TECHNICAL BULLETIN

SERVICE MANUAL

SERVICE MANUAL &

TECHNICAL BULLETIN

MODEL
DX MODEL N01 SERIES
SERIES
 INTRODUCTION

This service manual has been prepared to provide necessary information concerning the
maintenance and repair procedures for the NISSAN FORKLIFT NOt series.
Any changes effected in the series after publication of this service manual will be
announced in a technical bUlletin. It is, therefore, recommended that each relevant technical
bulletin be inserted in front of each section and be used together with the service manual
as a reference.
If a new model requires different service method or has undergone a major change,
revised sections will be issued to replace the applicable sections. Each revised section will
include the description of how to service the parts for the former specifications. The pub-
lication of a revised section will be announced in the technical bulletin.
This service manual consists of eleven sections as shown in the following table, which
gives the updated symbols. When a revised service manual is issued, this "INTRODUCTION"
sheet should be replaced with a revised one.

Section Symbol

GENERAL INFORMATION (GI)

MAINTENANCE (MA)
DRIVE CONTROL SYSTEM (DC)
FRONT AXLE (FA)
REAR AXLE (RA)
BRAKE SYSTEM (BR)
STEERING SYSTEM (ST)
HYDRAULIC SYSTEM (HD)
LOADING MECHANISM (LM)
BODY & FRAME
! ! !
(BF)
BODY ELECTRICAL
! !
(BE)

CONTROL SYSTEM (CS)

Edition: May 1992

Printing: May 1992 (01)
Printed in The Netherlands Publication No. SM2E.ON01EO
 FOREWORD
This manual contains maintenance and repair procedures.

In order to assure your safety and the efficient functioning of the lift truck, this manual should be read
thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely
understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication.
The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the technician and the efficient
functioning of the lift truck.
The service methods in this Service Manual are described in such a manner that the service may be
performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the tools and parts available.
Accordingly, anyone using service procedures, tools or parts which are not specifically recommended
by NISSAN must first be completely satisfied that neither personal safety nor the lift truck's safety will
be jeopardized by the service method selected.
No modifications or alterations to a powered industrial truck, which may affect, for example, capacity,
stability or safety requirements of the truck shall be made without the prior written approval of
NISSAN, its authorized representative, or a successor thereof. Contact an authorized NISSAN
FORKLIFT dealer before making any modification or alteration to your industrial truck that may affect,
for example braking, steering, visibility and the addition of removable attachments. After getting
approval of NISSAN, its authorized representative, or a successor thereof, capacity plate, decals tags
and operation and maintenance handbooks shall also be changed to the appropriate one.
Only in the event that NISSAN is no longer in business and there is no successor in the interest to the
business, the user may arrange for a modification or alteration to a powered industrial truck, provided,
however, that the user shall:

A. Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s)
expert in industrial trucks and their safety;

B. Maintain a permanent record of the design, test(s) and implementation of the modification or
alteration;

C. Approve and make appropriate changes to the capacity plate(s), decals, tags and Instruction
Handbook;

D. Affix a permanent and readily visible label to the truck stating the manner in which the truck has
been modified or altered together with the date of the modification or alteration, and the name and
address of the organization that accomplished the tasks.

© 2010 NFE B.V. Printed in The Netherlands

Revised November 2008

 GENERAL INFORMATION

SECTION GI
CONTENTS
HOW TO USE THIS MANUAL 2 MODEL VARIATION 4
Outline of This Manual 2 IDENTIFICATION NUMBERS 5
Contents of this Manual 2 GENERAL VIEWS 6
Technical Term Definitions 2
 HOW TO USE THIS MANUAL

Outline of This Manual

Abbreviations Section titles Topics

Outline and contents of this manual, Contents of this manual,

GI General information
Technical Terms Definitions, Model Variation, General Views

Precautions, Service data and specifications, Hydraulic system,

HD Hydraulic system
Tilt cylinder, Lift cylinder

Service data and specifications, Trouble diagnoses and

LM Loading mechanism corrections, Precautions, Fork, Lift chain, Carriage assembly,
Mast
BF Body and frame Construction illustration

Contents of this manual

This Manual contains the information on methods required to perform
appropriate forklift maintenance procedures depending on each sys-
tem.
CAUTION:
Because this is a supplementary manual, the coverage is not
comprehensive.

MAIN TEXT
The main text describes removal, disassembly, inspection, assembly,
installation, and adjustment procedures of units.
Step-by-step descriptions are provided for all of these procedures.
Other important information provided includes service points and tips,
basic units and values, tightening torque and special service tools.
Information pertaining to common tools generally found in mainte-
nance facilities is generally omitted. Exploded part views and illustra-
tions are included as required.

OTHER ENTRIES
The following information is included at the beginning of all sections
to supplement the main text.

Service data and specifications

Adjustment values, part selection information for adjustment and
specified tightening torque values are shown for all procedures
described in the main text.

Precautions
Precautions and related information pertaining to the whole section
are provided.

Special service tools

The name, tool number and use of special service tools are shown
for all procedures described in the main text. The illustration shows
the shape of the tool.

Technical Term Definitions

SPECIFIC TERMS
WARNING: Warns of instructions that must be followed to prevent
severe or fatal accidents.
CAUTION: Warns of instructions that must be followed to prevent
injury or damage to parts of the vehicle.
Standard value: The allowable range for a given measured value at
inspection and adjustment.

GI-2
HOW TO USE THIS MANUAL
Technical Term Definitions (Cont'd)
Limit value: The maximum or minimum acceptable measured value
at inspection or adjustment.

POSITION AND DIRECTION

The description of direction (front, back, left, right, up and down) in
this manual is based on the position of a driver sitting in the driver's
seat.

MEASURING UNITS AND VALUES

The UNITS given in this manual are primarily expressed as the SI
UNIT (International System of Unit), and alternatively expressed in
the metric system and in the yard/pound system.
"Example"
Tightening torque:
59 - 78 Nom (6.0 - 8.0 kg-m, 43 - 58 ft-Ib)

GI.3
 MODEL VARIATION

G N01 L 15 H Q

T Destination
Q Europe
V U.S.A. and Canada

H Minor-change model

Lifting capacity/Load center

For European countries

13 1.25 ton/500 mm (2,750 Ib/20 in)
15 1.5 ton/500 mm (3,300 Ib/20 in)
16 : 1.6 ton/500 mm (3,200 Ib/24 in)
18 : 1.75 ton/500 mm (3,850 Ib/20 in)

For U.S.A. and Canada

15 : 1.5 ton/500 mm (3,000 Ib/24 in)
18 : 1.75 ton/500 mm (3,500 Ib/24 in)

Gear type
L : Reduction gear

Basic model code

N01: Electric 3 wheeler, Hon series

Wheel base
S Short wheel base
D : Standard
G : Long wheel base

GI.4
 IDENTIFICAIOiN" NUMBERS

FGJl18A

CHASSIS SERIAL NUMBER

N01-XXXXXX
GN01-XXXXXX
SN01-XXXXXX

GI.5
 GENERAL VIEWS

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FGI120A

GI.6
 GENERAL VIEWS

1.1 Manufacturer Nissan Nissan Nissan Nissan Nissan

1.2 Model Name SN01L13HQ N01L15HQN N01L18HQN GN01L16HQ GN01L18HQ

en Power unit: battery, diesel, petrol, LP gas, Battery

0 1.3 Battery Battery Battery Battery
mains power
~
"f6 Operation: manual, pedestrain, stand on, seated,
1.4 driver seated driver seated driver seated driver seated driver seated
0 order picker
~
.s::.
1.5 Load capacity Q(t) 1.25 1.5 1.75 1.6 1.75
<..J 1.6 Load centre c(mm) 500 500 500 500 500
1.8 Front Overhang x (mm) 365 (380)*1 365 (380)*1 370 (385)*1 365 (380)*1 370 (385)*1
1.9 Wheel base y(mm) 1170 1275 (1170)*5 1275 1395 1395
2.1 Service weight kg 2765 2980 (3095)*5 3145 3020 3125
en
1: 3960/520 4480/395
Cl 2.2 Axle load with load, fronVrear kg 3540/475 4365/530 4145/475
(4025/370)*5
~ 2.3 Axle load without load, fronVrear kg 1360/1405
1440/1540
1415/1730 1550/1470 1655/1490
(1415/1480)*5

3.1 TteS, fronVrear SE(P/C)/ SE(P/C)/

SE(C)/SE(C) SE(P)/SE(P) SEISE
en ( =cushion, SE=super elastic, P=pneumatic) SE(P/C) SE(P/C)*4
~
z:. 3.2 Tyre size, front 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8
ell Tyre size rear 18x7-8 18x7-8 18x7-8 16x6-8 16x6-8
3.3
en
Qi 2x11 2x11 2x11 2x12 2x12
Q) 3.5 Wheels, number fronVrear (x=driven)
.s::.
:s: 3.6 Tread, front bl0 (mm) 880 (900)*2 880 (870)*2 880 (870)*2 930 930
3.7 Tread, rear bll (mm) - - - 205 205
4.1 Mast Tilt Angle a1~ (0) 4/6 4/6 4/6 4/6 4/6
4.2 Standard mast height, fully lowered hl (mm) 1955 1955 1955 1955 1955
4.3 Standard mast Free Lift h2 (mm) 95*3 95*3 100*3 95*3 100*3
4.4 Standard mast lift Height h3 (mm) 3000*3 3000*3 3000*3 3000*3 3000*3
4.5 Standard mast height, fully extended h4 (mm) 3945 3945 3945 3945 3945
4.7 Overhead Guard Height h6 (mm) 1980 1980 1980 1980 1980
4.8 Height of seaVstand on platform h7 (mm) 935 935 935 935 935
4.12 Towing coupler height hl0 (mm) 630 630 630 630 630
en 11 (mm) 2655 2760 (2685)*5 2795 2880 2885
4.19 Overall Length
"
0
'iii 4.20 Length to fork face 12 (mm) 1755 1860 (1785)*5 1895 1980 1985
"E
Q)
4.21 Overall width bl/b2 (mm) 1050 1050 1050 1050/1100 1050/1100
is 4.22 Fork Dimensions s, e,l (mm) 35xl00x900 35xl00x900 40xl00x900 35xl00x900 40xl00xll00
4.23 Fork carriage according to DIN 15173, class/form A, B FEMll FEMll FEMll FEM11 FEMll
4.24 Carriage width b3 (mm) 920 920 920 920 920
4.31 Ground clearance, mast ml (mm) 75 75 75 75 75
m2 (mm) 100 100 100 100 100
4.32 Ground clearance, centre of wheel base
Right angle stacking aisle, pallet 1000x1200 across 3310 3315
--
4.33 Ast(mm) 3085 3190 (3115)*5 3225
forks
4.34 Right angle stacking aisle, pallet 800x1200 along forks Ast(mm) 3210 3315 (3240)*5 3350 3435 3440
4.35 Turning radius Wa(mm) 1390 1495 (1420)*5 1525 1615 1615
5.1 Travel speed, with/without load km/h 12/13 11.5/13 11/13 14/15.5 13.5/15
5.2 Lift speed, with/without load m/s 0.32/0.44 0.30/0.44 0.28/0.44 0.35/0.50 0.28/0.44
Q)
5.3 Lower speed, with/without load m/s 0.50/0.55 0.50/0.55 0.50/0.55 0.50/0.55 0.50/0.55
0

"E
nl
5.6
Maximum drawbar pull, with/without load, 3 minute
N 7840/6566 7840/7154 784017056 784017154 784017056
rating
0
't: ~aximum gradeability, with/without load, 5 minute rat-
Q)
5.8 % 18/28 16/25 15/24 16/25 15/24
c.. mg
5.9 Acceleration time, with/without load (0-10m) s 5.0/4.7 5.3/5.0 5.6/5.3 5.3/4.9 5.4/4.9
5.10 Service brake hydr/electr. hydr/electr. hydr/electr. hydr/electr. hydr/electr.
6.1 Traction motor performance, 60 minute rating kW 3.9x2 3.9x2 3.9x2 3.9x2 3.9x2
6.2 Lift motor performance 20% rating kW 7.4 7.4 7.4 9.6 7.4
Q)
> 6.3 Battery according DIN 43531/35/36 A, B, C, no DIN43531A DIN43531A DIN43531A no no
;5
6.4 Battery voltage/rated capacity (5h) V/Ah 48/300*6 48/400*6 48/400*6 48/550*6 481720*6
6.5 Battery weight (+-5%) kg 520 675 (650)*5 675 825 930

f!1 Transistor Transistor Transistor Transistor Transistor

8.1 Type of drive motor control
Q)
.s::. chop. chop. chop. chop. chop .
0 8.2 Working pressure for attachments bar 120 120 120 120 120

*1: Figures in brackets refer to triplex masts. *3: Other mast heighVFree lift are available as *5: Figures in brackets refer to special compact
*2: Figures in brackets refer to cushion tyres. option. model
*4: No pneumatic tyres for compact model *6: Other battery capacities available as option

GI-7
 GENERAL VIEWS

APPROXIMATE WEIGHT
N01 series

For European countries For USA and Canada

SN01L13HQ N01L15HQ N01L18HQ GN01L16HQ GN01L18HQ N01L15HV N01L 18HV

1.25 ton 1.5 ton 1.75 ton 1.6 ton 1.75 ton 1.5 ton 1.75 ton

Truck weight
kg (Ib) 2245 2305 2470 2195 2195 (5190) (5555)
(without battery)

No Front axle kg (Ib) 1360 1440 1415 1550 1635 (3195) (3145)
Weight Weight
load Rear axle kg (Ib) 1405 1540 1730 1470 1490 (3430) (3845)
distribution
(with Front axle kg (Ib) 3540 3960 4365 4145 4480 (8500) (9345)
Full
battery)
load Rear axle kg (Ib) 475 520 530 475 395 (1125) (1145)

Note: Tire type: Super elastic

Mast type: 2W300

GI-8
September 10th, 1996
General Information
FGI96-N01

APPLIED MODEL: GN01 model I N01 1997 model

SERVICE NOTICE:
A high-performance model GNOILl6U (1.6 ton model) and GNOILl8U (1.75 ton model) have been
newly added to the NOI series.

The main specification of GNOI model is as follows:

1. Chassis dimension such as overall width, overall length etc. have become bigger (GN01)

2. Transistor chopper controller has been newly applied. (NOl/GNOl)

Together with this improvement, a field weakening control system has been newly applied. (GN01)

3. Two wheels have been applied to the steering wheel to ensure truck stability. (GN01)

4. Drive tires' rotation direction when steering has been controlled by roller type steering angle sensor.
So, steering angle switches have been eliminated. (NOl/GN01)

5. About the front axle, axle hub nut has been fixed with axle hub directly by bolts. So, lock washer for
axle hub nut has been eliminated. (GN01)

6. For GNOILl6U model, 9.6kw/5min. hydraulic pump motor and 17.0 ml/Rev. discharge hydraulic
pump has been applied. (GN01)

Please file this bulletin in the binder.

The information in this bulletin should not be interpreted as the basis for claims unless so designated.
 ., ,
GENERAL VIEWS

GENERAL VIEWS (

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Dimensions

NOI-U

For European countries For U .SA. and Canada

L13U L15U L18U L15U L18U
1.5 ton 1.75 ton
1.25 ton 1.5 ton 1.75 ton
(3,000 Ib) (3,500 Ib)
A Overall width mm(in) 1,050 (41.3) 1,050 (41.3)
Be Overall height Mast (Extended) mm (in) 3,945 (155.3) 4,260 (167.7)
BI Overall height Mast (Lowered) mm (in) 1,955 (77.0) 1,955 (77.0)
Bm Max.fork height mm (in) 3,000 (118.1) 3,000 (118.1)
C Free lift mm (in) 95 (3.7) 100 (3.9) 95 (3.7) 100 (3.9)
Of Ground clearance Under frame mm(in) 100 (3.9) 100 (3.9)
Om Ground clearance Under mast mm (in) 75 (3.0) 75 (3.0)
Dp Ground clearance Under power unit mm(in) 100 (3.9) 100 (3.9)
E Front overhang mm (in) 360 (14.2) 365 (14.4) 360 (14.2) 365 (14.4)
F Rear overhang mm (in) 220 (8.7) 250 (9.8) 220 (8.7) 250 (9.8)
G Overall length (without fork) mm (in) 1,750 (68.9) I 1,855 (73.0) 1,890 (74.4) 1,855 (73.0) 1,890 (74.4)
H Front tread Super elastic mm(in) 880 (34.6) 880 (34.6)
H Front tread Pneumatic mm (in) 880 (34.6) 880 (34.6)
H Front tread Cushion mm(in) 900 (35.4) 870 (34.3) 870 (34.3)
I Rear tread mm (in) - -
J Wheelbase mm (in) 1,170 (46.1) I 1,275 (50.2) 1,275 (50.2)
K Overall height Overhead guard mm (in) 1,965 (77.4) 1,965 (77.4)
Lb Tilt angle Backward degree 6 6
Lf Tilt angle Forward degree 4 4
M Min. turning radius Outside mm(in) 1,390 (54.7) 1,495 (58.9) 1,525 (60.0) 1,495 (58.9) 1,525 (60.0)
N Right angle stacking aisle mm(in) 1,750 (68.9) 1,855 (73.0) 1,890 (74.4) 1,855 (73.0) 1,890 (74.4)
0 Right angle intersecting aisle mm(in) 1,595 (62.8) 1,640 (64.6) 1,655 (65.2) 1,640 (64.6) 1,655 (65.2)
P Fork length (STD) mm (in) 900 (35.4) 900 (35.4)

Q Floor height mm (in) 540 (21.3) 540 (21.3)

R Seat height mm(in) 935 (36.8) 935 (36.8)

S Head room mm (in) 1,000 (39.4) 1,000 (39.4)

T Counterweight height mm(in) 870 (34.3) 870 (34.3)

U Backrest height mm (in) 910 (35.8) 905 (35.6) 910 (35.8) 905 (35.6)
V Max. fork spread mm(in) 910 (35.8) 910 (35.8)
W Min. fork spread mm (in) 205 (8.1) 205 (8.1)
9a Departure angle tan9 % 65 52 65 52
9d Approach angle tan9 % 27 27
9r Ramp breakover angle tan9 % 35 32 32

FGI120

GI-3
 GENERAL VIEWS

GENERAL VIEWS

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Dimensions
GNOI-U

For European countries

Ll6U I Ll8U
1.6 ton I 1.75 ton
A Overall width mm(in) 1,100 (43.3)

Be Overall height Mast (Extended) mm (in) 3,945 (155.3)

BI Overall height Mast (Lowered) mm(in) 1,955 (77.0)
Bm Max. fork height mm (in) 3,000 (118.1)
C Free lift mm (in) 95 (3.7) I 100 (3.9)
Of Ground clearance Under frame mm(in) 100 (3.9)

Om Ground clearance Under mast mm (in) 75 (3.0)

Dp Ground clearance Under power unit mm (in) 100 (3.9)
E Front overhang mm (in) 360 (14.2) I 365 (14.4)
F Rear overhang mm (in) 220 (8.7)

G Overall length (without fork) mm (in) 1,975 (77.7) I 1,980 (77.9)

H Front tread Super elastic mm(in) 930 (36.6)
H Front tread Pneumatic mm (in) 930 (36.6)

H Front tread Cushion mm (in) -

I Rear tread mm(in) 205 (8.1)

J Wheelbase mm (in) 1,395 (54.9)

K Overall height Overhead guard mm (in) 1,980 (77.9)

Lb Tilt angle Backward degtee 6

Lf Tilt angle Forward degree 4

M Min. turning radius Outside mm(in) 1,615 (63.6)

N Right angle stacking aisle mm (in) 1,975 (77.8) I 1,980 (78.0)

0 Right angle intersecting aisle mm (in) 1,710 (67.4)

P Fork length (STD) mm(in) 900 (35.4)

Q Floor height mm(in) 540 (21.3)

R Seat height mm (in) 935 (36.8)

S Head room mm (in) 1,000 (39.4)

T Counterweight height mm(in) 870 (34.3)

U Backrest height mm(in) 910 (35.8) I 905 (35.6)

V Max. fork spread mm(in) 910 (35.8)
W Min. fork spread mm(in) 205 (8.1)

9a Departure angle tan9 % 65 I 52

9d Approach angle tan9 % 27

9r Ramp breakover angle tan9 % 29

FGI120

GI-3-1
 MODEL VARIATION

MODEL VARIATION

G NOI L 15 U

T Destination
U : General areas

Lifting capacitylLoad center

For European countries
13 1.25 ton/500 mm (2,750 Ib/20 in)
15 1.5 ton/500 mm (3,300 Ib120 in)
16 1.6 ton/500 mm (3,200 Ib/24 in)
18 1.75 ton/500 mm (3,850 Ib/20 in)
For U.S.A. and Canada
15 : 1.5 ton/500 mm (3,000 Ib124 in)
18 : 1.75 ton/500 mm (3,500 Ib124 in)

Gear type
L : Reduction gear

Basic model code

NOl: Electric 3 wheeler, I-ton series

Wheel base
D Standard
G : Long wheel base

GI-4
 IDENTIFICATION NUMBERS I LOAD CHART

IDENTIFICATION NUMBERS
CHASSIS SERIAL NUMBER
Load chart plate
NOI-XXXXXX
GNOI-XXXXXX

Chassis serial number

FGI118

LOAD CHART
The load chart is located on the instru-
ment frame. This chart specifies
applicable attachments and range of
battery weights, and also indicates the
allowable lifting capacity, load center
and lifting height.

