condition Error Brake Battery Thermal Brush Error code Fail-safe process Reset method
Forward/reverse lever or acceleration setting error When lever is not in neutral or acceleration is not 0 at power ON AL080 Line contactor OFF Power reset
Seat switch setting error When signal is not input at power ON AL079 Line contactor OFF Switch ON
Tilt lever setting error When signal is input at power ON AL079 Line contactor OFF Switch OFF
Attachment 1 lever setting error When signal is input at power ON AL079 Line contactor OFF Switch OFF
Attachment 2 lever setting error When signal is input at power ON AL079 Line contactor OFF Switch OFF
Lift potentiometer error Input range exceeded Line contactor OFF Power reset

Data communication error The display indicates an error code when there is no data communication. AL006 Display Power reset
E2PROM error AL013 Line contactor OFF Power reset
Controller error ROM and RAM check at power ON Line contactor OFF Power reset
Battery voltage low The battery voltage is lower than 15 V at power ON AL055 Line contactor OFF Power reset
Battery voltage high The battery voltage is higher than 36 V at power ON AL059 Line contactor OFF Power reset
Battery voltage low When the truck is working, the battery voltage from 15 V to 18 V AL068 Output power control Voltage recovered
Battery voltage low When the truck is working, the battery voltage lower than 15 V AL067 Line contactor OFF Power reset
3-14
38
MAIN CONTROLLER Display
(6) Maintenance alarm function Hour glass symbol
shows the request of programmed maintenance or
the state of Alarm. In this case the relative
code will be displayed.

• Combination Display
• The combination display communicates with the
  controller and functions as indicated below.
• Its power is supplied from the controller.
• BDI (Battery discharge indicator) function
• Five LEDs, show the batterys State of Charge.
  Four Green, and one Red. With a fully charged
  battery, all the Green LEDs are illuminated. As
  the battery becomes discharged, the Green LEDs
  turn off progressively, one after the other, in
  proportion to the residual charge of the
  battery, until value of residual charge is
  reached. At this time the Red LED illuminates
  indicating a discharged battery.
• Hourmeter function
• Hourmeter indicates cumulative line contactor ON
  hours. When the hourmeter is working, hourglass
  symbol flashes.
• Error code display function
• The display shows an error code and flashes red
  LED when an abnormality occurs.
• Truck mode display function
• The display shows the turtle symbol when Economy
  Mode (Mode A) is selected.

• Action Lights
• Brush wear indicator Drive motor, pump motor
• Indicates when the the drive motor or pump motor
  brush becomes worn.
• Brake fluid indicator
• Indicates when the brake fluid level become low.
• Parking brake
• Illuminates when the parking brake is being
  applied.

(5) Software version display function When the
Key Switch is initially closed, the display
shows the EPROM Version for a few seconds.
(EPXXX where XXX represents the version).
Simultaneously the symbol of a Shifting Spanner
appears.
3-16
39
MAIN CONTROLLER
Removal and Installation Removal and Installation
of Controller
! WARNING
209029
Disconnect the battery plug before performing
maintenance on the controller.

• Removal of rear cover
• Turn the key switch off.
• Disconnect the battery plug.
• Remove the rear cover of the counterweight.

(2) Removal of controller
!
CAUTION
Be sure to regularly check the tightened torque
of high-tension battery cable terminals. If the
cables are loosely connected, excessive contact
resistance can cause over-heating or lead to a
fire in a worst case scenario. When checking or
adjusting the cable routing, avoid pulling the
cable. If cables move even slightly at the
terminals, loose connections will result. While
working with the cables be sure to tighten the
terminal connections.
Remove the power cables (for battery and motors).
Tightening torque for stud terminal (M6)
11.8 2.0 Nm (1.2 0.2 kgfm)
209030
(a) Note that a flat washer and a disc spring are
installed on each connector terminal. (See the
illustration at right.)
3-17
40
MAIN CONTROLLER
Disconnect connectors CNA, CNB and CNC
209031
NOTE
Hold the connectors to unplug. Do not pull the
harnesses to disconnect the connectors.
Remove the controller mounting screws (M8 4
places for controller), and remove the
controller.
209032
(3) Installation of controller Follow the removal
procedure in reverse.
209033
NOTE
There is thermal paste between the counterweight
and the controller. It is important for cooling
the controller. Spread the thermal paste evenly
before mounting the controller on the
counterweight.
3-18
41
MAIN CONTROLLER
Removal and Installation of Logic Card
(1) Removal of controller cover Remove the cover
mounting screws (M4 3 places), and remove the
controller cover.
209034

