CATERPILLAR CAT EP20K EP25K EP30K EP35K FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
Service Manual
Chassis, Mast Options
EP20K EP25K EP30K EP35K
ETB8B-00011-up ETB8B-50001-up ETB9B-00011-up
ETB9B-50001-up
For use with EP20K-EP35K Controller Service
Manual.
99759-6D100
2
FOREWORD
This service manual is a guide for servicing Cat
lift trucks of 2.0 ton, 2.5 ton, 3.0 ton and 3.5
ton models. The instructions are grouped by
systems to conveniently provide a ready
reference. A long productive life of your lift
truck depends to a great extent on correct
servicing servicing consistent with what you
will learn from this service manual. Read the
respective sections of this manual carefully and
familiarize yourself with all the components you
will work on before attempting to start a test,
repair or rebuild job. The descriptions,
illustrations and specifications contained in
this manual are of the trucks with the serial
numbers in effect at the time it was approved for
printing. Cat lift truck reserves the right to
change specifications or design without notice
and without incurring obligation. Safety
Related Signs The following safety related signs
are used in this service manual to emphasize
important and critical instructions
Indicates a specific potential hazard that could
result in serious bodily injury or death.
! WARNING
Indicates a specific potential hazard that may
result 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. 99759-6D100
3
!
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.

4
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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.
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. Place wiring away from oil pipe.
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.
9. 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.

• 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.
• 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.
• 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.
• When handling the parts containing asbestos, be
  careful not to inhale the asbestos. Doing so is
  hazardous to your health.
• If the shop dust may contain asbestos, follow the
  precautions described below.

1. Do not use compressed air for cleaning.
2. Do not brush or apply grinder on asbestos
   containing materials.
3. To clean asbestos containing materials, wipe
   with moistened cloth or use a vacuum cleaner
   with particle filter.
4. If you have to handle the parts containing
   asbestos for a long time, be sure to do it in a
   well-ventilated area.
5. If the asbestos in the air cannot be removed,
   wear a mask.
6. Be sure to observe the working rules and
   regulations.
7. When disposing of materials with asbestos, be
   sure to observe the environmental protection
   regulations of your area.
8. Avoid working in the atmosphere where asbestos
   particles may be suspended.

6
HOW TO USE THIS MANUAL (Removal, Installation,
Assembly and Disassembly) Disassembly diagram
(example)
2
1
Procedures are described in the text.
Disassembling sequence
209603
Sequence 1 Cover, Bolt, Washer (part name) 2 Snap
ring ................ (part name)
Suggestion for disassembling 1. Output shaft,
Removing Remove output shaft using a special tool.
209604
Service Data
Gear Backlash A 0.11 to 0.28 mm (0.0043 to 0.0110 in.)
Gear Backlash B 0.5 mm (0.020 in.)
A Standard Value B Repair or Service Limit
7
Symbols or abbreviation
OP R1/4 Rc1/8 G1/4A Rp1/8
Option Taper pipe thread (external) 1/4 inch
(formerly PT1/4) Taper pipe thread (internal)
1/8 inch (formerly PT1/8) Straight pipe thread
(external) 1/4 inch (formerly PF1/4-A) Straight
pipe thread (internal) 1/8 inch (formerly PS1/8)

• Units
• SI Units are used in this manual.
• The following table shows the conversion of SI
  unit and customary unit.