GI-285 FOM458

For except CE marking countries For U.S.A. and Canada

MOM0146

For countries where trucks with the CE

marking must be used

GI-5
 LIFTING POINTS

LIFTING POINTS
APPROXIMATE WEIGHT
NOI-U GNOl-U

For European countries For U.S.A. and Canada For European countries

Ll3U Ll5U Ll8U Ll5U Ll8U Ll6U Ll8U

1.5-ton 1.75-ton
l.25-ton 1.5-ton 1.75-ton 1.6 ton 1.75 ton
(3,000 Ib) (3,500 Ib)

Truck weight (without battery) kg (lb) 2,180 (4,810) 2,255 (4,975) 2,415 (5,330) 2,315 (5,105) 2,475 (5,455) 2,160 (4,765) 2,160 (4,765)

Front axle kg (lb) 1,320 (2,915) 1,400 (3,095) 1,385 (3,055) 1,443 (3,180) 1,427 (3,145) 1,535 (3,385) 1,615 (3,565)
Weight No load
Weight Rear axle kg (lb) 1,410 (3,110) 1,565 (3,445) 1,740 (3,835) 1,572 (3,465) 1,748 (3,855) 1,505 (3,320) 1,615 (3,565)
distribution
(with Front axle kg (lb) 3,490 (7,695) 3,915 (8,630) 4,320 (9,530) 3,955 (8,720) 4,365 (9,625) 4,120 (9,090) 4,450 (9,815)
battery) Full load
Rear axle kg (lb) 490 (1,085) 550 (1,215) 555 (1,220) 560 (1,235) 560 (1,235) 520 (1,150) 530 (1,170)

LIFTING POINTS e. After supporting 11ft truck with 3. Place wooden blocks under both
blocks, swing it back and forth and side frames. Gradually lower rear end
FRONT SIDE left and right to see if it is safe. to ground. Be careful not to dislocate
1. Place chocks behind rear wheels. blocks while lowering.
2. Lift outer mast with a hoist.
A WARNING:
a. Wooden blocks should be one-piece
and strong enough to support the
weight of the lift truck.
b. Do not use a supporting block
higher than 300 mm (11.81 in).
c. Raise the lift truck just high enough
to place the supporting block under
FGI060
the lift truck.
d. Place the same size wooden blocks
under the left and right sides of the
FGI083 frame, as shown in the figure below.
REAR SIDE
e. After supporting 11ft truck with
3. Place wooden blocks under both 1. Place chocks in front of front blocks, swing it back and forth and
side frames. Gradually lower front wheels. left and right to see If it is safe.
end to ground. Be careful not to dis- 2. Lift counterweight with a hoist.
locate blocks while lowering.

A WARNING:
a. Use the same size wooden blocks on
both sides of the lift truck. Wooden
blocks should be one-piece and I
strong enough to support the weight
of the lift truck. I
b. Do not use a supporting block

c.
higher than 300 mm (11.81 in).
Raise the lift truck just high enough
• FGI062

to place the supporting block under

the lift truck.
d. Never put your feet or hands under
the lift truck while lifting or lowering
it.

GI-6
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 MAl NTENANCE
(MA)

MODEL NOl SERIES

" "

CONTENTS

SERVICE DATA AND SPECiFiCATIONS MA- 2

DRIVE CONTROL SYSTEM MAINTENANCE MA- 2
CHASSIS AND BODY MAINTENANCE MA- 2
PERIODIC MAINTENANCE SCHEDULE MA- 3
DRIVE CONTROL SYSTEM MAINTENANCE MA- 3
CHASSIS AND BODY MAINTENANCE MA- 3
LUBRICATION CHART MA- 4
RECOMMENDED LUBRiCANTS MA- 5
RECOMMENDED LUBRiCANTS MA- 5
RECOMMENDED SAE VISCOSITY NUMBER MA- 5
APPROXIMATE REFILL CAPACiTIES MA- 5
DRIVE CONTROL SYSTEM MAINTENANCE MA- 6
TRACTION MOTOR MA- 6
CONTROLLER MA- 6
OTHERS MA- 7
CHASSIS AND BODY MAINTENANCE MA- 8
FRONT AXLE MA- 8
REAR AXLE MA- 8
BRAKE SYSTEM MA- 8
STE ERING SYSTEM MA-l0
HYDRAULIC SySTEM MA-12
LOADING MECHANiSM MA-13
SPECIAL SERVICE TOOL MA-14
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

DRIVE CONTROL SYSTEM MAINTENANCE Brake system

INSPECTION AND ADJUSTMENT Brake pedal free play mm (in) 2 - 4 (0.08 - 0.16)

Traction motor Pedal height mm (in) 143 (5.63)

Brush spri ng pressure 5.5 -7 Hand brake pulling force 147 - 196
N (kg,lb) (0.56 - 0.71, 1.24 - 1.57) N (kg,lb) (15 - 20, 33 - 44)

Commutator dia. limit 68.5 (2.697)

mm (in) [Initial 73 (2.87)]
Steering system
Power steering pump motor
Controller Brush spring pressure 4.9 -7.8
N (kg,lb) (0.50 - 0.80, 1.10 - 1.75)
Contactor coil resistance 11
FR and bypass contactors Brush wear limit mm (in) 13 (0.51)
Normal About 70
Commutator dia. limit
Open exciting coil 00 29.5 (1.161)
mm (in)

Pump contactor
Normal About 50 Hydraulic system
Defective surge killer o Hydraulic oil pump motor
Brush spring pressure 8.1 - 12.6
Open exciting coil 00
N (kg,lb) (0.83 - 1.29, 1.82 - 2.83)

Brush wear limit mm (in) 19 (0.75)

Commutator dia. limit

68.5 (2.697)
mm (in)

Main relief valve pressure

kPa (bar, kg/cm2 , psi)
1.25 - 1.5 ton 14,710 (147.10,150.04,2,133.0)

1.75 ton 15,681 (156.81,159.95,2,273.8)

CHASSIS AND BODY MAINTENANCE

INSPECTION AND ADJUSTMENT Loading mechanism Unit: mm (in)
Rear axle
Lift chai n deflection 25 - 30 (0.98 - 1.18)
Unit: degree
Clearance
Wheel alignment
Inner mast to carriage side 0.1 - 0.6
Camber
roller (0.004 - 0.024)
Caster
Inner mast to carriage 0.1 - 0.6
Kingpin inclination lift roller (0.004 - 0.024)

87.7° _86.4° Outer mast to 0.1 - 0.6

Max. steering angle lift roller (0.004 - 0.024)
(both left and right)
Outer mast to back-up 0.1 - 0.6
metal (0.004 - 0.024)

MA-2
 PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE SCHEDULE

The following tables list the servicing required to keep your Forklift operating at good mechanical condition, and should be
attended to as indicated, preferably by an authorized NISSAN dealer.

DRIVE CONTROL SYSTEM MAINTENANCE

NOTE:
a) Do not inspect any part of the system while the battery is being charged.
b) Before checking any part of the system, be sure to disconnect connectors from the battery and discharge the commuta-
tion condenser with a 50 to 500 ohms resistor.
c) When it is necessary to check with the battery connected, raise drive wheels. Be extremely careful to prevent electric
shocks.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Periodic maintenance should be performed after specified Months 1 2 3 4 5 6 7 8 9 10 11 12
intervals have elapsed in months or hours, whichever comes first. Hundreds of hours 2 4 6 8 10 12 14 16 18 20 22 24
1. Check brushes for pressure and wear, and surface of commutator for roughness X X
2. Clean dust from traction motors X X
3. Check resistance between truck body and negative/positive terminals of battery X X X X
4. Check operation of contactor points and plungers X X X X X
5. Check resistance of contactor coils X
6. Clean controller surface X X X X X
7. Check operation of commutation failsafe circuit X X
8. Check operation of low-voltage detecting circuit X X
9. Check wiring, bolts and nuts X X X X X
10. Clean and check operation of steering switch X X

Check: Check, correct-replace if necessary.

CHASSIS AND BODY MAINTENANCE

MAINTENANCE OPERATION MAINTENANCE INTERVAL
Periodic maintenance should be performed after specified Months 1 2 3 4 5 6 7 8 9 10 11 12
intervals have elapsed in months or hours, whichever comes first. Hundreds of hours 2 4 6 8 10 12 14 16 18 20 22 24
1. Check brake pedal free play X X X X X
2. Check hand brake X X X X X
3. Adjust wheel alignment X
4. Check steering chain tension X X
5. Check brake pad clearance X X X X X
6. Check lift chain tension X X X X X
7. Check lift bracket rollers for damage X X X X
8. Check mast operation X X X X X
9. Check mast rollers for damage X X
10. Check lift and tilt cylinder fitting X X X X X X X X X X X X
11. Check lift and tilt cylinder operation X X X X X
12. Check hydraulic oil pump operation X X X X X
13. Check power steering pump operation X X X X X
Check brushes for pressure or wear, and surface of commutator for roughness
14. X X
(Hydraulic oil pump and power steering)
15. Clean dust from motors (Hydraulic oil pump and power steering pump) X X
16. Change hydraulic oil (1) R R
17. Replace hydraulic oil micron filter (1) R R
18. Check or change drive gear oil X X X X R
19. Change brake fluid R
20. Repack wheel bearing grease (Steering axle) R
21. Lubricate steering chain X X X X X X X X X X X X
22. Grease steering chain stopper plate X X
23. Grease brake linkage X X X X
24. Lubricate lift chain (1) X X X X X X X X X X X X
25. Grease chain support guide bar (1) X X X X X X X X X X X X
26. Grease mast support bushing X X X X
27. Grease back-up metals X X X X X X X X X X X X
28. Grease mast rail X X X X X X X X X X X X

NOTE: (1) Under dusty or other dirty operating conditions, more frequent maintenance should be necessary.
Check: Check, correct-replace if necessary.
R: Replace
MA-3
 LUBRICATION CHART

LUBRICATION CHART

Every 12 months(2,400 hours} o Lubricate

Every 6 months (1,200 hours) • Change

Every 3 months (600 hours)

Every 1 month (200 hours)

Steering chain

Wheel bearing-

Hydraulic oil tank

Front axle case

Tilt cylinder pin

Mast support bushing

Micron filter Back-up metal

Reservoir- Thrust metal

Chain

Suitable oil
Item
Below 16°C (60°F) Above 16°C (60°F)

G) Gasoline engine oil SAE No. 20 SAE No. 30

@Gearoil SAE No. 90 SAE No. 140

(])W.B. grease NLGI No.2

@ Chassisgrease NLGI NO.1

@ Brake fluid FMVSS DOT3

@Hydraulic oil SAE No. 10W

(j) Replace element

FMA131

MA-4
 RECOMMENDED LUBRICANTS / APPROXIMATE REFILL CAPACITIES

RECOMMENDED LUBRICANTS

RECOMMENDED LUBRICANTS RECOMMENDED SAE

VISCOSITY NUMBER
Item Specifications Remarks

.... Refer to Recom-

co - Reduction gear API GL-4 MIL-L-2IOS mended SAE
r38 Viscosity Chart.

<l)
Chassis N.L.G.I. 1
'" Lithium soap base
c:;'" Wheel bearing N.L.G.1. 2
4>

Mast and chain guide bar N.L.G.I. 2 Graphite base

Hydraulic oil Hydraulic oil SAE No.1 OW Wear-proof oil -29 -18 -7 4 15
(-201 (01 (201 (401 (601

F.M.V.S.S.: Federal Temperature Range Anticipated

Before Next Oil Change
Brake fluid DOn (F.M.V.S.S. No. 116) Motor Vehicle
Safety Standard

APPROXIMATE REFILL CAPACITIES

Liter u.s. measure Imp measure

Hydraulic oil tank

2-stage standard mast 17.9 4-3/4 gal 4 gal

2-stage full-free mast 4-5/8 gal

20.9 5-1/2 gal
3-stage full-free mast
RH LH RH LH RH LH
Reduction case (left and right)
0.8 1.5 1-3/4 pt 3-1/8 pt 1-3/8 pt 2-5/8 pt

MA-5
 DRIVE CONTROL SYSTEM MAINTENANCE

DRIVE CONTROL SYSTEM MAINTENANCE

TRACTION MOTOR Sand lightly with No. 500 or No. 600 Bypass contactor
sandpaper. The wear limit of com- Normal
CHECKING BRUSH
mutator depth is 1.5 mm (0.059 in). If About 70 n
Check brushes for pressure and wear. the commutator diameter is less than Open exciting coil
1. Brush pressure should De measur- specified, replace armature assembly. con
ed with a spring balance. Pump contactor
Diameter limit:
Normal
68.5 mm (2.697 in)
About 50 n
[Initial 73 mm (2.87 in)]
Defective surge killer

Remove dust or fillings using dry com-

on
Open exciting coil
pressed air and wipe commutator sur-
face clean with a dry cloth.
con
CLEANING CONTROLLER
CLEANING DUST
Clean controller surface. Clean dust
Clean dust from traction motor.
with dry compressed air.

Spring pressure: CONTROLLER

5.5 -7 N CHECKING CONTACTOR
(0.56 - 0.71 kg,
Check operation of contactor points.
1.24 - 1.57Ib)
1. Disconnect battery connector.
2. Wear limit of brush 2. Discharge commutation conden-
Brush has a line which indicates its ser.
wear limit. 3. If entire contactor point surface
is charred or cratered, replace con-
tactor.
4. Ensure movable contact assembly
moves smoothly when lifted, and that
it returns qUickly to its original posi-
tion when released. If it does not,
disassemble and clean.

Abrasion CHECKING COMMUTATION

CHECKING CONTACTOR COIL
limit line FAIL-SAFE CIRCUIT
Check resistance of contactor coil.
Check operation of commutation fail-
FDC445
safe circuit.
1. Raise drive wheels with a jack,
3. Replace, if necessary.
placing chocks at rear wheels to pre-
Refer to section "DC" for replace- vent truck from moving.
ment procedures for brushes and brush 2. Turn key switch off and discon-
springs. nect battery connector, and discharge
commutation condenser.
CHECKING COMMUTATOR 3. Disconnect gate lead wire (white)
Check surface of commutator for ofSCRB.
roughness. 4. Connect battery connector and
1. If oil or dust comes into contact turn key switch on.
with commutator surface, remove it 5. Shift FR lever into F or R, and
using dry compressed air and wipe Circuit tester indication: depress accelerator pedal.
commutator surface clean with a dry FR contactor 6. If circuit is in good order, FR con-
cloth. Normal tactor points open and drive wheels
2. If the surface of commutator is About 70 n rotate and stop.
rough, it should be polished as fol- Open exciting coil If circuit is out of order, drive wheels
lows: con continue to rotate.

MA-6
 DRIVE CONTROL SYSTEM MAINTENANCE

CHECKING LOW VOLTAGE 3. Disconnect battery connector. 7. Turn key switch on.
DETECTING CIRCUIT 4. Discharge commutation conden- 8. Adjust power supply voltage to at
Check operation of low voltage ser. least 25 volts to ensure that low volt-
detecting circuit. 5. Remove fuses, FS1, FS2 and FS3. age lock lamp does not come on.
6. Connect power supply (described 9. Gradually decrease stabilizer volt-
1. Raise drive wheels with a jack,
below) to controller connector. age to ensure that low voltage lock
placing chocks at rear wheels to pre-
Voltage 18 - 30 (V) ... Variable lamp comes on within a range of 18 to
vent truck from moving.
Ampere About 2 (A) 22 volts.
2. Turn all electrical switches and
key switch to OFF. (ex. Lighting
switch)

CHECKING STEERING SWITCH

Steering cam Large angle

switch

Small angle
--
switch

0-0: on
FDC440

OTHERS Normal 00 n CHECKING WIRING, BOLT

If resistance value is "no infinity", AND NUT
CHECKING BODY RESISTANCE
check lead wires, controller and motor Check wirings, bolts and nuts.
Check resistance between truck body
windings for grounding. Correct or 1. Check harness covering of system
and negative/positive terminals.
replace faulty parts as necessary. components for damage or burns. Re-
place if necessary.
2. Check terminals and nuts of con-
troller, contactors and motor for
looseness. Retighten nuts and bolts as
reqUired.