• Removal of logic card
• Disconnect J1, J2 and J3.
• Remove the logic card bracket mounting screws
  (M4 2 places), and remove the logic card with
  bracket.
• Remove the logic card mounting screws (M3 5
  places), and the heat-sink mounting screws (M4 2
  places behind the bracket), and remove the logic
  card.

209035
(3) Installation Follow the procedure in reverse.
3-19
42

• MAIN CONTROLLER
• Basic Check
• Always following basic troubleshooting steps.
• Talk to the operator.
• Confirm his description of the problem with an
  operational check.
• Visually inspect cables, connectors, contactor
  tips, etc.
• Perform basic battery cables to frame resistance
  test. (at least 20 k ohm)
• Check battery condition.
• Always check each option and write down the
  reading.

• Testing Tools
• Circuit tester
• Clamp meter
• IC tip
• Digital console (Refer to Page 3-25.)

(b) (a) (c) 208282 20903
6
NOTE
The illustrations show digital circuit testers.
In these testers, the positive () terminal is
applied with positive charge, and the negative
(-) terminal with negative charge. It should be
noted that the terminals must be connected
inversely when using an tester.
! WARNING
Disconnect the battery plug before inspecting or
adjusting the controller.
Measurement of Logic Card Voltage
! WARNING
To prevent accidental movement of the vehicle,
place wood blocks under the vehicle to lift the
rear wheel off the ground. Do not stand close to
the rear wheel.
3-20
43
MAIN CONTROLLER

• Place wood blocks under the vehicle to lift the
  rear wheel off the ground.
• Turn the key switch off.
• Disconnect the battery plug.
• Remove the rear cover from counterweight.
• Reconnect the battery plug.
• Turn the key switch on. Connect the negative
  terminal of the circuit tester to the NEG
  terminal of the controller.
• Set the circuit tester to the 50- or 100- VDC
  range.
• Connect the positive terminal of the circuit
  tester to each pin of connectors CNA, CNB and
  CNC.
• NOTE
• Be careful not to short circuit pins. For the
  normal voltage value, refer to the logic card
  voltage chart on the following pages.

3-21
44
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45
MAIN CONTROLLER Check Contactor Coil
!
CAUTION

• Disconnect the battery plug before close the
  controller.
• Disconnect the lead wire of coil. Set the circuit
  tester to 200 ohm range. Measure coil
  resistance.
• If the measured value deviates from the above
  range, replace the contactor assembly.
• With the lead wire of contactor coil connected,
  set the circuit tester to 200 VDC range.
• Connect the negative (-) terminal of the circuit
  tester to the negative-side coil terminal (small
  fasten terminal) and the positive () terminal
  of the circuit tester to the positive-side coil
  terminal (large fasten terminal).
• Connect the battery, and operate the control
  device that activates the contactor.
• The circuit tester should indicate a value
  between 23.4 to 52 V after the contactor is in
  operation. If contactor resistance is found to
  be normal during the coil resistance test, but
  the measured voltage is not within the 23.4 to 52
  V range, replace the logic card.

• Check Contactor Tip
• Turn key switch off. Disconnect battery plug.
  Check voltage of contactor terminal.
• Check the tip condition and the movement. Check
  the gap.
• If the contactor shows any fault, replace or
  correct the contactor.

209037
3-22
46
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