CATERPILLAR CAT EP20K PAC, EP25K PAC, EP30K PAC, EP35K PAC FORKLIFT LIFT TRUCKS Service Repair

1
Service Manual
Chassis, Mast Options
EP20K PAC EP25K PAC EP30K PAC EP35K PAC
ETB8C-00011-up ETB8C-50001-up ETB9C-00011-up
ETB9C-50001-up
For use with EP20K PAC - EP35K PAC Controller
Service Manual.
99759-6A100
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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
trucks 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. 99759-6A100
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. Following 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.
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.

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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
• Cover, Bolt, Washer (part name)
• 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
8
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)
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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
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2
3
4
5
6
7
8
9
10
11
12
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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
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GENERAL INFORMATION
Vehicle Exterior
Joystick box (FC models) Control lever (MC
models)
103142
Models This manual applies to EP20K PAC, EP25K
PAC, EP30K PAC and EP35K PAC.
Class Truck Model Serial Number
2 ton EP20K PAC ETB8C-00011-up
2.5 ton EP25K PAC ETB8C-50001-up
3 ton EP30K PAC ETB9C-00011-up
3.5 ton EP35K PAC ETB9C-50001-up
1-1
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GENERAL INFORMATION Serial Number Locations
Mast number
Chassis number
Nameplate
208204
1-2
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GENERAL INFORMATION
Chassis and Mast Model Identification
Chassis EP 20 K PAC AC motor 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)
1-3
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GENERAL INFORMATION Dimensions
B E
F
C
D A
211638
1-4
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GENERAL INFORMATION
Technical Data
Truck model Truck model EP20K PAC EP25K PAC
Class Class 2.0 ton 2.5 ton
Load capacity/load center N (kgf)/mm 1bf/in. Load capacity/load center N (kgf)/mm 1bf/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 Cmm (in.)2200 (86.6) 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) 2775 (6118) 2995 (6603)
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) 20.0/20.0 (12.4/12.4) 20.0/20.0 (12.4/12.4)
Lift speeds Unloaded/loaded m (in.)/sec Lift speeds Unloaded/loaded m (in.)/sec 0.65/0.55 (25.6/21.7) 0.65/0.50 (25.6/19.7)
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 14.5 14.5
Pump motor output _at_ 15 duty factor kW Pump motor output _at_ 15 duty factor kW 20.0 20.0
Steering pump motor output (60 min. short duty) kW Steering pump motor output (60 min. short duty) kW 1.2 1.2
Drive motor control method Drive motor control method MOS-FET MOS-FET
Pump motor control method Pump motor control method MOS-FET MOS-FET
1-5
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GENERAL INFORMATION
Truck model Truck model EP30K PAC EP35K PAC
Class Class 3.0 ton 3.5 ton
Load capacity/load center N (kgf)/mm 1bf/in. Load capacity/load center N (kgf)/mm 1bf/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 Cmm (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) 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) 20.0/20.0 (12.4/12.4) 18.0/16.5 (11.2/10.3)
Lift speeds Unloaded/loaded m (in.)/sec Lift speeds Unloaded/loaded m (in.)/sec 0.60/0.45 (23.6/17.7) 0.55/0.40 (21.7/15.7)
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 14.5 14.5
Pump motor output _at_ 15 duty factor kW Pump motor output _at_ 15 duty factor kW 20.0 20.0
Steering pump motor output (60 min. short duty) kW Steering pump motor output (60 min. short duty) kW 1.2 1.2
Drive motor control method Drive motor control method MOS-FET MOS-FET
Pump motor control method Pump motor control method MOS-FET MOS-FET
1-6
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VEHICLE ELECTRICAL COMPONENTS
Electrical Component Locations ........................................................ 2 1
Console Box ............................................................................................ 2 5
Functions of Central Vehicle Monitor System (CVMS) ............................... 2 5
Electrical Components in Console Box ..................................................... 2 8
Disassembly and Reassembly .................................................................. 2 9
Direction Lever ........................................................................................ 2 10
Accelerator Control ............................................................................... 2 11
Key Switch ............................................................................................... 2 12
Lighting Switch ....................................................................................... 2 12
Fuses ......................................................................................................... 2 13
Lamp Specification Chart .................................................................... 2 13
Auto-light Systems ................................................................................ 2 14
Troubleshooting of Lighting and Horn Systems ............................ 2 15
Electrical System of FC (Finger-tip Control System) .................... 2 16
Nomenclature ........................................................................................... 2 16
Precautions to be taken when handling FC system .................................. 2 17
Description ................................................................................................ 2 17
Operating Principles ................................................................................. 2 18
How to Set Controller (Setup Option Setting) ............................................ 2 20
Troubleshooting ........................................................................................ 2 21
2
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VEHICLE ELECTRICAL COMPONENTS
Electrical Component Locations
6
Detail "A"
7
1
A
2
3
4 5
9
8
Detail "B"
13
12
B
10
11 11 11 211648
1 Central vehicle monitoring system (CVMS) 8 Contactor
2 Direction lever 9 Fuse holder
3 Lighting switch 10 DC/DC converter
4 Key switch 11 Horn
5 Auto-light switch 12 Foot brake switch
6 Head lamp 13 FC hydraulic control valve
7 Auto-light sensor
2-1
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VEHICLE ELECTRICAL COMPONENTS
14 15 211649
14 Parking brake switch 15 Brake fluid level
sensor
2-2
23
VEHICLE ELECTRICAL COMPONENTS
16 19 18 17 211650