MA-7
 CHASSIS AND BODY MAINTENANCE

CHASSIS AND BODY MAINTENANCE

FRONT AXLE Steering angle Adjust, repair or replace parts if neces-
CHECKING OR CHANGING Make sure steering angle is within sary.
DRIVE GEAR OIL specifications. If it is outside specifi- Steering angle:
cations, check steering chain for 90° -91.3°
Oil capacity: proper tension, and parts for proper (both left and right)
RH installation.
0.8 Q (1-3/4 US pt, 1-3/8 Imp pt)
LH
1.5 Q (3-1/8 US pt, 2-518 Imp pt)
BRAKE SYSTEM
CHECKING BRAKE PEDAL

Pedal stopper bolt

Lock nut A

Lock nut B
Push rod

REAR AXLE Pedal play "a":

REPACKING WHEEL 2.0 - 4.0 mm (0.079 - 0.157 in)
Pedal height "H":
BEARING GREASE 143 mm (5.63 in)
Pedal max. stroke "S":
1. Thoroughly clean grease and dirt
Less than 45 mm (1.77 in)
from wheel bearing with cleaning
solvent, and dry with compressed air Floor board
free from moisture. Check wheel
bearing to see that it rolls freely and is FBR530

free from noise, crack, pitting, or

wear. Replace, if necessary.
2. Pack each bearing cone with 1. Adjust pedal stopper until pedal (f) : Push rod lock nut "B"
multi-purpose grease. pad is 143 mm (5.63 in) above floor, 16 -22 N.m
and tighten lock nut "A". (1.6 - 2.2 kg-m,
12 -16 ft-Ib)
(f) : Pedal stopper lock nut "A"
19 -25 N.m Too small a free play pushes push rod,
(1.9 - 2.6 kg-m, blocking return port of master cylin-
14 - 19 ft-Ib) der and possibly resulting in dragging
brakes; too large a free play will dis-
2. Adjust push rod length until pedal locate push rod.
play is within the specified value. Then
3. After adjustment, check that
tighten lock nut "B" securely.
"pedal max. stroke" is less than 45
FA262 Pedal play: mm (1.77 in). If it is not, check brake
At pedal pad system.
ADJUSTING WHEEL ALIGNMENT 2.0 -4.0 mm 4. Depress and release pedal several
(0.079 - 0.157 in) times to see if it travels smoothly over
Camber and caster At push rod end its entire stroke without binding,
Camber and caster are preset at 0.4-0.8 mm twisting or interfering with adjacent
factory and cannot be adjusted. (0.016 - 0.031 in) parts.

MA-8
 CHASSIS AND BODY MAINTENANCE

5. Depress and release pedal several CHECKING HAND BRAKE Pad clearance adjustment
times. Make sure stop lamp switch Depress brake pedal to operate brakes
Check hand brake for proper oper-
comes on when pedal is depressed 7 to when adjusting pad clearance.
ation. Adjust if necessary.
13 mm (0.28 to 0.51 in) and goes off 1. Adjust bolt C until dimension L is
when it is released. Pulling force:
2 mm (0.08 in) and then tighten lock
147 -196 N
nut.
(15 - 20 kg,
33 - 441b) 2. Adjust bolt D until dimension M
is 1 mm (0.04 in) and then tighten
lock nut.
CfJ 9 - 12 (0.9.1.2.6.5.8.7) 3. After above adjustments have
been made, release brake pedal to
make sure brakes do not drag.

r Hand
gnp CHANGING BRAKE FLUID
1. Change brake fluid.
Pulling
force CAUTION:
adjusting
bolt Never reuse brake fluid because its
nature is changed by oxidization and it
may contain foreign material or dirt.

Use same procedure as in air bleeding

to change brake fluid in system. This
operation should be done one wheel at
a time.
CfJ 19.25 (1.9.2.6,14. 19)

CfJ: N.m (kg-m, ft-lb)

FBR 531

CHECKING BRAKE PAD

CLEARANCE
Check brake pad for wear. Adjust if
necessary.

2. Check brake fluid level.

3. Check for leaks.

MA-9
 CHASSIS AND BODY MAINTENANCE

LUBRICATION POINTS cation points indicated in figure will wear abnormally, and the motor
Apply a coat of brake grease to lubri- below. will ultimately be rendered inopera-
tive. Blow dust off with dry com-
pressed air and wipe with clean dry
cloth. If commutator surface if rough,
smooth with #500 or #600 emery
paper, and carefully clean area around
commutator with dry compressed air.
Clean undercut portion of com-
mutator in the same manner. If com-
mutator is excessively rough, it must
be corrected by cutting.
Diameter limit:
Air bleeder 29.5 mm (1.161 in)

2. Check for disconnection.

If motor will not rotate at all, use a
circuit tester to check motor lead for
disconnection or poor connection at
jointing portion.
3. Cleaning
Periodically clean inside of motor with
dry compressed air.

FMA056
Cleaning of motor
When motor is operated under severe
STEERING SYSTEM dust conditions, occasionally clean
motor interior using dry compressed
CHECKING POWER air in order to maintain original insu-
STEERING MOTOR lation resistance.
Checking brush

Check brushes for pressure and wear.

1. Brush pressure should be mea- CHECKING STEERING SHAFT
sured with spring balance. AND BALL BEARING

Spring pressure: Check steering shaft and ball bearings

4.9 -7.8 N for looseness.
FST417
(0.50 - 0.80 kg, Retighten if necessary. Replace worn
1.10 -1.75Ib) or damaged parts.
3. Replace if necessary.

Checking commutator
2. Wear limit of brush Check surface of commutator for
Brush has a line which indicates its roughness.
wear limit. 1. The commutator is a vital part of
Wear limit (min. length): the motor; if it should become con-
13 mm (0.51 in) taminated with oil or dust the brush

MA-10
 CHASSIS AND BODY MAINTENANCE

Checking steering chain tension and

lubrication points
Check steering chain tension. Adjust if
Steering wheel
necessary.
Apply a coat of multi-purpose grease
to lubrication points on the steering
column assembly shown in figure
at right.

Steering column assembly

FMA133

Lubrication points
Apply a coat of oil to chains.
Apply a coat of multi-purpose grease
to steering splines.

First chain tension adjustment Front

Steering column shaft assembly
Slide shaft (with built-in sprocket) in <:J
direction "B" until chain slacks 25 to
Multi-purpose
30 mm (0.98 to 1.18 in) in direction grease
"Q" with a force of 49 N (5 kg, 11Ib),
Lock nut
then tighten lock nut securely. (fJ 98 - 127 Steering --c~~ Multi-purpose grease 'I'
. ~
(10.13, spIme . Q If. Steering
72- 941 View F F IOil . spline
~
Shaft \-lst chain CiJ: N'm (kg-m, ft-Ib)
B

FMA134

MA-11
 CHASSIS AND BODY MAINTENANCE

Lubrication points II lb), then tighten bracket mounting Checking commutator

Apply a coat of oil to chains. bolts. Check surface of commutator for

Third chain tension adjustment roughness.
Second chain tension adjustment I. The commutator is a vital part of
Tighten nut on adjusting bolt until
the motor; if it should become con-
Slide shaft (with built-in sprocket) in chain slacks 8 to IS mm (0.31 to
taminated with oil or dust the brush
direction "A" until chain slacks by 0.59 in) in direction "I" with a force
will wear abnormally, and the motor
3 to 6 mm (0.12 to 0.24 in) in direc- of 49 N (5 kg, 11 lb), then tighten
will ultimately be rendered inopera-
tion "J" with a force of 49 N (5 kg, lock nut securely.
tive. Blow dust off with dry com-
pressed air and wipe with 'clean dry
Adjusting bolt
cloth. If commutator surface is rough,
- Lock nut smooth with #500 or #600 emery
t!J
25 - 32
paper, and carefully clean area around
12.6 - 3.3, 19 - 24)
commutator with dry compressed air.
Clean undercut portion of commu-
tator in the same manner. If commu-
tator is excessively rough, it must be
corrected by cutting.
3rd chain
Diameter limit:
68.5 mm (2.697 in)
Oil
2. Check for disconnection
If motor will not rotate at all, use
a circuit tester to check motor lead
f6r disconnection or poor connection
at jointing portion.
3. Cleaning
Periodically clean inside of motor with
dry compressed air.

N.m (kg-m, ft-lb) Cleaning of motor

FMA135 When motor is operated under severe

dust conditions, occasionally clean
motor interior using dry compressed
air in order to maintain original in-
HYDRAULIC SYSTEM Spring pressure: sulation resistance.
8.1 - 12.6 N
CHECKING HYDRAULIC OIL
(0.83 - 1.29 kg,
PUMP MOTOR
1.82 - 2.83 Ib)
Checking brush
2. Wear limit of brush
Check brushes for pressure and wear.
Brush has a line which indicate its
I. Brush pressure should be mea-
wear limit. Replace if necessary.
sured with a spring balance. If it is
faulty, replace. Wear limit (Min. length):
19 mm (0.75 in)

MA-12
 CHASSIS AND BODY MAINTENANCE

CHECKING HYDRAULIC Main relief valve set pressure: LOADING MECHANISM

OIL PUMP 1.25 . 1.5 ton model CHECKING CARRIAGE
14,710 kPa BRACKET ROLLER
Check hydraulic oil pump operation.
(147.10 bar, 150.04 kg/cm2,
1. Check hydraulic oil level. Add oil 1. Check carriage bracket rollers for
2,133.0 psi)
if necessary. abnormal wear, cracks or other
2. Check oil leakage from pump and 1.75 ton model
damage on contact surface of inner
15,681 kPa
piping. mast. Replace if necessary.
3. Check hydraulic oil relief pres- (156.81 bar, 159.95 kg/cm2,
2. Measure clearance between inner
sure. 2,273.8 psi)
mast and carriage roller. Adjust if
necessary.
6. Perform pump delivery test under
Clearance:
TEST PROCEDURES nonloaded and loaded conditions, and
Inner mast to carriage side roller
see if fork can be lifted normally.
1. Check oil level in tank and install 0.1 • 0.6 mm (0.004 - 0.024 in)
pressure gauge to control valve. I nner mast to carriage lift roller
0.1 - 0.6 mm (0.004 ,0.024 in)
CHANGING HYDRAULIC OIL
Changing procedure CHECKING MAST ROLLER

1. Turn key switch to ON position 1. Check mast rollers for abnormal

and fully extend lift cylinder. wear, cracks or other damage on con-
2. Return control lever to NEU- tact surface of inner or outer mast.
TRAL and key switch OFF. Replace if necessary.
3. Set control lever to LOWER posi- 2. Measure clearance between mast
tion and allow lift cylinder to contact and mast roller. If necessary, adjust
gradually, thus returning oil in lift cyl- using the following procedures.
inder to oil tank. Clearance:
4. Remove drain plug from oil tank; o- 0.6 mm (O - 0.024 in)
drain oil.
I-spool, 2-stage mast
2. Run hydraulic oil pump for 10 to 5. Refill tank with new oil.
15 minutes. • Set roller pitch of inner and outer
Quantity of hydraulic oil:
3. Move control lever to the for- masts to "L" dimension.
2.stage standard mast model
ward/backward tilt position and start
17.9£
pump motor.
(4-3/4 US gal, 4 Imp gal)
4. Turn adjusting screw on relief
2-stage and 3-stage fUll-free
valve to raise pressure from 0 to
mast model L
14,710 kPa (0 to 147.10 bar, 0 to
20.9£
150.04 kg/cm2, 0 to 2,133.0 psi) in
======rrl\~
1,961 kPa (19.6 bar, 20 kg/cm2, 284
psi) increments (1.25 to 1.5 ton
(5-1/2 US gal, 4-5/8 Imp gal)
C
"\dJ t Outer mast
~ermast

model), from 0 to 15,681 kPa (156.81

bar, 159.95 kg/cm2, 2,273.8 psi) in
1,961 kPa (19.6 bar, 20 kg/cm2,
FLM078
284 psi) increments, (1.75 ton model).
Place hand on pump body to check
for abnormal temperature rise. If tem-
perature of pump body is excessively
Unit: mm (in)
higher than hydraulic oil temperature,
disassemble oil pump to make sure Less than More than
Lift height 3,500 (137.80) 3,700 (145.67)
it is assembled correctly. 3,300 (129.92) 4,000 (157.48)
5. Set relief valve to standard pres- "L" dimension 294 (11.57) 364 (14.33) 414 (16.30) 494 (19.45)
sure.

MA-13
 SPECIAL SERVICE TOOL

I-spool, 3-stage mast 4. Check back-up metal for abnor-

• Set roller pitches of inner and mal wear, cracks or other damage on
middle masts, and middle and outer contact surface of inner mast. Also
masts. measure clearance between inner mast
and back-up metal.
Roller pitch:
445 mm (17.52 in) Clearance "A":
o - 0.5 mm (0 . 0.020 in)

3. Adjust clearance evenly "A" to 0

to 1.0 mm (0 to 0.039 in) for both left FLM092

and right sides with shim(s).

Shims: a. Number of shims must be the same
0.25 mm (0.0098 in) on right and left sides.
0.50 mm (0.0197 in) b. Apply a coat of grease to contact-
1.00 mm (0.0394 in) ing surface of inner or outer mast.
Adjustable range with shims: c. After clearance adjustment, push
1.0 - 4.0 mm inner mast to see if it operates
(0.039 - 0.157 in) properly.

SPECIAL SERVICE TOOL

Tool number Tool name

KV991009S1 Pressure gauge

MA-14
 DRIVE CONTROL SYSTEM
(DC)

MODEL NOl SERIES

CONTENTS

SERVICE DATA AND SPECiFiCATIONS

" " " " DC- 3
!

c
INSPECTION AND ADJUSTMENT DC- 3
TIGHTENING TORQUE DC- 3
PRECAUTIONS DC- 4
CIRCUIT DIAGRAM DC- 5
TROUBLE DIAGNOSES AND CORRECTIONS DC- 6
DRIVE CONTROL SySTEM DC-18
CABLE LAyOUT DC-18
CONTROLLER COMPONENT PARTS LAyOUT DC-19
INSULATION RESiSTANCE DC-20
THYRISTOR B, C DC-20
THYR ISTOR A DC-21
THYRISTOR THERMAL SWITCH , DC-22
PLUGG ING DIODE DC-22
BLOCKING DIODE DC-23
FREEWHEEL DIODE " DC-23
COMMUTATION CONDENSER DC-24
R EACTO R , DC-26
PUMP LOC KOUT MODU LE DC-27
B.D.1. (Battery Discharge Indicator) LAMP AMPLIFIER MODULE DC-27
CONT ACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. DC-28
F AND R CONTACTORS DC-28
BYPASS CONTACTOR DC-29
PUMP CONTACTOR DC-29
FUSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. DC-3D
SPECiFiCATIONS DC-3D
INSPECTION " DC-3D
OTHER COMPONENT PARTS DC-31
FR SWITCH DC-31
ACCELERATOR UNIT DC-31
ACCELERATOR LINKAGE DC-33
BRAKE SWITCH DC-33
STEERING SWiTCH DC-34
DEADMAN SEAT SWITCH DC-34
ACCELERATOR VOLUME ASSEMBLY DC-35
TRACTION MOTOR DC-36
TROUBLE DIAGNOSES AND CORRECTIONS DC-36
CONSTRUCTION DC-37
REMOVAL AND INSTALLATION DC-37
INSPECTION , DC-37
DISASSEMBLY AND ASSEMBLY DC-38
ANALYZER (Option) DC-39
SETUP PROCEDURES " , DC-39
DIAGNOSTICS DC-39
HARNESS CHECK DESCRiPTIONS DC-41
FAULT DESCRIPTIONS AND ACTIONS , DC-42
SHORT FORM DIAGNOSTIC LIST DC-49
WIRING DIAGRAM FOR CONTROLLER .. " '" .. DC-50
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS TIGHTENING TORQUE

Traction motor Controller

Self-ventilating Unit N.m kg-m ft-Ib

Type
DC series-wound
Main thyristor 5.15 - 5.69 0.525 .0.580 3.799 -
Model 3439TMS 730 (SCR A) fix nut 4.197
Commutation 4.0 - 4.8 0.41 -0.49 2.95 - 3.61
Maker B.K.B.
thyristor (SCR B, C)
Rated voltage v 48 Plugging diode, 27.1-31.64 2.764 - 3.227 19.989 -
commutation diode 23.338
Rated output kW/h 3.9
Blocking diode 27.1 - 31.64 2.764 - 3.227 19.989 -
23.338
Freewheel diode 27.1 -31.64 2.764 - 3.227 19.989 -
INSPECTION AND ADJUSTMENT 23.338

CONTACTOR Condenser fix nut 6.44-7.12 0.657 - 0.726 4.750 - 5.252

Resistance of exciting coil (Thyristor chopper controllerl Reactor fix nut 5.15-5.69 0.525 - 0.580 3.799 - 4.197
Shunt 5.15 -7.12 0.525 - 0.726 3.799 - 5.252
F contactor, R contactor,
About 70n Aluminum heatsink 4.51 - 4.99 0.460 - 0.509 3.327 - 3.681
BP contactor
Diode clamp 8.06 - 8.90 0.822 - 0.908 5.945 - 6.565
Pump contactor About 50n

Traction motor
Traction motor
Unit N.m kg.m ft-Ib
Brush' spring pressure 5.5- 7.0
Traction motor 41.52 4.2- 5.3 30-38
N (kg, Ib) (0.56 - 0.71, 1.24 - 1.57)
securing bolt
Commutator diameter
Initial mm (in) 73 (2.87)
Cable terminals
Limit mm (in) 68.5 (2.697)
Unit Nm kg-m ft-Ib
Insulation resistance Mn More than 1
Terminal PA 18.62 - 24.5 1.899 - 2.499 13.734 -
Minimum length of brush (M10)
19 (0.75) 18.071
mm (in)
*Other term inals 9.11 - 11.76 0.929 - 1.200 6.720 - 8.674
Commutator undercut 0.5.0.75 (M8)
mm (in) (0.0197 - 0.0295)
*RF, RFF, RDA, LF, LFF, LOA, AA, +, - and Fuse terminals.

DC-3
 PRECAUTIONS

PRECAUTIONS

WARNING: ii) Wait at least 10 minutes after

a. Before starting to work on any battery connector has been
part of electrical system, be sure disconnected.
to perform either i) or ii) below. b. If work requires battery con-
i) Disconnect battery connec- nector to be connected, be ex-
tor, and connect a 50 to tremely careful not to touch any
500n resistor (do not use a electrical parts or cables, and
metal-film resistor) across place chocks on wheels to pre-
commutation condenser to vent accidental movement of
discharge condenser. FDC008 truck.

CAUTION:
a. When checking with circuit tester,
be sure to set function selector at
the correct position, "A", "v" or
"n", depending on the checks to
be made.
b. Upon completion of work, again
check to see if lead wires are
connected to their original ter-
minals.

DC-4
____________ -:::c:~:R~C~U;IT~D~I~A~GR~A~M~;-----------
CIRCUIT DIAGRAM

,-

"o ~ "o

PUMP
~ MOTOR

-02T
To Horn re 1sy.
~
POWER_ ~ _CONTROLLER_
LTG sWitch,and
----

-is&
Flasher unit
BATTERY -=:=-
4BV .....L--

To Parking brake
warning buzzer

---

SEAT

Lamp check relay

)C446

DC-5
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

A WARNING:
Connector A
Whenever checking the truck for any -
malfunction, be sure to observe the
following instructions.
•
669 671 674
a. Before checking any part, discon-
nect battery connector and dis- 682 683 684
charge commutating condenser.
b. Before turning on power to check
electrical components, raise drive
wheels off the ground.
c. When measuring electrical circuit,
set measuring instrument at correct To chassis
harness
voltage levels before turning on Connector B
power.

Before attempting to check any sys-

•
tem of the electric forklift, ensure
that:
1. Fuses are not blown. 661
2. Harnesses are not broken and con- FDC411
nectors are tight.
3. The voltage value given in flowchart
is the voltage measured at the "8"
terminal of controller.
4. The mark @:D in flowchart indi-
cates the connector number in the
controller shown at right.

DC-6
 TROUBLE DIAGNOSES AND CORRECTIONS

ALL CONTACTORS DO NOT CLOSE.

NG
Check battery. .1 Recharge .

NG
Check fuses. . 1
Replace.

NG
Check for loose plugs or wiring connections. Tighten or replace.