Item SI unit Customary unit
Force 1 N 0.1020 kgf
Force (1 lbf) (0.4536 kgf)
Pressure 1 kPa 0.0102 kgf/cm2
Pressure (1 psi) (0.0703 kgf/cm2)
Torque 1 Nm 0.1020 kgfm
Torque (1 lbfft) (0.1383 kgfm)
8
GROUP INDEX
GROUP INDEX Items
GENERAL INFORMATION Serial Number Locations, Chassis and Mast Model Identification, Dimensions, Technical Data
VEHICLE ELECTRICAL COMPONENTS Electrical Component Locations, Console Box, Key Switch, Lamp Specification Chart, Electrical System of FC
POWER TRAIN General Structure, Removal and Installation
TRANSFER AND DIFFERENTIAL Structure and Functions, Procedures and Suggestions for Disassembly and Reassembly, Service Data
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 Suggestions for Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
STEERING SYSTEM Specifications, Structure and Functions, Procedures and Suggestions for Removal and Installation, Steering Gear, Hydraulic Circuit, Troubleshooting, Service Data
HYDRAULIC SYSTEM Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve
MAST AND FORK 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 Rearview Mirror Kit, Backup Buzzer Kit, Working Lamp Kit, Tire Kit, Foot Direction Control Kit
1 2 3 4 5 6 7 8 9 10 11 12
9
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
10
GENERAL INFORMATION
Vehicle Exterior
Joystick box (FC models) Control lever (MC
models)
103142
Models This manual applies to EP20K, EP25K,
EP30K and EP35K.
Class Truck Model Serial Number
2 ton EP20K ETB8B-00011-up
2.5 ton EP25K ETB8B-50001-up
3 ton EP30K ETB9B-00011-up
3.5 ton EP35K ETB9B-50001-up
11
GENERAL INFORMATION Serial Number Locations
Mast number
Chassis number
Nameplate
208204
12
GENERAL INFORMATION
Chassis and Mast Model Identification
Chassis EP 20 K
Generation designator Maximum capacity 20
2000 kg (4400 lb) 25 2500 kg (5500 lb) 30 3000
kg (6600 lb) 35 3500 kg (7700 lb) Battery type
Mast 4
R
35
C
30
Maximum lifting height 30 stands for 3000 mm
(118 in.) Order of the minor change (A for
the original, B for the first change, C for
the second change, and so on) Applicable truck
model designation 35 3.5 ton class Kind of
mast R simplex mast S duplex mast Y triplex
mast Major change (2 for the original, 3 for
the first change, and so on up to 9)
13
GENERAL INFORMATION Dimensions
B E
F
C
D A
211638
14
GENERAL INFORMATION
Technical Data
Truck model Truck model EP20K EP25K
Class Class 2.0 ton 2.5 ton
Load capacity/load center N (kgf)/mm lbf/in. Load capacity/load center N (kgf)/mm lbf/in. 19600 (2000)/500 4400/20 24500 (2500)/500 5500/20
Truck size Length to fork face A mm (in.) 2249 (88.5) 2274 (89.5)
Truck size Width B mm (in.) 1190 (46.9) 1190 (46.9)
Truck size Height of overhead guard C 2200 (86.6) mm (in.) 2200 (86.6)
Wheelbase D mm (in.) Wheelbase D mm (in.) 1520 (59.8) 1520 (59.8)
Truck weight (w/o battery) kg (lb) Truck weight (w/o battery) kg (lb) 2790 (6151) 2983 (6576)
Tread Front/rear E/F mm (in.) Tread Front/rear E/F mm (in.) 990/898 (39.0/35.4) 990/898 (39.0/35.4)
Tires size Front 23 ? 9 ? 10 23 ? 9 ? 10
Tires size Rear 18 ? 7 ? 8 18 ? 7 ? 8
Turning radius mm (in.) Turning radius mm (in.) 1950 (76.8) 1970 (77.6)
Travel speeds Unloaded/loaded km/h (mph) Travel speeds Unloaded/loaded km/h (mph) 16.4/16.0 (10.2/9.9) 16.4/16.0 (10.2/9.9)
Lift speeds Unloaded/loaded m (in.)/sec Lift speeds Unloaded/loaded m (in.)/sec 0.60/0.40 (23.6/15.7) 0.60/0.38 (23.6/14.96)
Lowering speeds Unloaded/loaded m (in.)/sec Lowering speeds Unloaded/loaded m (in.)/sec 0.50/0.50 (19.7/19.7) 0.50/0.50 (19.7/19.7)
Battery voltage V Battery voltage V 80 80
Battery rated capacity (5 hrs.) MAX Ah Battery rated capacity (5 hrs.) MAX Ah 600 600
Battery compartment size mm (in.) Battery compartment size mm (in.) 1025 ? 708 ? 769 (40.4 ? 27.9 ? 30.3) 1025 ? 708 ? 769 (40.4 ? 27.9 ? 30.3)
Battery weight kg (lb) Battery weight kg (lb) 1385 (3053) 1385 (3053)
Tilt angle (forwards backwards) Tilt angle (forwards backwards) 6 ? 8 6 ? 8
Drive motor capacity (60 min. short duty) kW Drive motor capacity (60 min. short duty) kW 12.0 12.0
Pump motor output _at_ 15 duty factor kW Pump motor output _at_ 15 duty factor kW 15 15
Steering pump motor output W Steering pump motor output W 550 550