1. Joystick box (FC only)
2. Controller cooling fan

1. Controller assembly
2. Contactor assembly

2-3
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VEHICLE ELECTRICAL COMPONENTS
24
D
Detail "C"
Detail "D"
22
21
C
23
20
211651

1. Drive motor
2. Drive motor thermal and speed sensor
3. Pump motor

1. Pump motor thermal and speed sensor
2. Steering pump motor

2-4
25
VEHICLE ELECTRICAL COMPONENTS
Console Box
1
6

1. Central vehicle monitoring system (CVMS)
2. Mode selector button
3. Steering tilt lever
4. Key switch
5. Lighting switch
6. Mode check button
7. Auto light switch

2
5
4
3
7 206900
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)
209510 Operations 209510 Operations 209510 Operations 209510 Operations 209510 Operations
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 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.
3 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.
4 Brake fluid level indicator Normal fluid level Low fluid level
2-5
26
VEHICLE ELECTRICAL COMPONENTS
No. Monitor name When OFF When ON or flashing Remarks
5 Parking brake indicator Parking brake disengaged Parking brake engaged
6 Fault detection indicator Normal Vehicle malfunction Error codes appear on the error code display.
7 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.
8 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 3 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 3 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 3 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 3 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 3 in the LED section will flash. When the indicator completely goes off, the remaining battery charge indicator 3 will be continuously lit and the vehicle enters power reduction mode.
9 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 209600A
Setting the clock

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

27
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 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.
2-7
28
VEHICLE ELECTRICAL COMPONENTS Electrical
Components in Console Box
Monitor harness Direction lever
harness 2 3 1 211652

1. Key switch 3 Auto light switch
2. Lighting switch

2-8
29
VEHICLE ELECTRICAL COMPONENTS
Disassembly and Reassembly Disassembly
2 1 5 3 4 211653
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.

Steering tilt lock
lever 211645
Reassembly Follow the disassembly procedure in
reverse. 2-9
30
VEHICLE ELECTRICAL COMPONENTS Direction
Lever Structure
4 1 2 3 211646

1. Lever
2. Harness

1. Connector
2. Screw, Spring washer

2-10
31
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.

2-11
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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
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VEHICLE ELECTRICAL COMPONENTS
Fuses
Capacity (A) Location Main connecting device
500 Contactor assembly Line contactor, Logic controller
10 Fuse holder Controller fans, DC/DC converter
50 Steering motor Steering pump motor
15 Fuse holder Horn switch, Lighting switch, Contactor
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
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VEHICLE ELECTRICAL COMPONENTS Auto-light
System System Operation With the auto-light
switch turned on, the contactor automatically
closes the head lamp and working lamp circuits
when the darkness sensed by the auto-light sensor
is enough to illuminate the lights.
Auto-light sensor assembly
A
Head lamp
B
Detail "A"
C
Auto-light sensor assembly harness
Harness D
Lighting switch
Red
Yellow
Yellow Red
Key switch
Harness B
White Blue
Blue White
Auto-light switch
Detail "C"
Detail "B"
211654
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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.
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VEHICLE ELECTRICAL COMPONENTS Electrical System
of FC (Finger-tip Control System) Nomenclature
3 2 4 1 5 103542A

1. FC hydraulic control valve
2. Seat switch
3. Controller

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

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38
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 the control system is within
  truck specifications.

209534

• 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 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.)
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• 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 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.

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