OK

• Check
and/or
for shorted controller (+) terminal
chopper heatsink*. IAAI
NG
Check traction motor. I
• Check for shorted controller (-) terminal
and/or chopper heatsink*. JAAI

OK * Refer to Wiring Diagram.

Turn key switch ON and measure voltage at

terminal ~.

NO Check key switch.

Check harness.

Place FR switch in "F" and measure voltage

at terminal ~.
Place FR switch to "R" and measure voltage
at terminal ~.

NO Check FR switch.
Check harness.

Sit in driver's seat, turn seat switch "ON"

and measure voltge at terminal ~.

NO Check: Seat switch

Seat relay
Harness

Depress accelerator pedal completely and

measure voltage at terminal ~.

@ (Go to next page.)

DC-7
 TROUBLE DIAGNOSES AND CORRECTIONS

NO Check accelerator
unit harness.

Check FR contactor points.

Check BP contactor points.

NG
Polish contact points.

Check FR contactor coil/harness for an open.

Check BP contactor coil/harness for an open.

NO
Replace contactor coil/harness.

Check operation of movable FR contactor.

Check operation of movable BP contactor.

NG
Check inoperative contactor.

Check all harness connections (inside NG

Tighten loose connections.
controller).

OK
NG
Check for shorted SCR A. Repair.

OK
NG
Check for open or shorted traction freewheel Repair.
diode circuit.

OK
Check dropper resistor for an open. Repair

OK
Faulty logic box.

DC-8
 TROUBLE DIAGNOSES AND CORRECTIONS

F OR R CONTACTOR OR ANY OTHER

CONTACTOR DOES NOT CLOSE.

Set steering wheel to Neutral and ensure

steering switch is ON.

Place FR switch in "F" and measure voltage at

terminal <:ED.
Place FR switch in "R" and measure voltage at
terminal ~.

NO Check FR switch.
Check harness.

Check FR contactor coil/harness for an open.

Check BP contactor coil/harness for an open.

NG Replace faulty contactor coil/

harness.

Check operation of movable FR contactor.

Check operation of movable BP contactor.

NG
Repair.

NG
Check harness connections (inside controller). Tigh ten loose connections.

OK
Check steering switch terminal voltage:
Turn steering wheel to left more than 36° and measure voltage at terminal @D.
Turn steering wheel to right more than 36° and measure voltage at terminal ~.
Turn steering wheel to left more than 80° and measure voltage at terminal @D.
Turn steering wheel to right more than 80° and measure voltage at terminal @D.

NO Check steering switch.

Check carn switch.
Check harness.

Faulty logic box. Replace

DC-9
 TROUBLE DIAGNOSES AND CORRECTIONS

FR CONTACTOR CLOSES BUT VEHICLE

DOES NOT MOVE.

NG
Check battery. Recharge.

OK
Check for loose connection/open circuit
NG
Repair.
between accelerator unit and controller.

OK
Depress accelerator pedal completely and
measure voltage at terminal~.

NO Check accelerator unit

harness.

Check for loose harness connections

NG
Repair.
(inside controller).

OK

Faulty logic box.

DC-10
 TROUBLE DIAGNOSES AND CORRECTIONS

VEHICLE STARTS BUT BYPASS

CONTACTOR DOES NOT CLOSE.

Check BP contactor points.

NG
Polish contactor points.

Check BP contactor coil/harness for an open.

NG
Replace coil/harness.

Check operation of movable BP contactor.

NG
Repair.

NG
Check operation of terminal switch. • Wait until heatsink
temperature decreases.
OK • Check terminal switch.

Measure steering switch terminal voltage:

Turn steering wheel to left more than 36° and measure voltage
at terminal <!ZD.
Turn steering wheel to right more than 36° and measure
voltage at terminal~.
Turn steering wheel to left more than 80° and measure voltage
at terminal ~.
Turn steering wheel to right more than 80° and measure
voltage at terminal ~.

Check steering switch.

Check cam switch.
Check harness.

DC-11
 TROUBLE DIAGNOSES AND CORRECTIONS

f
Check for loose harness connections or open
NG
Repair.
circuit between accelerator unit and controller.

OK
Depress accelerator pedal completely and
measure voltage at terminal~.

NO Check accelerator unit

harness.

Faulty logic box.

1
Replace

DC-12
 TROUBLE DIAGNOSES AND CORRECTIONS

FR CONTACTOR OPENS AS SOON AS

ACCELERATOR PEDAL IS DEPRESSED.

1
Check battery. NG
'"---.... ~I Recharge.

OK 1 Circuit
I I
Check circuit between I FFI and [B and circuit is open.
. Check motor.
between IDA\ and !AM
Circuit is closed.
NG
Check for open harnesses/loose connections to Repair.
SCR A, SCR Band SCR C.

OK
Measure gate signal waveforms for SCR A,
SCR Band SCR C.

NG Replace SCR A, SCR B,

and SCR C.

Check voltage at commutation condenser Co.

NO Replace commutation
condenser.

Check reactors for damage or open circuit.

NG
I Replace reactors.

OK
NG
Check for shorted or open traction freewheel Repair.
diode circuit.

OK

Check for shorted or open plugging diode. Repair.

OK
Check for loose harness connections or open NG
Repair.
circuits between accelerator unit and controller.

OK

A (Go to next page.)

DC-13
 TROUBLE DIAGNOSES AND CORRECTIONS

Depress accelerator pedal completely and

measure voltage at terminal ~.

NO Check accelerator unit

harness.

Check for loose harness connections (inside NG Repair.

controller).

OK
Faulty logic box.

DC-14
 TROUBLE DIAGNOSES AND CORRECTIONS

VEHICLE STARTS SLOWLY BUT DOES

NOT ACCELERATE.

NG
Check battery. Recharge.

OK

Check if brake pedal is released.

NG
I Check brakes. I
OK
Check traction motor and reduction gear. Check traction motor.
Check reduction gear.
OK

Check for loose power cable connection or NG

Repair.
open circuit.

OK

Check BP contactor points.

NG
Polish contactor points.

Check BP contactor coil/harness for an open.

NO
Replace coil/harness.

Check operation of movable BP contactor.

NG
Repair.

NG
Check operation of thermal switch. • Wait until heatsink
temperature decreases.
OK • Check thermal switch.

@ (Go to next page.)

DC-15
 TROUBLE DIAGNOSES AND CORRECTIONS

Check steering switch terminal voltage:

0
Turn steering wheel to left more than 36 and measure voltage
at terminal~.
0
Turn steering wheel to right more than 36 and measure voltage
at terminal C@.
0
Turn steering wheel to left more than 80 and measure voltage
at terminal C[8)
0
Turn steering wheel to right more than 80 and measure voltage
at terminal~.

NO Check steering switch.

Check carn.
Check harness.

Check for loose harness connection or open Repair.

circuit between accelerator unit and controller.

OK
Depress accelerator pedal completely and
measure voltage at terminal ~'

NO Check accelerator unit

harness.

Check for seized accelerator linkage. Repair.

OK

Faulty logic box.

DC-16
 TROUBLE DIAGNOSES AND CORRECTIONS

VEHICLE STOPS ABRUPTLY AS

"PLUGGING" IS ACTIVATED.

l
Check battery. - NG
__ .1
". Recharge.

OK r
Check for loose power cable connection or Repair.
open circuit.

OK
Check for loose harness or open circuit to
NG
Repair.
SCR A, SCR Band SCR C.

OK
Measure gate signal waveforms for SCR A,
SCR Band SCR C.

NG Replace SCR A, SCR B

and SCRC.

Check commutation condenser voltage.

NO Replace commutation
condenser.

NG
Check reactors for damage or an open. Replace reactors.

OK
Check for shorted plugging diode or open
NG
Repair.
circuit.

OK
NG
Check for shorted blocking diode or open Repair.
circuit.

OK

Faulty logic box.

DC-17
 DRIVE CONTROL SYSTEM

DRIVE CONTROL SYSTEM

CABLE LAYOUT

Right traction motor

Pump motor Left traction motor

Battery DA DA AA
+-
F F FF

FDC412

DC-18
 DRIVE CONTROL SYSTEM

CONTROLLER COMPONENT PARTS LAYOUT

1 Shunt 14 LH blocking diode

2 RH plugging diode IS Freewheel diode
3 LH plugging diode 16 RH blocking diode
4 Reactor 17 Fuse (FSl: For traction motor)
5 Commutation reactor 18 Fuse (FS2: For hydraulic pump motor)
6 Thyristor C 19 Fuse (FS3: For power steering motor)
7 Thyristor thermal switch 20 LH reverse contactor
8 Commutation condenser 21 LH forward contactor
9 Dropper resistor 22 B.D.L (Battery Discharge Indicator)
10 Thyristor A lamp amplifier module
II Pump lockout module 23 RH reverse contactor
12 Bypass contactor 24 RH forward contactor
13 Pump contactor 25 Thyristor B

FDC413

DC-19
 DRIVE CONTROL SYSTEM

INSULATION RESISTANCE
WIRE TO BODY
1. Disconnect battery connector.
2. Measure insulation resistance be-
tween battery connector (on the
controller side) and truck body.

Tester prove Tester

+ - indication
~ ~
~ Whit~Nfl.\'~
More than Cathode Anode coil
100 kn
o (Gate) ~,
FMA004 Anode Cathode coil ..J 0

Replace thyristor, if it shows only a

WIRE TO WIRE few il resistance.
I. Disconnect battery connector. FDC415

2. Measure insulation resistance be- Checking thyristor gate

tween two terminals of battery con-
1. Disconnect cathode terminal and Circuit tester indication:
nector (on the controller side).
gate terminal. Resistance (B probe ... cathode,
2. With circuit tester, measure resist- e probe ... gate) is smaller than
ance between gate terminal and cath. resistance (B probe ... gate, e
probe
ode terminal. ... cathode).

REMOVAL AND INSTALLATION

1 Shunt
2 R.H. plugging diode
Circuit tester indication: 3 L.H. plugging diode
More than 20 kil 4 Reactor
5 Commutation reactor
(Key switch OFF)
6 Thy ristor C
More than 300il 7 Thyristor thermal switch
(Key switch ON) 8 Commutation condenser
9 Dropper resistor
10 Thyristor A
25 Thyristor B

THYRISTOR B, C
INSPECTION
Checking puncture
1. Disconnect cathode terminal and
gate terminal (white).
2. With circuit tester set at IOOil
range, measure resistance between
FDC416
anode and cathode terminals.

DC-20
 DRIVE CONTROL SYSTEM

SCR 'B' 5. Select a new device, test, then Replace thyristor, if it shows only a
lightly smear the threaded portion few n resistance.
1. Unclip logic box from rail 'G'.
Remove connectors. and contact face with silicone grease.
2. Detach SCR gate leads at snap Replace onto controller. Tighten lock Checking thyristor gate
connectors on logic box. nut to 4.0 to 4.8 N.m (0.41 to 0.49
I. Disconnect cathode terminal and
3. Unscrew lock nut 'E' on con- kg-m, 2.95 to 3.61 ft-Ib).
gate terminal.
denser mounting plate and remove
2. With circuit tester, measure resist-
cathode lead.
ance between gate terminal and cath-
4. Using a suitable box wrench,
ode terminal.
unscrew and remove faulty SCR 'B'.
Ensure the vacant hole and area
around are wiped clean.
5. Select a new device, test, then
lightly smear the threaded portion
and contact face with silicone grease;
replace into heatsink by hand. Take
care not to damage the threads.
Tighten the SCR to 4.0 to 4.8 N.m
(0.41 to 0.49 kg-m, 2.95 to 3.61 ft-Ib).
6. Replace cathode lead to lug of
reactor 'F', taking care not to damage
reactor.
7. Reconnect gate leads at logic box.
8. Replace connectors in logic box, Circuit tester indication:
replace box on rail 'G'. Unit is now
Resistance (<B probe ... cathode,
ready for re-use.
e probe .. , gate) is smaller than
resistance (<B e
probe ... gate, probe
... cathode).

THYRISTOR A
INSPECTION

Checking puncture
6. Replace cathode lead to con- 1. Disconnect cathode terminal and
denser plate or terminal pillar. Tighten gate terminal (white).
lock nut 'E'; reconnect gate leads at 2. With circuit tester set at won
.'
logic box. range, measure resistance between
7. Replace connectors in logic, re- anode and cathode terminals.
place logic on rail 'G'. Unit is now
ready for re-use.

SCR 'C'

I. Unclip Iqgic box from rail 'G'.

Remove connectors
2. Detach SCR gate leads at snap FDC417

connectors on logic box.

3. Unscrew lock nut 'F' on lug of
Tester prove Tester
reactor and remove cathode lead
(Take care not to damage reactor). + - indication
4. Unscrew lock nut on base of
SCR 'C' and remove faulty device. Cathode Anode oen
Ensure that vacant hole and area
around are wiped clean.
Anode Cathode oen

DC-21
 DRIVE CONTROL SYSTEM

REMOVAL AND INSTAllATION THYRISTOR THERMAL

SWITCH
1 Shunt
INSPECTION
2 R.H. plugging diode
3 L.H. plugging diode I) Place the iron plate in some hot
4 Reactor
water in order to warm it up.
5 Commutation reactor
6 Thyristor C
7 Thyristor thermal switch
8 Commutation condenser
Thermometer
9 Dropper resistor
10 Thyristor A
25 Thyristor B

FDC088

2) Place thyristor's thermal switch

FDC416 on the iron plate, and check it using a
circuit tester.
1. Unclip logic box from rail 'G'. 6. *Fit new calmp 'K' making sure
Remove connectors. all location 'pips' line up. Lightly
2. Detach SCR gate leads at snap load fixing bolts 'J' until the assembly
connectors on logic box. is parallel to the heatsink. Then
3. Loosen the two fIxing bolts 'J' tighten evenly until the leaf spring is
evenly until clamp 'K' and the in- flat.
sulating block can be fitted away from CiJ : 5.2- 5.7 N.m Iron
the heatsink. (0.53 - 0.58 kg-m, plate
4. Lift shunt and slide faulty SCR 3.84 - 4.20 ft-Ibl.
out; discard old device and clamp.
Thoroughly clean contact areas on 7. Reconnect gate leads at logic
box, replace logic box connectors and FDC089
heatsink and shunt.
S. *Select new device, test, lightly refit logic box to rail 'G'. Unit is now
smear contact faces with silicone ready for re-use. Circuit tester indication:
grease. Insert under shunt with anode *NOTE on Below 95°C (203°FI
face to heatsink. Locate 'pip' in shunt Pips must line up accurately before con , Above 95°C (2Q-3°FI
in recess in cathode. clamping or both SCR and clamp
system will be permanently damaged.
PLUGGING DIODE
INSPECTION
Leaf spring (Clamp) @
I. Disconnect lead wires.
2. With circuit tester set at ohm
range, measure resistance between lead
Fixing bolt
@ wire terminals.

Shunt

Gate FDC419

DC-22
 DRIVE CONTROL SYSTEM

If tester does not register as BLOCKING DIODE

Tester probe Tester indicated in chart at left, replace
INSPECTION
+ - indication diode.
1. Disconnect lead wires.
Anode Cathode 00
2. With circuit tester set at ohm
range, measure resistance between lead
Cathode Anode Continuity wire terminals.

REMOVAL AND INSTALLATION

I Shunt
2 R.H. plugging diode
3 L.H. plugging diode
4 Reactor
5 Commutation reactor
6 Thy ristor C
7 Thyristor thermal switch
8 Commutation condenser
9 Dropper resistor (D.) FDC019
10 Thyristor A
25 Thyristor B
Tester probe
Tester
+ - indication

Anode Cathode 00

Cathode Anode Continuity

If tester does not register as

indicated in chart above, replace
FDC416 diode.

1. Unclip logic box from rail G and

remove connectors.
2. Disconnect pinch-clamp lead from FREEWHEEL DIODE
diode by slackening M5 nut, lift clamp
INSPECTION
clear. Or undo pigtail lead from
contactor, bussbar etc., noting build 1. Disconnect lead wires.
up of washers, lock washers, etc. Cut 2. With circuit tester set at ohm
ty-wrap and remove light current lead. range, measure resistance between lead
3. Using a suitable box wrench, wire terminals.
loosen and remove defective device.
Clean around face of heatsink and
threaded portion of hole.
5. Reconnect 'pinch-clamp' lead and
4. Select a new device*, lightly
tighten M5 nut or reassemble pigtail
smear silicone grease around thread
and light current lead. The light
and contact face and by hand screw
current lead should go on top of
into heatsink taking care not to cross
the pigtail lead. The pigtail lead
or damage the thread. Tighten down
should make face-to-face contact with
with a torque wrench set at 27.1 to
the bussbar, contactor, etc. Steel
31.64 N.m (2.764 to 3.227 kg-m,
washers must not be interposed of
19.989 to 23.338 ft-lb) pressure. [n] FDC420
heating due to eddy current effects
may occur.
6. Replace logic on rail G and Tester probe Tester
reconnect. Unit is now ready for use. indication
+ -
* To save time, pre-test the new device
before installation and check device Anode Cathode 00

is correct polarily for application

Cathode Anode Continuity
(stud anode or stud cathode).

DC-23
 DRIVE CONTROL SYSTEM

If tester does not register as The location of freewheel diode's COMMUTATION CONDENSER
indicated in chart above, replace anode and cathode differs from that
INSPECTION
diode. of any other diode.
1. Remove lead wire from commuta-
tion condenser.
2. With circuit tester set at won
REMOVAL AND INSTAllATION
range, measure resistance.

13 Pump contactor
14 L.H. blocking diode
15 Freewheel diode
16 R.H. blocking diode

Circuit tester pointer should first

indicate zero n and slowly return
to "infinity."
If pointer does not move as de-
scribed above, replace commutation
condenser.
FDC412

I. Disconnect pinch-clamp lead from

diode by slackening M5 nut, lift clamp
clear. Or undo pigtail lead from
contactor, bussbar etc., noting build
up of washers, lock washers, etc. Cut
ty-wrap and'remove light current lead.
2. Using a suitable box wrench,
loosen and remove defective device.
Clean around face of heatsink and
threaded portion of hole.
3. Select a new device *, lightly
smear silicone grease around thread
and contact face and by hand screw
into heatsink taking care not to cross 4. Reconnect 'pinch-clamp' lead and
or damage the thread. Tighten down tighten M5 nut or reassemble pigtail
with a torque wrench set at 27.1 to and light current lead. The light
31.64 Nrn (2.764 to 3.227 kg-m, current lead should go on top of
19.989 to 23.338 ft-Ib) pressure. the pigtail lead, the pigtail lead should
make face-to-face contact with the
bussbar, contactor, etc. Steel washers
must not be interposed of heating
due to eddy current effects. may occur.
* To save time, pre-test the new device
before installation and check device
is correct polarity for application
(stud anode or stud cathode).