Drive motor control method Drive motor control method IGBT chopper IGBT chopper
Pump motor control method Pump motor control method IGBT chopper IGBT chopper
15
GENERAL INFORMATION
Truck model Truck model EP30K EP35K
Class Class 3.0 ton 3.5 ton
Load capacity/load center N (kgf)/mm lbf/in. Load capacity/load center N (kgf)/mm lbf/in. 29400 (3000)/500 6600/20 34300 (3500)/500 7700/20
Truck size Length to fork face A mm (in.) 2522 (99.3) 2577 (101.5)
Truck size Width B mm (in.) 1230 (48.4) 1230 (48.4)
Truck size Height of overhead guard C mm (in.) 2250 (88.6) 2259 (88.9)
Wheelbase D mm (in.) Wheelbase D mm (in.) 1690 (66.5) 1690 (66.5)
Truck weight (w/o battery) kg (lb)3231 (7123) Truck weight (w/o battery) kg (lb)3231 (7123) 3665 (8080)
Tread Front/rear E/F mm (in.) Tread Front/rear E/F mm (in.) 990/898 (39.0/35.4) 990/898 (39.0/35.4)
Tires size Front 28 ? 9 ? 15 250 ? 15
Tires size Rear 18 ? 7 ? 8 18 ? 7 ? 8
Turning radius mm (in.) Turning radius mm (in.) 2180 (85.8) 2230 (87.8)
Travel speeds Unloaded/loaded km/h (mph) Travel speeds Unloaded/loaded km/h (mph) 16.4/16.0 (10.2/9.9) 16.4/16.0 (10.2/9.9)
Lift speeds Unloaded/loaded m (in.)/sec Lift speeds Unloaded/loaded m (in.)/sec 0.54/0.34 (21.3/13.4) 0.45/0.28 (17.7/11.0)
Lowering speeds Unloaded/loaded m (in.)/sec Lowering speeds Unloaded/loaded m (in.)/sec 0.50/0.50 (19.7/19.7) 0.50/0.50 (19.7/19.7)
Battery voltage V Battery voltage V 80 80
Battery rated capacity (5 hrs.) MAX Ah Battery rated capacity (5 hrs.) MAX Ah 750 750
Battery compartment size mm (in.) Battery compartment size mm (in.) 1025 ? 852 ? 769 (40.4 ? 33.5 ? 30.3) 1025 ? 852 ? 769 (40.4 ? 33.5 ? 30.3)
Battery weight kg (lb) Battery weight kg (lb) 1872 (4127) 1872 (4127)
Tilt angle (forwards backwards) Tilt angle (forwards backwards) 6 ? 8 6 ? 8
Drive motor capacity (60 min. short duty) kW Drive motor capacity (60 min. short duty) kW 12 12
Pump motor output _at_ 15 duty factor kW Pump motor output _at_ 15 duty factor kW 15 15
Drive motor control method Drive motor control method IGBT chopper IGBT chopper
Pump motor control method Pump motor control method IGBT chopper IGBT chopper
16
VEHICLE ELECTRICAL COMPONENTS
Electrical Component Locations ........................................................ 2 1
Console Box ............................................................................................ 2 4
Functions of Central Vehicle Monitor System (CVMS) ............................... 2 4
Electrical Components in Console Box ..................................................... 2 7
Disassembly and Reassembly .................................................................. 2 8
Direction Lever ........................................................................................ 2 9
Accelerator Control ............................................................................... 2 10
Key Switch ............................................................................................... 2 11
Lighting Switch ....................................................................................... 2 11
Fuses ......................................................................................................... 2 12
Lamp Specification Chart .................................................................... 2 12
Troubleshooting of Lighting and Horn Systems ............................ 2 13
Electrical System of FC (Finger-tip Control System) .................... 2 14
Nomenclature ........................................................................................... 2 14
Precautions to be taken when handling FC system .................................. 2 15
Description ................................................................................................ 2 15
Operating Principles ................................................................................. 2 16
How to Set Controller (Setup Option Setting) ............................................ 2 18
Troubleshooting ........................................................................................ 2 19
2
17
VEHICLE ELECTRICAL COMPONENTS
Electrical Component Locations
5
5
2
1 3 4
View "A" 8
7
A
6
9
211639