DC-24
 DRIVE CONTROL SYSTEM

REMOVAL AND INSTALLATION The correct torque setting is vital to

the correct functioning of the unit;
1 Shunt under or over torque will damage the
2 R.H. plugging diode condenser.
3 L.H. plugging diode
9. Check with Avo or similar that
4 Reactor
5 Commutation reactor condenser is insulated from panel
6 Thy ristor C baseplate.
7 Thyristor thermal switch 10. Replace bolts 'J' and clamp 'K'
8 Commutation condenser and retorque as described in section
9 Dropper resistor
on SCR 'A' replacement.
10 Thyristor A
25 Thyristor B 11. Refit rail 'G' with plain washers.
Fit nut(s) 'M' and torque to 5.15 to
5.69 Nm (0.525 to 0.580 kg-m, 3.799
to 4.197 ft-Ib). Ensure that a brass
bolt is used as the fixing through
reactor.
12. Reconnect gate leads at logic box,
replace connectors in logic box.
13. Refit logic box to rail 'G'. Unit
is now ready for re-use.
FDC416

REPLACEMENT OF CONDENSER

FDC422

1. Unclip logic box from rail 'G'. 6. Remove and discard condenser.
Remove connectors. Ensure that all surfaces are clean and
2. Detach SCR gate leads at snap free from dirt and grease.
connectors on logic box. 7. Locate new, tested condenser
3. Loosen bolts 'J' evenly until over centra~ bolt, refit condenser
clamp 'K' and insulating block can be plate, paper washer, insulating bush
lifted away from the heatsink. (where fitted) and pressure plate.
4. Undo nuts 'M' and remove rail 8. Replace wave washer and nut
'G'. 'N', torque to 6.44 to 7.12 N.m
5. Undo nut(s) 'N' and remove (0.657 to 0.726 kg-m, 4.750 to 5.252
pressure plate, paper washer and ft-Ib).
condenser plate.

DC-25
 DRIVE CONTROL SYSTEM

REACTOR ever, a check can be made for an open

circuit with multimeter or continuity
INSPECTION
light.
Coil resistance is so low that an Simply measure resistance (continuity)
accurate resistive measurement (for a across the two coil leads. If open;
short circuit) cannot be made. How- replace coil.

REMOVAL AND INSTALLATION

1 Shunt
2 R.H. plugging diode
3 L.H. plugging diode
4 Reactor
5 Commutation reactor
6 Thy ristor C
7 Thyristor thermal switch
8 Commutation condenser
9 Dropper resistor
10 Thyristor A
25 Thyristor B

FDC416

1. Unclip logic box from rail 'G'. tighten nut (or bolt) to 5.15 to 5.69
Remove connectors. N.m (0.525 to 0.580 kg-m, 3.799 to
2. Detach SCR gate leads at snap 4.197 ft-lb). Ensure that a brass bolt
connectors on logic box. is fitted.
3. Loosen nuts 'M' and 'F' on coil 6. Reconnect coil terminations (re-
terminations. Note position of light member light current leads) taking
current leads. care not to damage coil.
4. Loosen coil clamp nut. Remove 7. Reconnect gate leads at logic box.
coil and discard. Replace connectors in logic box.
5. Fit new coil, align on panel and 8. Refit logic box to rail 'G'. Unit
is now ready for reuse.

DC-26
 DRIVE CONTROL SYSTEM

PUMP LOCKOUT MODULE

This module is used where the pump
motor is controlled by a contactor
only. The module is wired to the
sync bus and provides low battery
charge pump lockout together with a
signal back to the traction logic in-
crementing the hours count when the
pump contactor is closed. Pump lockout
module

Check method
When pump module is installed on
control unit, voltages should be as IT]
follows:
Normal: 0 volts
~
(V)
Pump cut unit ON: 2 volts

FDC447

B.D.I. (Battery Discharge

Indicator) LAMP
AMPLIFIER MODULE
This module is used in conjunction
with a 48V, 3W lamp to indicate
battery discharge at 25% to 00%.
The module provides the necessary
drive current for the lamp.
At 25% to 20% battery discharge the
lamp will flash simultaneously with
the display at a frequency of 1Hz.
When the display reaches 20% the BDI lamp
lamp will be continuously on to indi- amp module
cate pump lockout and a flat battery.

Check method
When amplifier module is installed on
control unit, voltages should be as
follows:
Normal: 0 volts FDC448
Low voltage lamp ON: 5 volts

DC-27
 CONTACTOR

CONTACTOR
F AND R CONTACTORS
CONSTRUCTION

Description No. OFF

CD Top cover fixing screw 4

@ Top cover 2

@ Straight link 1
@ Cranked link 2

CID Fixed contact assembly 4

@ Return spring 2
(j) Movable contact assembly 2
Single normally-closed
@ 2
contact
Double normally-closed
@ 1
contact
@ Contact insulator 4
Coil and magnet frame
(j]) 2
assembly
@ Spring armature cap 2

FDC423

INSPECTION Circuit tester indication:

About 70Q .......•.. Normal
Checking exciting coil and surge killer
coQ .•...•.•.... Exciting coil
disconnection

Checking contact point

• Ensure that the movable contact
assembly moves smoothly when
lifted, and that it returns quickly to
its original position when released.
If it does not, disassemble and
clean.

DC-28
 CONTACTOR

• If entire contactor point surface is BYPASS CONTACTOR

charred or cratered, replace con-
CONSTRUCTION
tactor.
• Check contact points for con-
tinuity.

Description No. OFF

CD Top cover fixing screw 2
@ Top cover I
FDC425 @ Terminal contact assembly 2
@ Return spring I

CID Movable contact assembly 1

Coil and magnet frame
@ 1
assembly
(j) Spring armature cap 1

FDC429

PUMP CONTACTOR
FDC426 CONSTRUCTION

Description No. OFF

FDC427
CD Cover screw and washer 2
@ Top cover 1

@ Terminal contact assembly 2

@ Return spring 1

CID Movable contact assembly I

@ Top cover base molding 1
(j) Movable c.ontact plunger 1
Coil and magnet frame
@ I
assembly
@ Spring armature cap 1

FDC428 FDC430

DC-29
 FUSE

INSPECTION Circuit tester indication:

Bypass contactor
Checking exciting coil and surge killers
About 70n Normal
(Pump contactorl
oon Exciting coil
disconnection
Pump contactor (n)
About son Normal
on Surge killer faulty
oon Exciting coil
disconnection FDC432
(n)
Checking contact point
• Ensure that the movable contact
assembly moves smoothly when
FDC431 lifted, and that it returns quickly
to its original position when re-
leased. If it does not, disassemble
and clean.
• If entire contactor point surface
is charred or cratered, replace
contactor.
• Check contact points for con-
FDC433
tinuity.

FUSE
SPECIFICATIONS

Fuse Model Rating Circuit protected Symptom when fuse melts

1 All 42SA Traction motor Truck stops.

2 All 32SA Pump motor Pump motor does not work.

3 All SOA Power steering motor Power steering motor does not work.

INSPECTION
If fuse 1, 2 or 3 melts, you will be
able to see through the clear glass.

FDC434

DC-30
 OTHER COMPONENT PARTS

OTHER COMPONENT PARTS

FR SWITCH
INSPECTION
Position _
• Test continuity through each ter-
minal. Terminal F N R

• Make sure resistance between ter-

minals @ and CID is at least 1 Mil.
---------
1
2 (
)
0
• Make sure resistance between metal 3 0
part of case and respective ter- 4 0
4 5
minals CD, @, 00, @ and CID is 5 (

at least 1 Mil.
FDC280

ACCELERATOR UNIT
CONSTRUCTION

o o

Figure 1

Connector
Chassis harness No. Color
No.
r-----------,
. No connection Yellow 1
CD 664 Y
Black @
- VE supply voltage 2 663 BLK
Output voltage Green 3 @ 665 P
Blue 4
Orange @ Not used -
Brown 5 @ Not used -
Red 6
7 @ Not used -
FS 1 White 8
Figure 3 IJ) 666 OR
~~+VEPOW~~_.:...J 9 @ 667 W
Figure 2 @ Not used -
FDC435

DC-31
 ACCELERATOR UNIT

Check method To measure voltage, attach negative

Voltage check: (-) tester probe to terminal (663)
(Connect necessary wiring and turn of connector No.2.
key switch ON.)

Voltage (Standard value)

Circuit No.
Accelerator pedal Accelerator pedal Remarks
(Connector No.)
released depressed

48 volts 48 volts
664 (l)
(battery voltage) (battery voltage)

As pedal is gradually
depressed to floor,
4.6 volts
voltage increases
665 (3) OV - O.5V (maximum pedal from 0 volt to the
depression) specified range of
4.6 volts.

48 volts 48 volts
666 (7)
(battery voltage) (battery voltage)

48 volts
667 (8) OV
(battery voltage)

If measured values excessively differ from those indicated in table above, ensure
wiring is in good condition, then replace accelerator unit.
Voltage at terminals (664), (665) and (667) can be measured on the controller
side. (Refer to WIRING DIAGRAM FOR CONTROLLER.)

DC-32
 ACCELERATOR UNIT

ACCELERATOR LINKAGE

v
A
~-:l
I i
--j
G:J 19 - 22
(1.9 - 2.2, 14 - 16)

A
G:J 3.7 - 4.9
(0.38 - 0.5, 2.7 - 3.6)
G:J 9.1-11.8
(0.93 - 1.2, 6.7 - 8.7)

Stopper bolt G:J : N'm (kg-m, ft-lb)

FDC436

ADJUSTMENT ADJUSTMENT
Linkage stroke (with accelerator pedal
fully depressed).
1. Completely depress accelerator
pedal so that accelerator unit is fully
open. With accelerator unit held in
that position, back off stopper bolt
one rotation.
2. Check accelerator pedal for
smooth operation. If it is not smooth,
coat frictional parts with multi-
purpose grease.
INSPECTION

BRAKE SWITCH Depress and release pedal several

times. Make sure switch comes on or
REMOVAL AND INSTALLATION off when pedal is depressed 7 to 13
Disconnect harness connector and re- mm (0.28 to 0.51 in) and goes off or
move lock nut. on when it is released.
Press

FBE549

DC-33
 ACCELERATOR UNIT

STEERING SWITCH
INSPECTION

Steering cam Large angle

switch

\(f E
Steering sWitc~h
for a right turn

~~ \ -~

0-0: on
FDC440

DEADMAN SEAT SWITCH INSPECTION

r Deadman seat switch

~~= " '"9' \2l
FDC441

DC-34
 ACCELERATOR UNIT

ACCELERATOR VOLUME ASSEMBLY

Q
i/:: ..~
21

Ii

FDC443

Check. method
Resistance between terminals CD and
CID: 5 K-ohms
Resistance between terminals CD and
@: 0 - 5 K-ohms
Turning accelerator volume clockwise
increases resistance between CDand
@.

DC-35
 TRACTION MOTOR

TRACTION MOTOR
TROUBLE DIAGNOSES AND CORRECTIONS

Symptom Probable cause Remedy

Motor does not start. 1. Insufficient power supply 1. Charge battery or use proper power sup-
ply.
2. Fuse blown 2. Replace.
3. Excessive load 3. Reduce load.
4. Poor or incorrect wiring connection 4. Tighten or correct.
5. Open control circuit 5. Replace.
6. Poor contact of brush 6. Clean or adjust contact pressure.
7. Open field coil circuit 7. Repair or replace.
8. Open armature coil circuit 8. Repair or replace.

Motor starts but 1. Insufficient power 1. Charge battery or use proper power sup-
vehicle does not ply.
attain rated speed. 2. Poor contact of armature circuit

Vibration or noise is 1. Faulty bearing 1. Replace.

excessive. 2. Loose bolts or nuts 2. Tighten.
3. Armature rubbing field core 3. Repair or replace faulty parts.
4. Hissing noise at brush 4. Clean or adjust contact pressure.
5. Imbalance of armature, coupling, etc. 5. Balance properly.

Bearing is overheated. 1. Improper bearing installation 1. Install properly.

2. External vibration 2. Eliminate cause of vibration or take
countermeasures for vibration.
3. Faulty bearing 3. Replace.
4. Degradation or lack of grease charged in 4. Replace.
bearing

DC-36
 TRACTION MOTOR

CONSTRUCTION

BruSh", ~
Rear ~\1)lI
bracket

FDC444

REMOVAL AND
INSTALLATION
1. Disconnect battery connector.
2. Remove floor panel assembly.
3. Remove hydraulic pump motor.
Refer to HYDRAULIC PUMP
MOTOR (Section HD) for removal.
4. Remove traction motor. Abrasion
limit line
5. , To install, reverse the order of
removal.
FDC445

INSPECTION BRUSH PRESSURE Brush spring pressure:

BRUSH WEAR LIMIT Brush pressure should be measured by 5.5.7 N
Abrasion limit line indicated on brush. spring balance. (0.56 . 0.71 kg, 1.24 - 1.57 Ib)

DC-37
 TRACTION MOTOR

INSULATION RESISTANCE

Measure insulation resistance between

yoke and each terminal, using SOOV
megger.
Insulation resistance:
More than 1MQ
Matching
mark
If insulation resistance is less than
IMQ, remove dirt or dust with dry
compressed air and wipe commutator FDC218 () FDC220
clean with dry cloth.

DISASSEMBLY AND 3. Remove brush cover.

ASSEMBLY 4. Remove brush, and retain brush 8. Lightly tap rear side bracket with
1. Remove brake disc, and then sepa- spring on brush side. a wooden mallet to remove it.
rate traction motor and front axle as- 9. Drive front side bracket out with
sembly. a puller.
Before separating traction motor and
front axle assembly, make matching
marks in order to install correctly.

s. Remove front side bracket at-

taching bolts.

10. Assembly is in the reverse order of

Be sure to hold brake rotor, not axle disassembly.
hub, and turn nuts during installation • Insert bearing into front side
and removal. bracket and secure bearing retainer
with bolts.

6. Draw out armature assembly with

Locking hole
fomt side bracket from yoke.
FDC083
7. Remove rear side bracket at-
FDC223
taching bolts from brush side.

2. Make matching marks in order to

assemble correctly.

DC-38
 ANALYZER (Option)

INSPECTION 1. Sand lightly with No. 500 or No. Diameter limit:

Commutator
600 sandpaper. The wear limit of com- 68.5 mm (2.697 in)
mutator depth is 1.5 mm (0.059 in). If [Initial 73 mm (2.87 in)]
• Remove oil or dust from commuta- the diameter of commutator is less
tor using air blower and wiping than specified value, replace armature
commutator clean with dry cloth. assembly.
• If the surface of commutator is 2. Remove dirt or dust with air
rough, it must be polished by the blower and wipe commutator clean
following procedure. with dry cloth.

ANALYZER (Option)

SETUP PROCEDURES f) With the link in place return to the START.UP CHECKS

To use the ANALYZER the following drivers seat, ensure drive controls When power is first applied, the con-
are in neutral, connect the battery, troller carries out initial safety checks
procedures must be followed.
and turn the key switch on. and power-up sequence tests.
g) Display will appear after key
switch is turned on.
RUN.TIME PROCEDURE CHECKS
h) Remove service or edit link. (Neces-
sary in order to check harness). These tests make sure the correct
i) Harness check begins. Malfunction drive sequences are being used and
diagnosis begins. that the controller is operating within
its limits while in use. Procedure
numbers displayed are prefixed by the
letter "P" and are generally classed as
DIAGNOSTICS warnings rather than faults.
The MCM controller incorporates com-
prehensive diagnostics, capable of RUN-TIME FAULT CHECKS
diagnosing faults in the panel instal- These diagnostics run continuously
lation, vehicle motor and customer when the vehicle is operating, and
a) Ensure the battery is disconnected wiring. The diagnostics are normally shut down the controller in a safe,
and the key switch is off. shown as numbers on the display unit controlled manner if a fault is detect-
b) Jack vehicle up, drive wheels must and have different effects on con- ed. These faults are prefixed by the
be clear of the ground. troller operation. The audi'ble sounder letter "F".
c) Gain access to the logic box mount- in the display head bleeps 3 times
ed on the panel. when a diagnostic number is displayed MAINTENANCE CHECKS
d) With the logic box still clipped into (see fault logging and fault displaying
These diagnostics are used to check
position and the non-connector side section for extra information).
the vehicle harness switches and
of the box showing, remove the Detailed information on each diag-
contactor operations, normally before
grommet (opposite corner from 24 nostic can be found at the end of this
panel installation or when a wiring or
way BICC connector) revealing 2 section.
vehicle control fault is suspected.
sockets. (Necessary in order to Diagnostics fall into 4 main areas:
Each vehicle truck control and each
check harness). a) Start up checks.
controller contactor will be tested in
e) Fit the supplied "service link" or b) Run time procedure checks.
turn using a step sequence test.
"edit link" in the sockets. (Neces- c) Run time fault checks.
sary in order to check harness). d) Maintenance checks.

DC-39
 ANALYZER (Option)

Example - If the reverse cOntactor is the display indicating that the pro- i. FSI is open.
to be tested cessor is outputting a drive for a con- ii. The contactor coil and mechani-
Switch between forward and reverse tactor. If "On" is not displayed when cal assembly are faulty.
until test No. 11 is indicated at the reverse is selected it may be for safety iii. Contactor wiring and connectors
left of the display. Close FS 1 and reasons. Check that: are faulty.
select reverse, the contactor will close i. The main heatsink is greater iv. The logic con tactor drive is faulty.
and the buzzer will sound. Select than 3 volts and less than the Test No. 15 displays the accelerator
neutral and the 'contactor will open. battery volts. (It should be ap- output in the form of numbers at the
The harness contactor checks are proximately 1/2 battery volts). right-hand side of the display increas-
visual; only inspection of the con- ii. The hardware failsafe has not ing from 0 to 99 as the accelerator is
tactor is required to verify correct tripped (Fault F42 in drive). depressed.
operation. For example, if the field iii. The logic contactor protection has When FSI is closed, the middle seg-
weakening contactor is not fitted, not tripped due to a contactor ment of the display is lit.
test 13 will still show 'on' and sound fault (Fault F43 in drive). Test No. 16 is similar to 15, but it
the buzzer when the test is begun. checks the spare analog input.
If "On" is displayed but the selected A complete list of checks follows.
During contactor checks, the display
contactor does not close, this may be
will show "On" at the right hand of
because:

DC-40
 ANALYZER (Option)

HARNESS CHECK DESCRIPTIONS

Display if test operating

Test No. Tests Display if not operating
(Switches req.)

01 Forward direction switch 01: on buzz 01: off no buzz

(Forward)

02 Reverse direction switch 02: on buzz 02: off no buzz

(Reverse)

03 Accelerator (FS I) switch 03: on buzz 03: off no buzz

(FSI)

04 Seat/Deadman switch 04: on buzz 04: off no buzz

(Seat/Deadman)

05 Outer steer switch 05: on buzz 05: off no buzz

(Outer steer)

06 Left steer switch 06: on buzz 06: off no buzz

(Left steer)

07 Not used

08 Inner right steer switch 08: on buzz 08: off no buzz

(Right steer)

09 Left forward contactor 09: on buzz 09: off no buzz

(Reverse) + FS 1

10 Left reverse contactor 10: on buzz 10: off no buzz

(Reverse) + FS 1

11 Right reverse contactor 11: on buzz 11 : off no buzz

(Reverse) + FS 1

12 Bypass contactor 12: on buzz 12: off no buzz

(Reverse) + FS I

13 Right forward contactor 13: on buzz 13: off no buzz

(Reverse) + FS 1

14 Not used

15 Accelerator potentiometer 15: 0 - 99 (0 - 5V) 15: 0 - 99 (0 - 5V)

(Segment lit when FSI closes) (Accelerator + FSl)

16 Spare analog input 16: 0 - 99 (0 - 5V) 16:0-99(0-5V)

(Inpu t voltage)

17 Not used

18 BDllowoutput 18: on buzz 18: off no buzz

(Reverse)

DC-41
 ANALYZER (Option)

FAULT DESCRIPTIONS AND ACTIONS

DISPLAY DESCRIPTION AND ACTION

P.OI INCORRECT POWER UP SEQUENCE.

Cause Direction or FSI selected before key switch.
Condition A direction or FSI input> 3V before key switch operated.
Effect Vehicle not operable.
Action Rewind direction and FSI to neutral.
Make sure a) Correct sequence used.
b) Direction and FSI switches are operating correctly.
c) Wiring to switches is correct.

P.02 INCORRECT DRIVE SELECTION.

Cause FSI selected before a direction.
Condition FSI input> 3V 2.5 secs. or more before a direction input> 3V.
Effect Vehicle not operable.
Action Rewind FSI to neutral.
Make sure a) Correct sequence is used.
b) Direction and FSI switches are operating correctly.
c) Wiring to switches is correct.
Notes There is a 2-second delay before fault indication if FS I is opened
while a direction is being selected.

P.03 BOTH DIRECTIONS SELECTED SIMULTANEOUSLY

Cause Forward and reverse directions or forward and reverse inching buttons sr
selected together.
Condition Forward and reverse inputs are> 3V.
Effect Vehicle not operable.
Action Rewind both directions to neutral.
Make sure a) Only one direction is selected.
b) Direction and inching switches are operating correctly.
c) Wiring to switches is correct.

P.06 SEAT/DEADMAN SWITCH OPEN.

Cause Seat/deadman switch opened in drive for more than 2.5 seconds.
Condition Seat/deadman switch input> 3V during drive.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind direction and FSI to neutral.
Make sure a) Seat/deadman switch is closed.
b) Seat/deadman switch is operating correctly.
c) Wiring to switch is correct.

P.09 - 10 RESERVED FOR FUTURE USE.

DC-42
 ANALYZER (Option)

DISPLAY DESCRIPTION AND ACTION

P.II THERMAL CUTBACK.

Cause Panel temperature exceeding 95°C (203°F). The thermal switch has operated.
Condition Thermal input voltage is at 5V with the switch open.
Effect Vehicle operable but with restricted performance.
With the thermal switch option current limit is reduced to 50%.
Actions Allow controller to cool down, return the economy potentiometer to its
100% setting or select neutral to clear the display.
Make sure a) Controller is operating within specified limits.
b) Controller is mounted and installed following installation instructions.
c) Thermal switch is operating and wired correctly.

P.12 - 20 RESERVED FOR FUTURE USE.

F.21 FORWARD CONTACTOR DID NOT CLOSE.

F.22 REVERSE CONT ACTOR DID NOT CLOSE.

Cause Forward/Reverse contactor did not close when demanded.
Condition Main heatsink < 6V below battery voltage 200 ms after contactors requested
to close.
Effect Vehicle not operable.
Action Rewind key switch to clear display .
Make sure a) There are no obstructions between contractor tips.
b) Contactor tips are not excessively worn.
c) Contacts close/open normally make and good connection.
d) There are no slow operating contactor (> 200 ms close time).
e) Main connections to contactors are secure.
f) Coil connections to contactor are secure.
g) There are no open circuits or incorrectly connected motors.
h) There are no open circuit traction fuses.

F.23 FORWARD CONTACTOR DID NOT OPEN.

F.24 REVERSE CONTACTOR DID NOT OPEN.

Cause a) Forward/Reverse contactor did not open when demanded.
b) Main heatsink at battery volts after key switch on.
Condition Main heatsink > 3V below battery voltage 200 ms after contactors requested
to open, or immediately after power up.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind key switch to clear display.
Make sure a) There are no short circuits between contactor tips.
b) Contactor tips are not welded.
c) Contactor is not jammed shut.
d) There are no slow-operating contactors (> 200 ms open time).
e) Freewheel or plugging diodes are not short circuited.
f) Motor is connected correctly and not short circuited.
g) There is no excessive leakage from battery +VE to truck frame.

DC-43
 ANALYZER (Option)

DISPLAY DESCRIPTION AND ACTION

F.26 BYPASS CONTACTOR DID NOT OPEN.

Cause Bypass contactor did not open when demanded.
Condition Main heatsink < 5V 200 ms after contactor requested to open.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind key switch to clear fault display.
Make sure a) Check contactors for short circuits between tips.
b) Contactor tips are not welded.
c) Contactor is not jammed shut.
d) There are no slow-operating contactors (> 200 ms open time).
e) Check for short circuit across SCR A.

F.27 - 30 RESERVED FOR FUTURE USE.

F.3l MAIN SCR A FAILED TO COMMUTATE OFF IN DRNE.

Cause Main SCR A failed to turn off.
Condition Main heatsink < 5V 400 pS after SCR B fired.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind key switch and battery connector to clear fault display.
Make sure a) Gate and main connections to SCR Band SCR C are secure.
b) SCR Band SCR C devices are not faulty.
c) Current does not exceeding controller rating.
d) There is no short circuit across SCR A.
e) SCR A device and connections are OK.
f) Commutation condenser is OK and mounted are correct.
g) Commutation reactor and connections are OK.
h) There is no incorrectly connected or open circuits on motor.
i) All shunt connections and polarity are correct.

F.32 MAIN SCR A FAILED TO TURN ON IN DRNE.

Cause Main SCR A failed to turn on.
Condition Main heatsink < 5V 100 p.S after SCR A fired or 100 pS before SCR B fires.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind key switch to clear fault display.
Make sure a) Check gate and main connections to SCR A are secure.
b) SCR A device is not faulty.
c) SCR Band SCR C are not short circuited.
d) SCR Band SCR C are not open circuited.
e) There is no incorrectly connected or open circuit motor.

F.35 MAIN SCR A FAILED TO COMMUTATE OFF IN PLUGGING.

Cause Main SCR A failed to turn off in plugging or after direction change.
Condition Main heatsink < 5V 400 p.S after SCR B fired.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind key switch and battery connector to clear fault display.

DC-44
 ANALYZER (Option)

DISPLAY DESCRIPTION AND ACTION

F.35 Make sure a) Check gate and main connections to SCR Band SCR C are secure.
b) There are no faulty SCR Band SCR C devices.
c) Current does not exceeding controller rating.
d) There are no short circuits across SCR A.
e) SCR A device and connections are OK.
f) Commutation condenser is OK and mounted correctly.
g) Commutation reactor and connections are OK.
h) There is no incorrectly connected or open circuits on motor.
i) All shunt connections and polarity are correct.

F.36 MAIN SCR A FAILED TO TURN ON IN PLUGGING.

Cause Main SCR A failed to turn on in plugging or after direction change.
Condition Main heatsink < 5V 100 J.1.Safter SCR A fired.
Effect Vehicle coasts to a halt and becomes inoperable.
Action Rewind key switch to clear fault display.
Make sure a) Gate and main connections to SCR A are secure.
b) SCR A device is not faulty.
c) SCR B or SCR C are not short circuited.
d) There is no incorrectly connected or open circuits on motor.

F.39 - 40 RESERVED FOR FUTURE USE.

F.41 CONTROLLER IN AN UNSAFE CONDITION.

Cause Main heatsinkfmotor connection is at battery negative when drive not
selected.
Possible unsafe condition.
Condition Main heatsink < 5V in the neutral condition. Under normal conditions it
is approximately 40% - 60% of battery volts.
Effect Vehicle not operable.
Action Rewind key switch and battery connector to clear fault display.
Make sure a) Bypass contact or welded or jammed is secure.
b) Short circuits on controller between main heatsink and battery negative
are secure.
c) Main SCR A is not short circuited.
d) Freewheel diode is not short circuited.
e) There are no voltage dips or spikes from the controller or other equip-
ment on the battery when fault occurs.
f) All shunt connections and polarity are correct.
g) Key switch has been rewound correctly. (Rapid recycling of the key
switch may give an F.41 under certain circumstances.)
h) There is no excessive leakage from battery -VE to truck frame.

DC-45
 ANALYZER (Option)

DISPLAY DESCRIPTION AND ACTION

F.42 HARDWARE FAILSAFE TRIPPED.

Cause Main heatsink/motor connection is at battery negative for longer than 80 ms.
Condition Main heatsink < 2.5V dUring pulsing for longer than 80ms.
Effect Vehicle not operable.
Action Rewind key switch and battery connector to clear fault display.
Make sure a) Bypass contact or is not welded or jammed.
b) There are no short circuits on controller between main heatsink and
battery negative.
c) Main SCR A is not short circuited.
d) Freewheel diode is not short circuited.
e) There are no voltage dips on the battery when fault occurs.

F.43 CONTACTOR PROTECTION TRIPPED.

Cause One of the 6 contactor drive outputs from the logic is short circuit to battery
positive or connected via a low resistance approximately < 10 Ohms.
Condition Contactor drive transistors are sWitching> 10 Amps.
Effect Vehicle not operable.
Action Rewind key switch to clear fault display.
Make sure a) Contactor wiring is correct.
b) Contactor coils are not short circuited.
c) Battery positive is not short circuited.
d) Key switch has been rewound correctly.
(Rapid recycling of the key switch may give an F.43 under certain
circumstances.)

F.44 ACCELERATOR FAULT.

Cause Maximum accelerator input without FSI closed, or immediate maximum
accelerator when FS 1 first closed.
Condition Accelerator input >4.7V with no FS 1 or immediately after FS 1.

Effect Vehicle not operable.

Action Rewind key switch to clear fault display.
Make sure a) - VE connection to accelerator.
b) Remaining connections to accelerator are secure.
c) Accelerator produces a varying output voltage in response to accelerator
movement from 0 to 5V.
d) None of the external modules connected with the accelerator violate the
test conditions.
e) Accelerator wiring is not reversed.

F.45 POWER DIPPED OR POWER LOSS FAULT-.

Cause Power removed or dipped.
Condition Power supply input to the logic from the dropper resistor is < 13V for> 2.5
ms.
Effect Vehicle not operable.
Action Rewind key switch to clear fault display.

DC-46
 ANALYZER (Option)

DISPLAY DESCRIPTION AND ACTION

F.45 Make sure a) Battery voltage at time of falt is correct.

b) Connection from battery and key switch are secure.
c) There are no voltage dips or spikes from the controller or other equip-
ment on the battery when fault occurs.
d) Correct dropper resistor is fitted for battery voltage.

F.46 EDITOR ADJUSTMENT RESET.

Cause Editor adjustments/personalities corrupted.
Condition Logic detects a check sum error in the non volatile memory used for
storing the editor adjustments, after key switch on.
Effect Warns that any adjustments made following delivery of the controller will
be lost. A preset range of adjustments or baseline personalities are loaded
into memory and used by the controller. These baseline personalities allow
the controller to operate safely although the controller may have to be set up
again obtain the correct performance.
Action Rewind key switch or select drive to clear fault display.
Make sure a) Controller correctly is wired and installed.
b) All contactors not driven from the logic have been suppression fitted.
c) There are no large voltage drops in the battery negative connections.
d) There is no EMI noise or transients from other equipment.
e) All power diodes are working correctly.
f) Vehicle horn is suppressed.
g) Logic negative is true negative and not via a contactor coil or other low
resistance.

F.47 LOW BATTERY TERMINAL VOLTAGE

Cause Battery voltage has been detected at < 60%.
Condition Measured battery voltage < 60% of nominal battery voltage set in personality
number 16 for> 10 ms only when the BDI display is O.
Effect Vehicle operable. Warning only. No further action is taken.
Action Rewind key switch to clear fault display.
Make sure a) Battery is fully discharged.
b) Personality 16 is set up correctly for battery voltage.
c) There are no voltage dips or spikes from the controller or other equip-
ment on the battery when fault occurs.

F.48 NOT USED AT PRESENT.

DC-47
 ANALYZER (Option)

DISPLAY DESCRIPTION AND ACTION

F.49 MICROPROCESSOR MALFUNCTION

Cause The logic software has detected a malfunction in the microprocessor

system.
Condition A software "watchdog" timer has timed out.
Effect Vehicle not operable.
Action Rewind key switch to clear fault display.
Make sure a) There is no "noise" on logic power supplies.
b) Voltages at dropper resistoris correct.
• Battery volts on red wire
• Greater than 12 volts on purple wire (when controller is pulsing)

NUMBERS ABOVE F.49 NOT USED AT PRESENT.

DC-48
 ANAL YZER (Option)

SHORT FORM DIAGNOSTIC LIST

MAIN DIAGNOSTICS HARNESS DIAGNOSTICS

P.01 Incorrect power up sequence 01 Forward switch
P.02 Incorrect drive selection 02 Reverse switch
P.03 Both directions selected together 03 FSI switch
P.04 Not used 04 Seat/Deadman switch
P.05 Not used 05 Outer steer switch
P.06 Seat/safe switch fault 06 Inner left steer switch
P.07 Not used 07 Not used
P.08 Not used 08 Inner right steer switch
P.11 Thermal trip 09 Left forward contactor.
F.21 Forward contactor did not close 10 Left reverse contactor.
F.22 Reverse contactor did not close 11 Right reverse contactor.
F.23 Forward contactor did not open 12 Bypass contactor
F.24 Reverse contactor did not open 13 Right forward contactor.
F.25 Not used 14 Not used
F.26 Bypass contactor did not open 15 Accelerator input
F.31 Main SCR A failed to turn off in drive 16 Spare analog inpu t
F.32 Main SCR A failed to turn on in drive 17 Not used
F.33 Not used 18 BDllowoutput
F.34 Not used
F.35 Main SCR A failed to turn off in plugging
F.36 Main SCR A failed to turn on in plugging
F.41 Controller unsafe, main heatsink at OV
F.42 Hardware failsafe tripped
F.43 Contactor protection tripped
F.44 Accelerator fault
F.45 Power dipped or power loss
F.46 Editor adjustments reset
F.47 Low battery terminal voltage
F.48 Not used at present
F.49 Microprocessor malfunction

DC-49
 WIRING DIAGRAM FOR CONTROLLER

WIRING DIAGRAM FOR CONTROLLER

• ,---:o~,. !---L---- .
BL~ Al IC I ~ ':

BL . 3 81 : I : ' 01 SPLAY UNIT

(OPTION)
y y' : ':

SCREEN CABLE o 5 V : ' ~ I

0) SCREEN CABLE

0)'

y. """~
0)
,.- ----- ------ -- f-------
0)'
~ - L--.J
- --~ /'

1\
~gj :0-11--
U U
~ "''--...
'-Vl

u • ~ /< OVl

"''''
oa:: ""'7"'1. v

- ~TOR

• >
I I I
• >

/ \
I V/
rrrrH ~
..
I
.... L2
m

0 ~ BYPASS
~
'-'

~
W 12l

o.
BATTERY-
+
- -
~S~~RDL

-o:>-<:D- - - -
KEY SWI TCH

-d""'o- - --,

Q. w~
CONTACTOR
I
I
I () (
~~ SCRA
"
~ BDI LAMP
AMPLI F I ER MODULE
PUMP LOCKOUT MODULE
I
I
"
/'
z
U ~ rTTl.
THERMAL
sWI TCH

I SHUNT AA
h V'

.
~
~ [
~ ..
9po ] L~~JfJ]
~I '1 ul "I
I I I I
j
I
I

L_ ~
\---------- -------- -
CONNECTOR
BLK b-l
A
I
I
I

.J --.J I
I I VALVE
I I L - - - - ~o-
SWITCH
__ -,
I
I
I
I

~o--
:~==============j=j------------~--~
_o"""o-!~~~~t:!!...;;!E~!.!'l~-
'I~o-I--o"""o-!~~..!:~~~~~~ II
-- - -- -- - ----- ----J.
I
BL 0- ~_o"""0-9u.f~ ~~~'!!~ - - ~ I I
L. -<1"""0- -' II I
v b-l- _o"""o-E~RW~~ .-J.: :
.N 0- _o"""~~~~ .J I I

III
~~=~=========j.::;--------------~
.... 0-5__ ::::-]:::" -'1 I I
:
I
II BL 0- - - - e- - - - - - - - - - - -Ill I I
I ...
II
b-'---I-----------.J I I I
. ~--~-----------"~-------------I~-~
----... To power steer Ing __ ~ - - ~ - - - - SEAr - - - - - Ii rJ - Not used I I
D" 0- - - .J - _0"""0- - - - - - - --' I I I Not used I I
I • Q-J.l--.J------------1-r_ Not used ~ I I
• 0- - __ 1__ ~BQI-L'!W-L~M!: _..J II • • • I

b
PS

MOTOR ARMATURE L. H. • Ii >

I ~t!1 (
~t Q-J.,__ .J II ,-- 66 - 6 - b6

M~LH.
W(2)
LOA e) =rr-
woo,
4r=
W'"
'OA

W(2)
::l
u.
z
... ''":::
0
LI1
'"
Vl
::l
u.
'"
LI1
'"
'"
i:"
Vl ;; PUMP
~~
CO~N~~:;
~==: ~:~~::: l~ 511J FS~~l,
~:~
..
REVERSE
CONTACTOR
L. H.
FORWARD
CONTACTOR
L. H. ,
REVERSE
CONTACTOR
R. H.
FORWARD
CONTACTOR
R. H.
'-----
U
D.-
>:
::l
'-
Ol

'"~~
'" "''''
LI1 CONTACTOR ,.....,...
Not used _ - - -<)' -I I I
.• w • P
'"
::" o..u.
MOTOR ARMATURE R. H.
\ ~----~
LFF LF ( OF OFF ACCELERATOR
~A

I
MOTOR FIELD

r=r
R. H.

I ~
BATTERY

0----;1~-1~
_----=---:F
BATTERY LI NE Dr SCONNEcT

FDC452

DC-50
 WIRING DIAGRAM FOR CONTROLLER

Logic plug" AU

Logic plug "A" Detail

1 SCR C gate

2 SCR B gate

3 Logic supply .ve

4 SCR C anode

5 SCR C cathode

6 SCR B cathode

7 Dropper resistor in

8 Dropper resistor ou t

9 SCR A anode

10 SCR A cathode

11 Polarising pin

12 Shunt + ve input

13 Shunt .ve input

14 Not used

15 L.H. motor plug input

16 Thermal switch

17 SCR A gate

18 Battery .ve

19 Battery .ve

20 Battery .ve

21 R.B. motor plug input

22 -•._. not used .._-

23 Armature bottom/(AA)

24 '-_.. not used .....

DC-51
 WIRING DIAGRAM FOR CONTROLLER

Logic plug "B"

Logic plug "B" Detail INPUT/OUTPUT voltage Controller harness No.