1. Central vehicle monitoring system (CVMS)
2. Direction lever
3. Lighting switch
4. Key switch
5. Head lamp

1. Horn
2. Brake fluid level sensor
3. Accelerator sensor
4. Speed sensor

2-1
18
VEHICLE ELECTRICAL COMPONENTS
10 12 11 13 211640
10 Joystick box (FC only) 11 Traction controller

1. Hydraulic controller
2. Contactor

2-2
19
VEHICLE ELECTRICAL COMPONENTS
18 17 14 15 16 211641

1. Fuse holder
2. FC hydraulic control valve 16 Drive motor

• Pump motor
• Steering motor
• (2 ton class and 2.5 ton class only)

2-3
20
VEHICLE ELECTRICAL COMPONENTS Console Box
103148

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

For setting the clock and selection of KPH or
MPH, refer to Selection of KPH or MPH and
Setting the clock.
Functions of Central Vehicle Monitor System (CVMS)
Operations 208077 Operations 208077 Operations 208077 Operations 208077 Operations 208077
No. Monitor name When OFF When ON or flashing Remarks
1 Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached.
2 Worn motor brush indicator Drive motor and pump motor brushes in operable condition Worn brushes After brushes are replaced, indicator turns OFF.
3 Controller/motor overheat indicator Controller, drive motors and pump motor in normal temperature Overheat Overheat causes significant output loss. When component temperature lowers to normal level, output power returns.
4 Remaining battery charge warning indicator Normal battery condition Flashing indicates battery needs to be recharged soon. ON indicates battery needs to be recharged and lifting function inoperable.
5 Brake fluid level indicator Normal fluid level Low fluid level
2-4
21
VEHICLE ELECTRICAL COMPONENTS
No. Monitor name When OFF When ON or flashing Remarks
6 Parking brake indicator Parking brake disengaged Parking brake engaged
7 Fault detection indicator Normal Vehicle malfunction Error codes appear on the error code display.
8 Vehicle speed and error code display Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction. Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction. The vehicle speed display can be switched between KPH and MPH. Follow the steps in Selection of KPH or MPH below.
9 Battery discharge indicator (BDI) The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning indicator 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 4 will be continuously lit and the vehicle enters power reduction mode. The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning indicator 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 4 will be continuously lit and the vehicle enters power reduction mode. The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning indicator 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 4 will be continuously lit and the vehicle enters power reduction mode.
10 Hourmeter, time display It normally displays the time. When the key switch is set to the I (ON) position, the drive motor, pump motor, and vehicle service hours are indicated sequentially. It normally displays the time. When the key switch is set to the I (ON) position, the drive motor, pump motor, and vehicle service hours are indicated sequentially. The time of clock can be adjusted. Follow the steps in Setting the clock below.

• Selection of KPH or MPH
• Apply the parking brake.
• Place the direction lever in NEUTRAL.
• Turn the key switch to the I (ON) position.
• Push and hold button 1 for one to two seconds.
• NOTICE Display will show KPH and a 24-hour clock
  until it is changed. When MPH is selected, the
  clock will change to a 12-hour clock.

Button 2 Button 1 211642
Setting the clock

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 until the minutes display
   flashes.
5. Release button 1.
6. Adjust the minutes with button 2.
7. Push button 1 and release when the hours display
   flashes.
8. Adjust the hour with button 2.
9. Push button 1 to lock in the time.

2-5
22
VEHICLE ELECTRICAL COMPONENTS Error code display
Indication Indication Indication Condition
E E E If the key switch is turned I (ON) while the direction lever is either in the forward or reverse position and/or if the accelerator pedal is depressed.
(E) (E) (E) Faulty setting of seat switch
E 0 ON Drive motor overheated
E 2 ON Pump motor overheated
E 3 ON Traction module overheated
E 4 ON Worn drive motor brush
E 6 ON Worn pump motor brush
E 7 ON Hydraulic module overheated
H 1 ON Faulty setting of lift lever
H 2 ON Faulty setting of tilt lever
H 3 ON Faulty setting of attachment lever 1
H 4 ON Faulty setting of attachment lever 2
L O ON Battery consumption too much
(E) indicates flashing E.
2-6
23
VEHICLE ELECTRICAL COMPONENTS
Electrical Components in Console Box
Monitor harness Direction lever
harness 2 1 211643
1 Key switch 2 Lighting switch
2-7
24
VEHICLE ELECTRICAL COMPONENTS Disassembly and
Reassembly Disassembly
2 1 5 3 4 211644
Sequence

1. Console box (front panel)
2. Central vehicle monitor panel
3. Direction lever

1. Steering tilt lock lever
2. Console box (rear panel)

• Disassembly procedure
• Remove the front panel and monitor panel from the
  console box.
• Disconnect the harness connectors from the horn
  and direction lever.
• Remove the screw from the steering tilt lock
  lever, and remove the lever from the rear panel
  of the console box.
• Remove the rear panel.