1 Not used - -

2 Accelerator pot wiper 0- 5V (Accerator) (Connector B)

3 Bypass contactor output - -

4 Accelerator pot - ve - -
Dual motor right
5
reverse contactor output
- -

Dual motor left

6
reverse contactor output
- -

7 Reverse direction input 48V (FR SW R SELECT) (Connector B)

8 Forward direction input 48V (FR SW F SELECT) (Connector B)

Dual motor right

9
forward contactor output
- -

10 Start switch (FSl) input 48V (FSI SW ON) (Connector B)

11 Keyswitch input 48V (KEY SW ON) (Connector B)

Dual motor left

12
forward contactor output
- -

13 Not used - -
14 Accelerator pot + ve Approx.5V (Connector B)

15 Pump sync/BDI cutout - -

16 Seat switch input 48V (SEAT SW ON) (Connector B)

Dual motor 48V (STRG SW INNER)

17 (Connector A)
inner left steer switch LEFTON

18 Spare analog input o- 5V (Accel. Vol.) (Connector B)

19 Not used - -
Dual motor
20 48V (STRG SW OUTER ON) (Connector A)
Outer steer switch input

Dual motor 48V (STRG SW INNER)

21 (Connector A)
Inner right switch input RIGHT ON

22 Not used - -
23 BDI low output - -
24 Battery - ve OV -

DC-52
 WIRING DIAGRAM FOR CONTROLLER

Logic plug "e"

Logic plug "c" Detail

1 -ve supply

2 Data

3 Clock

4 Polarising key

5 Not used

6 +ve supply

DC-53
 WIRING DIAGRAM FOR CONTROLLER

Connector A

LOADING
To Controller harness
00 654

321
669 671 674

682 683 684

To Chassis harness

Controller Input signal or Chassis Chassis

Detail I/O
harness No. Output load harness No. harness color
1 CONTACTOR COIL- - - 682 W
2 CONTACTOR COIL + - - 683 OR
3 PUMP SINC OUTPUT CIRCUIT 684 GY

STEERING
Controller Input signal or Chassis Chassis
Detail I/O
harness No. Output load harness No. harness color
4 INNER RIGHT STEERING SWITCH INPUT MECHANICAL CONTACT 669 L
5 INNER LEFT STEERING SWITCH INPUT MECHANICAL CONTACT 671 G
6 OUTER STEERING SWITCH INPUT MECHANICAL CONTACT 674 Y

Connector B

15 12
CJ
9 6 3
•
To controller harness 14 11 8 5 2 To chassis harness

13 10 7 4 1

TRACTION

Controller Input signal or Chassis Chassis

Detail I/O Output load
harness No. harness No. harness color
1 FORWARD SWITCH INPUT MECHANICAL CONTACT 661 L
2 RPVERSE SWITCH INPUT MECHANICAL CONTACT 662 GY
3 FS1SWITCH INPUT MECHANICAL CONTACT 667 W
4 ACCELERATOR POT (+) OUTPUT CIRCUIT 664 Y
5 ACCELERATOR POT (-) OUTPUT CIRCUIT - -
6 ACCELERATOR POT (V) INPUT ANALOGUE 665 Pu
7 GND - - - -
8 KEY SWITCH INPUT MECHANICAL CONTACT 686 OR
9 NOT USED - -
10 SEAT SWITCH INPUT MECHANICAL CONTACT 685 G
11 NOT USED - -
I--
12 BDI LOW OUTPUT OUTPUT LAMP 312 OR
13 ANALOGUE INPUT INPUT ANALOGUE 677 P
14 NOT USED - -
15 NOT USED - -

DC-54
 Service Bulletin
Issue : SB 0407
Date : July 2004

Applied model: (G)N01 with (SEM controller)

Subject: Neutral brake setting

Introduction:
We have received several complaints about the regenerative function which stays activated even
with travel speed zero. This is causing a heated up traction motor.
This continuously on regen function only occurs when the accelerator pedal is pressed rapidly
on/off and when the neutral brake personality setting is set between 0 and 20 Amps.

Solution:
The neutral brake personality setting should be changed.

Instruction:
Only the following settings can be used:
• 0 A (factory setting)
or
• 20A and higher
• (Values between 0 and 20 are not allowed and will cause problems)

Use the CAN calibrator

Select:
1 Traction
Traction personality 1.1
Ntrl Regen 1.1.7
Adjust value to 0 or 20 and higher

The information in this bulletin should not be interpreted as base for claims, unless so designated

Page 1 of 1 3/26/2007
 CONTENTS

1. Introduction

2. System description
2.1 Outline
2.2 Potentiometers
2.3 Control valve
2.4 Control valve specifications
2.5 Electric components

3. Calibrator
3.1 Hours counter
3.2 Pump personalities adjustment
3.3 Pump status information
3.4 Pump test

4. Fault finding flow charts

5. Diagrams
September 1998 FCS 98-N01

Model : GN01 / N01 1997 model

Subject : Pump controller

1. Introduction:
This technical bulletin explains the Sevcon 'MOS90' pump controller which is
available as an option from November 1998 NFESA production.
With this system it is possible to adjust the percentage "on" time for 4 ports (lift,
tilt, 3rd & 4th spool) separately and the acceleration delay applying to these ports
(one setting for all ports).
Please add this Technical Bulletin in chapter "DC" of the existing N01 service
manual (publication no. SM2E-0N01E1).

2. System description:
2.1 Outline

Figure 1& 2 & 3

Traction controller Traction controller

no pump controller with pump controller
fitted fitted
N01-STD 29310-31K60 29310-31K70 *
N01-HP 29310-31K61 29310-31K71 *

* Location of some components has changed (e.g. main fuses).

Pump contactor has been removed.

2.2 Potentiometers
Besides the potentiometer for traction acceleration, two potentiometers have been
added to the meter panel (figure ..)
The upper one is to adjust the acceleration of the pump motor for all functions;
lift, tilt, 3rd and 4th spool valve.
The lower one is to adjust the maximum lifting speed.

2.3 Control valve

 The specifications of the tilt spool have been changed.
For standard models 1.5 & 1.75 ton the relief orifice diameter was changed from
ø 2.0 mm to ø 1.8 mm.
For the HP 1.6 ton model the tilt back orifice diameter was changed from ø 2.3 to
ø 2.8 mm and relief orifice diameter from ø2.4 to ø 2.0 mm

N01
Standard High performance
1.5 & 1.75 ton 1.6 ton
Standard With Standard With
pump pump
controller controller
Tilt Meter in 3.1 3.1 3.1 3.1
spool (orifice "w")
spec.
Tilt forward 1.6 1.6 1.6 1.6
(orifice "x")
Tilt backward 2.8 2.8 2.3 2.8
(orifice "z")
Bleed off 2.0 1.8 2.4 2.0
(orifice "y")

Figure 4

2.4 Control valve specifications:

Figure 5

2.5 Electric components:

Compared with the standard model, the 'pump controller' model has different
circuits of control valve switches, loading speed adjustment potentiometer and
circuits of loading acceleration adjustment potentiometer.

2.5.1 Control valve switch

checking and adjustment procedure of the switch itself is the same as for
standard model without loading chopper.
Check of valve harness (see list below)

Figure 6
 Terminal Operation Continuity
1-3 Tilt ON
1-2 Lift ON
1-4 3 spool ON
1-5 4 spool ON

2.5.2 Loading speed and acceleration adjustment potentiometer

The same potentiometer is used for drive acceleration and it can be
checked in the same way.

3. Calibrator
The calibrator used for the pump controller is different from the one used for the
traction controller.
Figure 7

The part number for this calibrator is: 29499-31K70.

With the calibrator the hours count is displayed (3.1), pump personalities can be
adjusted (3.2), pump status can be read (3.3) and the wiring harness, potentiometers
and switches can be checked (3.4). Refer to the tree structure shown below.

Figure 8

3.1 Hours counter

When the calibrator is first plugged in, the display shows the hours reading.
Initially a minute/second count is displayed. By pressing the '-' button, hours are
displayed and by pressing the '+' button 1,000s of hours are displayed.
E.g., a count of 1,436 hours 27 minutes and 20 seconds would be:
- Initial display would be 27.2 indicating 27 minutes, 20 seconds.
- Hold down '-' button to display hours, i.e. 436
- Hold down '+' button to display 1,000s of hours, i.e. 1.
Releasing the buttons reverts back to the minute and 10's of second display. The
decimal point 'blinks' every second during drive (read pump usage). The counter will
record up to 65,500 hours before rolling over to '0'.
 3.2 Pump personalities adjustment
The following personalities can be adjusted:

Calibrato Function Settin Min. Max. Unit Adjustable Adjustable using

r g yes / no
Speed 1 Lift speed 100 0 100 % Yes Volume or calibrator
Speed 2 Tilt speed 85 0 100 % Yes Calibrator
Speed 3 3rd spool function 40 0 100 % Yes Calibrator
speed
Speed 4 4th spool function 100 0 100 % Yes Calibrator
speed
Speed 5 5 speed (not usable) 100 0 100 % No -
Speed 6 6 speed (not usable) 100 0 100 % No -
Speed 7 7 speed (not usable) 100 0 100 % No -
Speed 8 8 speed (not usable) 100 0 100 % No -
Creep Pump creep (not 0 0 25 % No -
usable)
Ramp Acceleration delay for 0.2 0.1 5.0 Sec Yes Volume or calibrator
lift, tilt, 3 and 4 spool
Extra Additive % (not 0 0 100 % No -
usable)
I. Max. Maximum current 400 50 400 Amp Yes Calibrator

- connect the calibrator to the controller as shown below and power up the
truck.
Figure 9

- No LED segment will be lit and the minutes/seconds count is displayed.

Pressing the 'select' button reverts the calibrator to its normal operation,
i.e. the I. Max segment (left top corner) will be lit. Please note, this is
"Speed 1, Lift speed" as the calibrator is used on a pump controller.
- When the desired parameter has been selected, it may be increased or
decreased by means of the '+' and '-' buttons on the right of the calibrator.

Figure 10

3.3 Pump status information

Following the tree structure from 1.2.4 by pressing the 'select' button, the
actual battery voltage, motor voltage, motor Amps and heatsink temperature is
displayed.

Cal. ref. Parameter displayed Min. display Max. display

 1.2.1 Pulsing minutes 0 59.5
1.2.2 Pulsing hours '-' 0 999
1.2.3 Pulsing hours x 1000 '+' 0 65
1.2.4 Battery voltage (nom) 0.0 V 99.5 V
1.2.5 Battery voltage (max) '+' 0.0 V 99.5 V
1.2.6 Motor voltage 0.0 V 99.5 V
1.2.7 Motor current 0.0 Amp 1020 Amp
1.2.8 Pump controller temp (nom) - 50 ° + 205 °
1.2.9 Pump controller (max) '+' - 50 ° + 205 °
+ = displayed by pressing '+' on calibrator
- = displayed by pressing '-' on calibrator

3.4 Pump test

When selecting the last segment 'Test' on the calibrator, the wiring harness,
potentiometers and switches can be checked.
If the 'select' button is pressed at any time during the tests, they will be terminated
and the minutes/seconds count will be displayed.

SAFETY
WHEN TEST IS SELECTED, THE TRUCK CAN STILL OPERATE !

From 'Test' press the '+' or '-' button to select the next or previous test.
To do the actual test, operate the potentiometer or switch and check its function.
The first test selected is the potentiometer test. This displays pump acceleration
output as 0 - 100% as the potentiometer is turned from min. to max.

Cal. ref. Input displayed Min. display Max. display Remarks

1.3.1 Speed pot. 0% 100% To adjust the maximum lifting speed
1.3.2 Pump switch 1 1.OP 1.CL To check the tilt switch
1.3.3 Pump switch 2 2.OP 2.CL To check the lift switch
1.3.4 Pump switch 3 3.OP 3.CL To check the 3rd spool switch
1.3.5 Pump switch 4 4.OP 4.CL To check the 4th spool switch
1.3.6 Pump switch 5 5.OP 5.CL
1.3.7 Pump switch 6 6.OP 6.CL
1.3.8 Pump switch 7 7.OP 7.CL
1.3.9 Pump switch 8 8.OP 8.CL
1.3.10 Inhibit 10.OP 10.CL

Control valve switches

display Normal condition
Switch OFF OP
Switch ON CL Continuity

Note: 1.3.10 'Inhibit'

CL: Pump cut system will operate when the battery voltage drops below a certain
level.

4. Fault finding flow charts

The condition of the controller can be checked by means of the LED.

LED Problem
Off Mosfets did not turn on
2 flashes Pump inhibit input operating
3 flashes Short circuit across Mosfets, or motor open circuit
7 flashes Battery voltage less than 13 Volts
8 flashes Thermal cutback operating
On None
May 2002 SB-0201

Model : N01 SERIES ( only N01 SEM truck )

Subject : Controller setting in a replacement

1. Introduction:
This Technical Bulletin explains how to adjust the traction controller (Micropak) in a replacement.
Our spare parts for traction controller is only one part number.
But, this traction controller must have 4 kind setting in each model as following.
Therefore, the following setting must be adjusted before truck operation.

Traction Controller Setting 1.6.3 Trc Setup 1.7.2 Motor setup

Truck model Mode Fld I low

N01 With Pump chopper Pump 7A

Without Pump chopper No Pump 7A
GN01 With Pump chopper Pump 5A
Without Pump chopper No Pump 5A

2. Instruction for adjusting :

The each item can be selected by the following figures and can be adjusted by using “+”, “–“ buttons.
Each setting in the below tables must be adjusted and confirmed before truck operation.

1) Cal.1.6.3 Traction Setup Mode

Setting 1.6.3 Trc Setup Here

Truck Spec. Mode

With Pump chopper Pump

Without Pump chopper No Pump

Note) If this changing is impossible with normal
connection, please use direct connection to
RH controller.
2) Cal.1.7.2 Motor Setup Fld I Low

Setting 1.7.2 Motor setup Here

Truck Model. Fld I low

N01 (STD) 7A

GN01 (HP) 5A

The information in this bulletin should not be interpreted as base for claims, unless so designated
 INTRODUCTION ..................................................1 TROUBLESHOOTING FLOWCHARTS ..................23
Controller Type ...................................................... 1 1FF ....................................................................... 23
Controller Features ................................................ 1 2FF ....................................................................... 23
PRECAUTIONS ......................................................... 2 3FF ....................................................................... 24
CONTROLLER........................................................... 3 4FF ....................................................................... 25
Construction ............................ :.............................. 3 5FF ....................................................................... 28
Specifications .........................................................3 6FF ....................................................................... 29
Contactor Exploded Views .....................................4 7FF ....................................................................... 30
Controller Logic Replacement ...............................7 8FF ....................................................................... 31
PANEL CONNECTORS .............................................8 9FF ....................................................................... 32
Connector CA ........................................................ 8 LED Off ................................................................ 33
Connector CB ........................................................ 8 SAFETY ................................................................... 34
Connectors C and D ..............................................9
CONTROL WIRING DIAGRAM ...............................10
Customer Connections ........................................10
> Panel Wiring ........................................................ 11
Z C.A.N. CALIBRATOR ............................................ 12
System Overview .................................................12
List of Tuning Items ............................................. 13
Working Examples ............................................... 17
Working Example . Steering Potentiometer
Adjustment ..................................................... 19
Fault Message Priorities ......................................21
 INTRODUCTION

As from August 1996 the 1\01 1996 and N01 HP 3-Wheel Electric Powered Forklift Truck with dual front
wheel drive wil1 incorporate a Sevcon Microprocessor MOSFET Controller which offers constant, high fre-
quency proportional control of the two traction motors.

This system replaces the Sevcon MCM2 non-proportional thyristor controller which was installed from May
1993 onwards.

Controller Type
Controller Range: 2 = SC2000 series
Controller Type: 5 = Dual Traction with Proportional Control

,! l
Voltage range: 4 = 48V
Current Limit: 2 = 250A (each motor)

Controller Features
Enclosed unit to IP34 with field replaceable logic.
Dual Traction motor drive with proportional speed control in one enclosure. Proportional control elimi-
nates steering shock.
Dual motor steer factor adjustment to optimise cornering to truck geometry.
Microprocessor control.
Constant, high Frequency (silent) operation.
Internal watchdog monitoring internal microprocessor operation.
Arcless contactor switching and built-in contactor suppression.
Bypass with overcurrent dropout.
Field Weakening (High performance model only).
Pump Contactor off delay to prevent contactor 'chatter' and reduce wear on tips.
Start-up safety sequence.
Seat switch timer.
Static Return to Off (SRO).
BDI. Battery Discharge Indicator with adjustable warning and cutout levels.
Acceleration ramp potentiometer (Economy).
Low input impedance for protection against water.
Thermally compensated current limit.
Braking proportional to accelerator pedal position.
Undervoltage protection.
Accelerator wire-off detect.
Flexible accelerator interface, with minlmax voltages programmable.
Short circuit and open circuit contactor detect.
Hardware and Software failsafe protection + autofailsafe check every power-up.
Contactor drive short circuit detection.
Fault detection with LED display.
Fault and Service Log.
Serial communications bus (C.A.N. based).
Selected adjustments, diagnostics and service information via plug-in CAN Calibrator.
Keyswitch, drive and material handling hours count displayed via CAN Calibrator.
CAUTION:
e Before removing or inserting mainlmeter print board connectors, turn the key switch to the OFF
position and remove the battery plug. Failure to do so may cause a malfunction in the print board.
a Make sure the mainlmeter print board connector cord is free from twisting when the connector
is removed or inserted. A twisted cord may cause poor connector contact. When removing the
connector, always hold the connector body and do not pull on the cord.
a When removing wiring harnesses andlor bus bars, note their relative locations so they can be
reinstalled in their original positions during reassembly.
a When installing a controller element which is used with insulating film, be sure to place insulat-
ing film on the contacting surface of the element and mating part. If a controller element is not
used with insulating film, apply silicone-based grease to the contacting surface of the element
and mating part during installation.
e Before checking controller elements during on-vehicle inspection, remove the wiring harnesses
and bus bars. Inadvertent current flow may damage the element or other parts being checked.
e Before using flow charts as a guide to troubleshoot units and parts, become familiar with the
instructions outlined under "TROUBLE DIAGNOSTIC PROCEDURES".
NOTE:
a Controller and unit conditions are determined by checkinglmeasuring the resistance values (continuity)
of, or voltage values produced across, various parts affected. However, this section deals with only
resistance measurement procedures.
 CONTROLLER

Construction

CUT OUT

Specifications
Truck Type
Model (SC----) SC2542
Voltage 48V
Current (lminute rating) Drive = 250A per side
Traction -
Pump
Configuration
Dual Motor Non-Prop. -
Dual Motor Proportional X
Frequency 15.7KHZ
No. of Power Terminals 8
Unit Length Panel = 532, Controller = 360
Dimensions (mm) Unit Width Panel = 360, Controller = 230
Unit Height Panel = 145, Controller = 113
Storage Temperature -40°C +70°C
Vibration 6.OG, 40 200HZ, for 1 hour, in x, y, z planes.
Environmental Protection IP34
Approval Standards Designed to meet relevant EEC Directives
AI1 terminals M8: 10 12 N,m
Tightening Torques
Pump contactor terminals M10: 13 15 N.m
CONTROLLER

Contactor Exploded Views

DIRECTION CONTACTORS
ITEM No. DESCRIPTION
1 TOP COVER FIXING SCREW
2 HARDWARE KIT
3 ASSEMBLED TOP COVER
4 RETURN SPRING
5 MOVING CONTACT ASSEMBLY
6 ASSEMBLED NORMALLY CLOSED FIXED CONTACT
7 NORMALLY CLOSED FIXED CONTACT INSULATOR
8 NORMALLY CLOSED FIXED CONTACT PEG
9 ASSEMBLED COIL AND FRAME
ADDITIONAL PART NUMBERS:
CONTACTOR DC88B-27 24VOLT

Technical data:
m Coil Resistance - 28.5Q to 30.4Q (at ambient of 20°C).
m Coil Voltage - 24V.
m 1 Hr Current - lOOA.
50% Duty - 150A.
m Max. Current - 800A.