Reassembly Follow the disassembly procedure in
reverse.
Steering tilt lock lever
211645
2-8
25
VEHICLE ELECTRICAL COMPONENTS
Direction Lever Structure
4 1 2 3 211646

1. Lever
2. Harness

1. Connector
2. Screw, Spring washer

2-9
26
VEHICLE ELECTRICAL COMPONENTS Accelerator Control
Accelerator pedal
Accelerator pedal rod Stopper bolt Lock nut
Initial position
1.5 to 2.5?
For reference H 38 to 40 mm (1.50 to 1.57 in.)
H
Switching position of idle switch Lever
E2
IDL
Adjusting screw
Position meter
209531

• Adjustment Procedures
• Disconnect the battery plug.
• Install the position meter by loosely mounting
  the adjusting screws.
• Connect the accelerator pedal rod to the lever.
• Check that there is no continuity between the E2
  and
• IDL terminals.
• Move the lever 1.5 to 2.5 from the initial
  position.
• Check that there is continuity between the E2 and
  IDL terminals (the idle switch in the position
  meter is ON), then finally tighten the adjusting
  screws of the position meter.
• Make sure the stopper bolt height H is
  approximately 38 to 40 mm (1.50 to 1.57 in.).
  Depress the accelerator pedal until it comes in
  contact with the stopper bolt. Adjust the height
  H of the stopper bolt until letter 15 flashes
  on the I/O diagnosis display.

2-10
27
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
Terminal 2, 5 2, 5 3 3 3 6 6
Connection destination Battery Battery Head lamps Head lamps Head lamps Working lamps Working lamps
1st position (Circuit 1)
1st position (Circuit 1)
2nd position (Circuit 1 2)
2nd position (Circuit 1 2)
OFF
Push
1 3 Cir. 1 4 Cir. 2 6
2
BAT
1st (cir. 1) 2nd (cir. 1 2)
5
209515
2-11
28
VEHICLE ELECTRICAL COMPONENTS Fuses
Capacity (A) Location Main connecting device
325 Contactor assembly Traction motor
325 Contactor assembly Pump motor
50 Contactor assembly Steering pump motor
15 Fuse holder Horn switch, Lighting switch
10 Fuse holder Key switch, Contactor
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 80 V External diagram Remarks
Head lamps 2 Clear 55 W
Working lamp 1 Clear 55 W
205833
2-12
29
VEHICLE ELECTRICAL COMPONENTS Troubleshooting of
Lighting and Horn Systems
Complaint Complaint Possible cause Remedy
Lamps- general Will not light Dead or weak battery Fuses blown out Open or short in circuit Bulbs burnt out Recharge or replace. Check and replace. Repair or replace. Replace.
Lamps- general Will light dimly Dead or weak battery Burned contact points in switches Loose terminals Dirty lenses Water drops inside lenses Bulbs service life expired Check and recharge. Repair or replace. Retighten. Clean. Dry and replace packings. Replace.
Head lamps Will not light Lighting switch defective Bulbs burnt out Replace. Replace.
Other lamps Backup lamps will not light Backup lamp switch defective Bulbs burnt out Correct if improperly installed replace if internally defective. Replace.
Horn Will not sound Fuse blown Open or short in circuit Horn switch defective Horn defective Horn button defective Check and replace. Repair or replace. Replace. Replace. Repair or replace.
Horn Will give an offensive sound Horn switch defective Horn defective Replace. Replace.
2-13
30
VEHICLE ELECTRICAL COMPONENTS Electrical System
of FC (Finger-tip Control System) Nomenclature
5 6 103144

1. FC hydraulic control valve
2. Flow regulator valve
3. Seat switch

1. Controller
2. Emergency switch
3. FC control levers (finger-tip control system)

2-14
31
VEHICLE ELECTRICAL COMPONENTS

• Precautions to be taken when handling FC system
• The FC system is controlled by a microcomputer in
  the controller. As the microcomputer is a
  delicate electronic component, take the
  following precautions when handling and
  inspecting the FC system.
• When removing the controller cover, take proper
  precautions to keep out all moisture such as rain
  and splashing water.
• After using the controller setting function,
  check to make sure control system is within
  truck specifications.

208084A

• NOTE
• Improper setting of the system will result in the
  inability to lower the forks in an incremental
  manner.
• Before performing repairs which require welding,
  be sure to disconnect the battery plug and the
  controller from the system at its connectors.
• When handling the controller by hand, never touch
  its electrical terminals, or the static charge
  from your body will rupture some of the
  electronic elements in the internal controller
  circuits.

Description The FC system, unlike the
conventional mechanical control, is
electronically actuated to reduce the effort
required of the operator in moving the control
levers for lift, tilt and attachment functions.
101466A

• This system provides the following safety
  functions

1. The lift, tilt and attachment functions are not
   performed even if the control levers are moved
   when the emergency switch is in ON (pushed)
   position.
2. The lift, tilt and attachment functions are not
   performed even if the control levers are moved
   when the seat switch is not ON (the operator is
   not seated).

(c) The system indicator light in the LED
section alerts the operator to problems
occurring in the electrical system and, at the
same time, stops function. (If any problem
occurs in the lift system, for example, the
system becomes inoperative.)
2-15
32

• VEHICLE ELECTRICAL COMPONENTS
• Operating Principles
• The system is activated by turning OFF (pulled,
  not pushed) the emergency switch when the key
  switch and the seat switch are ON (when the
  operator is seated).
• As the control levers (joysticks) are moved to
  operate the equipment (mast and forks), the
  amount of lever movement will be translated into
  an electrical signal this signal goes into the
  controller where it is converted to an output
  signal. At this point the controller issues an
  ON signal to increase the pump motor speed,
  thereby hydraulic pressure will be introduced
  into the control valve. The system is now ready
  to actuate the equipment. The output signal is
  applied to the proportioning solenoid, selected
  by the direction of the joystick movement.
  Inside the control valve of the solenoid, the
  spool valve is forced to slide, altering the
  internal oil passage that directs the oil to the
  corresponding cylinders. The spool keeps on
  sliding until it comes to the position where the
  pressure of its pilot chamber becomes equal to
  the force of its centering spring. In the
  meantime, the cylinder extends or retracts
  against its load. As the joystick is moved back
  to its neutral position, the signal to the
  proportioning solenoid decreases in order to
  lower the pilot chamber pressure and allow the
  centering spring to push the spool to its
  neutral position, whereby the line to the
  cylinder shuts off. The pressure in the line is
  now trapped, holding the cylinder in place. At
  the same time, the motor speeds lowers and the
  part of the system actuating the equipment goes
  into a no-load state.
• Supply power to the controller is initiated from
  the Power Relay through a 10-Amp fuse. Pressing
  the emergency switch shuts down the output to
  solenoids.

2-16
33
VEHICLE ELECTRICAL COMPONENTS

• How to Set Controller (Setup Option Setting) Set
  the controller on any of the following occasions
  Occasions
• After the mast has been changed, or an optional
  equipment added.
• After the controller assembly has been replaced.
  How to set
• See the Setup Option Setting section in the
  Controller Service Manual GROUP 1 CONTROLLER.
• General Precautions
• Use low air pressure to clean electrical
  equipment (controller, motor, battery, cable,
  etc.). If using steam, do not blow it directly
  on the equipment.
• When the counterweight back door is removed,
  make proper measures to keep out rain.
• After using DRS (Diagnosis Run Set) switch,
  recheck the switch setting.
• The controller containing the microcomputer
  should never come into contact with water. When
  the cover is removed, take proper precautions to
  keep out all moisture such as rain and splashing
  water.
• In case of some welding work on the frame or
  body, disconnect the battery from the power
  supply line. And disconnect the controller from
  the system by undoing all connectors. If the
  welding job has to be performed near the
  controller position, remove the controller from
  the truck.
• Your body could pick up a large static charge.
  Keep this in mind when you handle the controller
  by hand never touch its electrical terminals, or
  the static charge from your body will rupture
  some of the electronic elements in the
  controller's internal circuit.

Failures resulting from incorrect setting (1)
Incorrect setting for truck size (2.5 ton, 3 ton)
or incorrect model setting
(a) An incorrect setting will result in abnormal
lowering speed and inching feel. If a setting
for a 2.5 ton model is made on a 3 ton model,
for example, the lowering speed will be
abnormally low. If a setting for a 3 ton model
is made on a 2.5 ton model, the lowering speed
will be abnormally high.
(2) Incorrect setting for number of control
valve spools

• If the setting made for the number of spools is
  greater than the actual (FAULT lamp lights and
  error code is displayed), the equipment does not
  operate.
• (Regarded as open-circuit in control valve
  solenoid or joystick.)
• If the setting made for the number of spools is
  less than the actual, only the devices equal to
  the number of set spools will be actuated.

(3) Incorrect setting for mast

1. A setting for a dual-stage full free mast or
   triple-stage full free mast on a truck with dual-
   stage panoramic mast will not affect the
   lowering speed.
2. If the setting is made for dual-stage panoramic
   mast on a truck with dual-stage full free or
   triple-stage full free mast, the lowering speed
   of the 1st lift cylinder will be abnormally low.
   This setting will not affect the lowering speed
   of the 2nd lift cylinders.

2-18
34
VEHICLE ELECTRICAL COMPONENTS
Troubleshooting

• 1. Preparatory steps
• The system receives supply power when the battery
  connector is connected, the key switch is turned
  to the ON position, and the emergency switch is
  turned OFF (pulled, not pushed). The finger-tip
  control becomes operable after the seat switch
  closes (when operator is seated).
• Before deciding to replace a blown fuse, make
  sure the harness connectors in the power line
  are all in good condition.
• The use of the test-use connector (special tool)
  is recommended for checking the
  connector-to-connector lines for continuity and
  for reading the voltage across two terminals and
  the ohmic resistance of a line.
• When coupling or uncoupling a connector, make
  sure that the key switch is turned OFF and the
  battery connector is disconnected. Never try to
  forcibly insert or pull off the connector, or
  its pins will be damaged. When coupling a
  connector, be sure that the inserted half snaps
  into its self-locking position.
• Before starting troubleshooting work, check to be
  sure that the conditions indicated in the
  following table are met on the machine side.

205038
2-19
35
VEHICLE ELECTRICAL COMPONENTS Inspection of
machine side components Shown in the following
table are the machine side basic components that
must be inspected first when a problem occurs in
the FC system and the conditions and points for
performing their checking.
Conditions in the machine Check item What to check Remedy
Key switch OFF Emergency switch ON Hydraulic line Hoses, pipes and connectors for damage and sign of leak. Repair leaking or damaged parts.
Key switch OFF Emergency switch ON Hydraulic devices Check control valve and hydraulic cylinders for damage and oil leaks. Repair damaged or leaking parts, if any.
Key switch OFF Emergency switch ON Electrical connectors and wires Check connectors for tightness, burns and breakage check wires for insulator stripping and signs of rubbing. Repair.
Key switch ON Emergency switch OFF System check lamp Check to be sure the lamp goes ON and OFF properly if not, check the bulb. Replace lamp bulb if blown.
Key switch ON Emergency switch OFF Hydraulic devices With your hands off the control levers, see if the solenoid valves and hydraulic pump are making any abnormal sounds. Refer to the sections dealing with control valve and hydraulic pump, respectively.
Key switch ON Emergency switch OFF Hydraulic devices Operate the control levers to see if any abnormal sounds, indicative of flow throttling, comes from control solenoid valve or from any other solenoid valve. (Proper function of solenoid valves is essential to troubleshooting.)
Key switch ON Emergency switch OFF Work attachments Check each work attachment for the following Does it work properly? Does it inch properly? Does mast go down with proper speed? See 4. Troubleshooting guide for solenoid control valves on page 2-24.
2-20
36
VEHICLE ELECTRICAL COMPONENTS
2. How to move the mast in an emergency If the
truck fails during operation, and you have to
drive it (if the engine is OK) or tow it to some
distant place like the repair shop, follow the
instruction below.
208076A
!
CAUTION
Before doing these steps, be sure that there is
no one standing under the mast.

• Mast lowering
• Loosen lock nut 1 on the lift section of the
  control valve.
• Using an Allen wrench, slowly loosen screw 2.
  This causes the mast to go down by gravity
  tighten screw 2 and the mast will stop.
• Tighten lock nut 1.

!
CAUTION
Leaving nut 1 loose is dangerous the mast might
suddenly start descending by gravity.
2-21
37
VEHICLE ELECTRICAL COMPONENTS (2) How to cope
with a failed (open-circuit) seat switch. Your
troubleshooting investigation might reveal that
the seat switch is an open-circuit or otherwise
faulted and will not function. In such a case,
you can create a temporary circuit through the
seat switch wiring. The method is explained in
this illustration. The seat switch is a safety
part. Be sure to replace it with a new one as
soon as possible.
205012B
Two connectors are in the seat switch line at
the indicated location Open these connectors,
and couple up the male and female connector
halves to form a circuit bypassing the seat
switch.
!
CAUTION
Illustrated above is a band-aid method
permissible only in an emergency situation. Be
sure to restore the seat switch line to the
normal hookup after replacing the failed switch.
2-22
38
VEHICLE ELECTRICAL COMPONENTS
3. How to clean harness connectors and system
components (1) Open-circuit troubles are often
due to dirty harness connectors and components.
Dust, together with greasy matter forms grime,
which in time penetrates electrical connections
resulting in loose metal-to-metal contact or
electrical separation of contact surfaces. For
this reason, it is essential that the connectors
and components be cleaned at each periodic
inspection and at the time of servicing the
truck. Instead of a commonly used solvent, use
the electronic parts cleaner (in the manner
illustrated on the right).
205046A
Three Bond 29D or Pow-R-Wash CZ
Electronic parts cleaner
NOTE The cleaner liquid is volatile. All you
have to do is just give a strong spray to wash
off grime. No need to wipe off the sprayed
liquid.
(2) After checking the connector for continuity,
wash it as shown. Then, uncouple the connector
and spray the contact surface activator onto
contact surfaces. Now, install and remove the
connector several times to wet the surfaces
thoroughly with the activator liquid. After
coupling up the connector, check to be sure that
it is correctly locked.
205047
Contact surface activator
Three Bond 2501S (aerosol) or Nyogel 760G
NOTE
Do not spray too much bear in mind that this
spray liquid reacts with some resins (plastic
materials).
Products contained in Terminal Maintenance
Kit (SE000003).
2-23
39
VEHICLE ELECTRICAL COMPONENTS 4.
Troubleshooting guide for solenoid control valves
Trouble symptom Possible cause Remedy
The pump discharge pressure will not build up Sticky plunger in proportioning solenoid of reducing valve, or sticky shuttle in reducing valve Open in lead wire or in solenoid coil Input current to solenoid too small Unload valve stuck open Spool stuck in flow-divider valve Disassemble and clean by washing. If the plunger is sticky, replace the solenoid. Repair or replace. Check to make sure that solenoid is drawing specified maximum input current. Check unload solenoid for action. Check unload valve for action. Disassemble and clean by washing.
Sticky spool Sticky plunger in proportioning solenoid of reducing valve, or sticky shuttle in reducing valve. Disassemble and clean by washing. If plunger is sticky, replace solenoid.
2-24
40
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41
POWER TRAIN
General Structure ................................................................................... 3 1
Common Removal and Installation Procedures ............................ 3 2
Front Wheel Removal and Installation ....................................................... 3 2
Battery Removal and Installation ............................................................... 3 4
Power Train Assembly Removal ......................................................... 3 5
Power Train Assembly Installation .................................................... 3 8
3
42
POWER TRAIN
General Structure
Power flow 208364
Location of Power Train Component
1 Drive motor 6 Right wheel brake
2 Transfer gear 7 Left axle shaft
3 Differential gear assembly 8 Left wheel hub
Right axle shaft Right wheel hub 9 Left wheel brake
The power train mainly consists of the following
three units.
differential gear system is a device that makes
it possible it detects the difference in
turning resistance between inside and outside
wheels being turned and automatically
differentiates the number of revolutions between
them accordingly. The power transmitted to the
output gear is then sent to the differential
gear assembly 3. When the vehicle is turning,
the right axle shaft 4 and left axle shaft 7
rotate at different speeds. The power distributed
to the right axle shaft 4 is transmitted to the
right front wheel by way of the right wheel hub
5. The power distributed to the left axle shaft 7
is transmitted to the left front wheel via the
left wheel hub 8. When the vehicle is running
in a straight direction, its left and right
wheels are equal in turning resistance and
therefore no speed difference occurs between
them. Each of the left and right wheel hubs 5, 8
is provided with a wheel brake drum. In the
brake drum is housed the internal expansion
duo-servo type wheel brake 6, 9. For further
information about the structures of individual
components and system operation, refer to the
relevant sections.

1. Drive motor
2. Transfer and differential assembly
3. Front axle assembly

These units are connected to each other
internally through splines and gears to transmit
driving power and externally through cases
joined together with bolts to form a power train
assembly. The power train assembly is secured to
the vehicle frame with bolts at the front axle
supports. The output of the drive motor 1 is
first transmitted to the input gear shaft of the
transfer gear 2. The transfer gear 2 is a
3-stage reduction gear. At each reduction stage,
the motor output is decreased in the gear speed
and increased in the turning torque in inverse
proportion before transmitted to the output gear
(bolted to the differential gear) of the final
reduction stage. The gears used are noise-free
helical gears for quiet vehicle operation. To
allow the vehicle to make a curve smoothly,
outside wheels must turn faster than inside
wheels. The
43
POWER TRAIN
Common Removal and Installation Procedures Front
Wheel Removal and Installation Removal
101206A

1. Park the truck on level floor with the parking
   brake applied, the direction lever in neutral,
   the forks lowered, and the key switch in the OFF
   position.
2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.

To Raise Front Wheel
100828A
NOTE
Loosen, but do not remove, the wheel nuts.
5. Raise the front end of the truck. Use one of
the appropriate methods illustrated at right.
Position the jack under the frame and raise the
front wheel.
! WARNING
To prevent possible injury, do not replace the
front wheel when the truck is loaded. Dismount
the truck before raising the front wheel. To
prevent possible personal injury, raise the truck
only until the front wheel just clears the
ground. Do not put any portion of your body under
the truck. Securely support the truck on blocks
after raising it.
Alternative Method
100913
6. Remove the wheel nuts (loosened in Step 4.).
NOTE Be careful not to damage the bolt threads
when removing the wheel.
Tilt the mast all the way back, place blocks
under the mast, and tilt the mast forward.
7. Remove the wheel.
100680
Inspection of Tires for Wear Replace the tire if
the depth of its tread groove is less than 5 mm
(0.2 in.).
44
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