PUMP CONTACTOR
ITEM No. DESCRIPTION
1 COVER SCREW AND WASHER
2 TOP COVER
3 TERMINAL CONTACT ASSEMBLY
4 RETURN SPRING
5 MOVING CONTACT ASSEMBLY
6 TOP COVER BASE MOULDING
7 MOVING CONTACT PLUNGER
8 COIL AND MAGNET FRAME ASSEMBLY
9 SPRING ARMATURE CAP
ADDITIONAL PART NUMBERS:
CONTACTOR SW200-359 24VOLT

Technical data:
m Coil Resistance - 15.0Q to 16.5Q (at ambient of 20°C).
m Coil Voltage - 24V.
m 1Hr Current - 250A.
50% Duty - 360A.
m Max. Current - 1500A.
CONTROLLER
Contactor Exploded Views (Cont'd)

ITEM No. DESCRIPTION

1 TOP COVER FIXING SCREW
2 TOP COVER
3 TERMINAL CONTACT ASSEMBLY
4 RETURN SPRING
5 RETURN SPRING INSULATOR
6 MOVING CONTACT ASSY (LESS CONTACTS)
7 MOVING CONTACT
8 COIL AND MAGNET FRAME ASSEMBLY
ADDITIONAL PART NUMBERS:
CONTACTOR SW82-3 24VOLT

Technical data:
a Coil Resistance - 28.5Q to 30.4Q (at arnbient of 20°C).
a Coil Voltage - 24V.
a 'I Hr Current - lOOA.
50% Duty - 150A.
a Max. Current - 800A.

REGEN CONTACTOR
ITEM No. DESCRIPTION
1 TOP COVER FIXING SCREW
2 FIXED CONTACT ASSEMBLY
3 ASSEMBLED TOP COVER
4 RETURN SPRING
5 MOVING CONTACT ASSEMBLY
6 ASSEMBLED NORMALLY CLOSED FIXED CONTACT
7 NORMALLY CLOSED FIXED CONTACT INSULATOR
8 COIL AND MAGNET FRAME ASSEMBLY
9 END CAP
ADDITIONAL PART NUMBERS:
CONTACTOR SW181-203 24VOLT

Technical data:
a Coil Resistance - 17.0Q to 19.5Q (at arnbient of 20°C).
a Coil Voltage - 24V.
a 1Hr Current - 150A.
50% Duty - 225A.
a Max. Current - 1000A.
CONTROLLER
Contactor Exploded Views (Cont'd)
BYPASS CONTACTOR
ITEM No. DESCRIPTION
1 TOP COVER FIXING SCREW
2 TOP COVER
3 FIXED CONTACT ASSEMBLY
4 RETURN SPRING
5 MOVING CONTACT ASSEMBLY
6 COIL AND MAGNET FRAME ASSEMBLY
7 ENDCAP
ADDITIONAL PART NUMBERS:
CONTACTOR SW1908-3 24VOLT

Technica1 data:
e Coil Resistance - 17.0Q to 19.5Q (at ambient of 20°C).
e Coil Voltage - 24V.
e lHr Current - 150A.
50% Duty - 225A.
e Max. Current - 1000A.
 CONTROLLER

Controller Logic Replacement

The controller logic board can be replaced simply and quickly by following the procedure below:

ll Logic to Power PCB

Intecomection Pins

1. Using CAN Calibrator, note traction personality, traction BDI and traction set-up settings prior to remov-
ing logic PCB.
2. Unscrew the end covers.
3. Remove the top cover. (2 flat-head screwdrivers required for this operation.)
4. Locate the logic board and remove the 6 fixing screws and spacers.
5. Remove the logic board.
6. Place the 4 sets of interconnection pins int0 their sockets on the new logic PCB.
7. Place the plastic stand-offs into the fixing holes of the new logic board.
8. Press the new logic board firmly int0 position ensuring that the 4 sets of interconnection pins locate cor-
rectly in the interconnection sockets of the Power PCB.
9. Refit the 6 fixing screws.
10. Refit the top cover.
11. Refit the end covers ensuring the end cover with the connector cutouts is located at the correct end.
Refit the end cover screws.
12. Using CAN Calibrator, verify that traction personality, traction BDI and traction set-up settings are Same
as per replaced logic PCB.
 PANEL CONNECTORS

Connector CA: Customer Connector, 6 way,

Panel Harness

Panel Harness Connector CA

- Denotes not connected

n Connector CB: Customer Connector, 15 way,

Panel Harness
U'

-x\ -,. q
f 6 ! j 5 ) ( 4 )
L' L/' u

U
Panel Harness Connector CB

- Denotes not connected

 PANEL CONNECTORS

Connectors C and D: 6 way CAN Calibrator

and CAN 10 module:
'The connectors are connected in parallel and provide inputloutput capability for the CAN calibrator to
communicate with the controller and the controller to communicate with the CAN 10 module.
User Connector for CAN Calibrator and CAN 10 module:
PIN No. MAIN FUNCTION PIN TYPE Available
1 10.5 Volts Digital 0
2 B- SUPP~Y 0
3 10.5 Volts Digital 0
4 10.5 Volts (+ve supply) SUPP~Y 0
5 CAN + (Data) Digital 0
6 CAN - (Data) Digital 0
Key: 0- Available
X - Not Available
Note: CAN Calibrator plug and CAN 10 module plug can be inserted int0 either connector socket.
SC2542 DUAL MOTOR PROPORTIONAL (ACTIVE Hl)
WIRING DIAGRAM (NISSAN N0.lINOIHP TRUCK)
 CONTROL WIRING DIAGRAM

Customer Connections

Connector CA
Nissan
BDl +ve 1 1

-
4 3 ! Pumo Switch

Connector CB
KSW
B?,a:t
Forward Switch (FWD)
Reverse Switch (REV)
FS1
Acceleration Delay Supply
-----
Accelerator

Connector for CAN Calibrator

Connector for CAN Module

n
I
I
I \
1 CAN I 0
MODULE
/
! I.

!
 C.A.N. CALIBRATOR

System Overview

C = Controller
A = Area
N = Network

Functions:
* Enables personality adjustments for traction.
* Status and test information for traction.
* Displays traction fault diagnostics.
* Service Log information.
* Fault Log information.

Screen Map: The calibrator menus are arranged in a tree structure. The diagram below shows how the
various main sections can be accessed. The correspond to the up, down, left and right arrow keys of the
calibrator. The menu items under each heading are explained in detail in the tables that follow.

Keyswitch ON

+1 '
Traction O Calibrator
OK OK
t

1
A

4.1 Calibrator
Lang. English
Selecting a certain language is
done by pressing the "+" or "-" keys.

I + ' ' ' '

'
P

1.l Traction O 1.2 Traction O l.3 Traction O l.4 Traction O 1.5 Traction O 1.6 Traction O
Personalities Status Tesi BDI Fault log Set Up
t t t
t
1.1.1 Trac Pers '1.1.2 Trac Pers '
I. Max 250A Accel. 0.5s
t t
 C.A.N. CALIBRATOR

List of Turiing Items

TRACTION SYSTEM PERSONALITIES (controller adjustments)

I Cal.
Ref.
1.1.1
I Traction
Personalities
1. Max
Content

Over Current Limit value

l Range

50 - 250A
Nissan Default
Level
210A
Adjustable

X
1.1.2 Accel Soft start 0.1 - 5.0 sec. 1 .O sec. 0
1 1 . l .3 I Decel I Soft stop I 0.1 - 0.5 sec. 1 0.5 sec. I X I
1 1 . l .4 1 Creep speed I min. duty 1 O-25% 1 3% I 0 I
1 1.1.5 1 Max speed I max. duty 1 O-100% 1 100% 1 0 I
1 1.1.6 1 Cut seeed 1 I max. dutv 1 1 O-100% 1 100% 1 X I
1 . l .7 Cut Accel 1 max. soft start 2 0.1 - 5.0 sec. 0.1 S X
1 .l
.8 Cut speed 2 max. duw 2 O - 100% 40% X
1 1. l .9 1 Cut Accel 2 1 max. soft start 2 E - 5.0 sec. I 0.1 sec. I x 1
11.1.10 I Dir. Brake I Braking current 1 50-250A 1 180A I X I
1 1.1.11 1 Ntrl Brake I Neutral brake current I 0 - 250A I OA I X I
11.1.12 (Foot Brake I Footbrake current I 0 - 250A I 50A 1 X I
1.1.13 Bypass Out Bypass overcurrent value 0 - 370A 260A X
1.1.14 F.W. In Field Weakening Pull In Current 50 - 250A 90A X
11.1.15 IF.w.OU~ 1 Field Weakening Drop Out Current 1 50 - 250A I 150A I x 1
1 1.1.16 I Steer Delay I PS contactor OFF delay I O - 60 sec. 1 1 sec3 I X I
11.1.17 I~eatDelav I Seat switch delav I 0.0- 5.0 sec. 1 2.5 sec. I X 1
1 . l .18 Regen Speed Regen Speed Factor 0 - 255 200 X
1.1.19 Brake Const. Brake Constant Factor 0.5 - 25.5 1 X
1 1.1.20 ( ~ c c e lZero
. I ~ c c e l voltage
. when duty = 0% I 0.0 - 5.OV I 0.1V I 0 I
1 1.1.21 1 ~ c c e l Full
. I ~ c c e lvoltage
. when duty = 100% 1 0.0 - 5.OV I 4.5V I 0 I
1 1 . l.22 I Brake Zero I Brake oot. zero voltaae 1 0.0 - 5.0V I 2.0V I X I
1.1.23 Brake Full Brake pot. max. voltage 0.0 - 5.0V 0.OV X
1 . l.24 Econ Zero Power control zero voltage 0.0 - 5.0V 0.OV X
1.1.25 Econ Full Power control max. voltage 0.0 - 5.0V 4.0V X
1 1.1.26 I Steer Left I Steer Pot. full left voltage 1 0.00 - 5.00V I I 0 I
11.1.27 I Steer Right I Steer Pot. full right voltage 1 0.00 - 5.00V I 1 0. I
1 1 . l.28 I Steer Factor I Dual Motor Steer Factor 1 0.1 - 5.0 1 2.9 I X I
1.1.35 Dead Band Steering Deadband Angle O - 26" 15" X
1.1.36 Bypass Bypass Delay 0.1 - 5.0 sec. 0.8 sec. X
Key: 0- Available
X - Not Available
Adjustments to the personalities are made using the '+' and '-' keys of the calibrator.
* Adjusted values; refer to page CS-19 & CS-20
 C.A.N. CALIBRATOR

TRACTION STATUS INFORMATION

The traction status information can be used to view various aspects of the left and right motors during
operation. Incorporated into several of the traction status items is a service log which stores the minimum
andlor maximum value for that characteristic since the service log was last rest. The items marked * and **
are service log items.
Cal. Traction Parameter Dealer
Min. Display Max. Display Step size
Ref. Displayed Availability
1.2.1 Battery V OV 127 V 0.1 Volts 0
1.2.1 Battery Max V OV 127 V 0.5 Volts 0
1.2.2R Right Motor V OV 127 V 0.5 Volts 0
1.2.2L Left Motor V OV 127 V 0.5 Volts 0
1.2.3R Right Motor A OA 1200 A 6 Amps 0
1.2.3R Right Motor Max A * OA 1200 A 6 Amps 0
1.2.3L Left Motor A OA 1200 A 6 Amps 0

Service Log items are marked * and **.

* - Displayed by pressing "+" on the calibrator when in the relevant menu item.
** - Displayed by pressing "-" on the calibrator when in the relevant menu item.

CS-I 4
 C.A.N. CALIBRATOR

TRACTION TEST INFORMATION

The traction test information can be used for troubleshooting and diagnostic tests. It is possible to observe
the status of al1 the potentiometers and switches in the test section.
Cal. Traction Input Dealer
Used for Min. Display Max. Display Step size
Ref. Displayed Availability
1.3.1 Accelerator % Acc ilp O% 100 % 1 % 0
1.3.2 1 Accelerator V I Acc ilp I 0.0 V 1 5.5 V I 0.1 V / O I
1.3.3 1 Footbrake % I FBS~IP ( 0% 1 100% I 1% I 0 I
1.3.4 1 Footbrake V I FBS ilp I 0.0 V 1 5.5 V ( 0.1 V I 0 I
1.3.5 1 Economy % * ( AccDelayilp I 0% 1 100% I 1% I 0 I
1.3.6 Economy V * Acc Delay ilp 0.0 V 5.5 V 0.1 V 0
1.3.7 Steer Angle Steer ilp -90" +90° 1" 0
1.3.8 Steer V Steer ilp 0.0 V 5.5 V 0.01V O
1.3.9 ( Forward I FWD 1 Open I Closed I I 0 I
1.3.10 I Reverse I REV I Open I Closed ( I 0 I
1.3.11
1.3.12
FS1
Seat
FS1
SWS
Open
Open
Closed
Closed
0
0
I
1.3.13 Handbrake Open Closed 0
1.3.14 Cutback 1 Open Closed 0
1.3.15 Cutback 2 Open Closed 0
1.3.16 Trigger Open Closed 0
1.3.22 Software 5.50 F 5.50 F 0
e Potentiometer on the dashboard Key: 0- Available
X - Not Available
TRACTION B.D.I. INFORMATION
The traction BDI information is used to store and display the battery information. The warning and cutout
levels are used to set the level of charge remaining when the battery low warning and battery low cutout
occur. When BDI Warning level is reached the controller uses the CAN 1 0 module to flash the BDI warn-
ing lamp at 1Hz. When BDI Cutout is reached the BDI warning lamp is lit continuously, pump operation is
inhibited and traction is limited by the value of personalities:

.8 Cut Speed 2
1 .l
1 .l
.9 Cut Accel. 2
Cal. BDI Parameter Dealer
Min. Display Max. Display Step size Nissan Default
Ref. Displayed I Adjusted Adjust?
1.4.1 % Charge remaining O% 100 % 1% NIA NIA
1.4.2 Battery Volt 24 96 2V 48 V X
1.4.3 Reset VICell 2.00 2.50 0.01 2.09 V 0
1.4.4 Empty VICell 1.50 1.99 0.01 1.60 V 0
1.4.5 Warning % O% 90 % 1% 20 % 0
1.4.6 Cutout % O% 90 % 1% 15 % 0
 C.A.N. CALIBRATOR

TRACTION FAULT LOG

The traction fault log stores a log of the total number of times a particular flash fault has occurred. The key
hours time and diagnostic message of the most recent fault for each type of flash fault is also displayed.

Flash Fault Displayed Min. Display Max. Display Step Size

O Flash Fault OxOOF, O.Ohr 99xOOF, 65279.9hr IxOOF, 0.1hr
1 Flash Fault OxOIF, O.Ohr 99x01F, 65279.9hr 1 x 0 1 ~ 0.1hr
:
3 Flash Fault Ox03F, O.Ohr 99xO3F, 65279.9hr Ix03F, 0.1hr
4 Flash Fault Ox04F, O.Ohr 99xO4F, 65279.9hr Ix04F, O.lhr
6 Flash Fault Ox06F, O.Ohr 99xO6F, 65279.9hr Ix06F, 0.1hr
7 Flash Fault Ox07F, O.Ohr 99xO7F, 65279.9hr Ix07F, 0.1hr
9 Flash Fault Ox09F, O.Ohr 99xO9F, 65279.9hr Ix09F, O.lhr
Fault Log reset - -

TRACTION SET LIP

Cal.
Parameter Adjusted Adjustable Range Nissan Default Dealer Adjust
Ref.
1.6.1 Contactor Chopping ONIOFF ON X
1.6.2 Accelerator Type LINEICURVER'SLOPE 2*SLOPE X

The Accelerator Type selects the mapping between the accelerator output ratio and the Mosfet percentage
on time. The Curve and 2*Slope setting can be used to give improved low speed control than is achievable
with the linear setting.

Linear

Curve

2*Slope

70 Accelerator output ratio

 C.A.N. CALIBRATOR

Working Examples
-
WORKING EXAMPLE TRACTION ACCELERATOR ADJUSTMENT
MEASURE THE ACCELERATION VOLTAGE
Operation Indication of Calibrator
Keyswitch ON Traction OK

\3 1 .l Traction Personalities

D x2
1.3 Traction Test

\3 1.3.1 Traction Test Accelerator xxx %

1.3.2 Traction Test Accelerator x.x V *

Read the value under the following conditions:

m Accelerator pedal in free position. (memorise)
m Accelerator pedal in max. position. (memorise)

ADJUST THE ACCELERATOR ZERO VOLTAGE

Operation Indication of Calibrator

1 . l.20 Trac. Pers

Accel Zero X.X V *

Adjust the value * to the following level by using the "+" or "-" buttons:
m "Accelerator pedal free voltage" (reading from "test mode") plus 0.1V
 C.A.N. CALIBRATOR
Working Examples (Cont'd)
ADJUST THE ACCELERATOR FULL VOLTAGE
Operation Indication of Calibrator

rl
1.1,.21 Trac. Pers

Accel Full X.X V

l I I
t value * to the following level by using the "+" or "-" buttons:
~ d j u sthe
o "Accelerator pedal max. voltage" (reading from "test mode") minus 0.1V

CONFIRMATION OF ACCELERATION STAGE

Operation Indication of Calibrator

v 1.3.2 Traction Test

Accelerator x.x V

1.3.1 Traction Test

Accelerator xxx %*

Confirm that the value * increases from O to 100 % as the Accelerator pedal is depressed.

CONFIRMATION OF DIAGNOSTIC MESSAGE

Operation Indication of Calibrator

Traction

x2
Depress the Accelerator pedal to its stroke end, and confirm that this indication is OK.
 C.A.N. CALIBRATOR

Working Example - Steering Potentiometer

Adjustment

MEASLIRE THE STEER POTENTIOMETER VOLTAGE RANGE

Operation Indication of Calibrator
Keyswitch ON , Traction OK

v 1 .l Traction Personalities

r3 x2
1.3 Traction Test

v 1.3.1 Traction Test Accelerator xxx %

1.3.8 Traction Test Steer Pot. x.xx V*

x7
Read the value * under the following conditions:
e Steering Wheel rotated fully clockwise (memorise).
e Steering Wheel rotated fully anti-clockwise (memorise).

ADJUST THE STEER POTENTIOMETER LEFT VOLTAGE LEVEL

Operation Indication of Calibrator

1.1.26 Trac. Pers

Steer Left X.XX V *

Adjust the value * to the following level by using the "+" or "-" buttons:
e "Steering Wheel rotated fully anti-clockwise" (reading from "test mode") minus 0.04 or 0.05V
 C.A.N. CALIBRATOR
Working Example - Steering Potentiometer
Adjustment (Cont'd)
ADJUST THE STEERING POTENTIOMETER RIGHT VOLTAGE LEVEL
Operation Indication of Calibrator

1 .l
.27 Trac. Pers

Steer Right X.XX V*

Adjust the value * to the following level by using the "+" or buttons:
"-l1

a Steering Wheel rotated fully clockwise (reading from "test mode") plus 0.04 or 0.05V.

CONFIRMATION OF STEER POTENTIOMETER SETTING

Operation Indication of Calibrator

v 1.3.2 Traction Test

Steer Pot. x.xx V

1.3.1 Traction Test

Steer Angle XXO*

Confirm that the value * increases from -90" to 90" as the Steering Wheel is rotated from fully clockwise
and anti-clockwise.

CONFIRMATION OF DIAGNOSTIC MESSAGE

Operation Indication of Calibrator

A x2
Traction

OK

Rotate the steering wheel through its range and confirm that the indication is OK at al1 times.
 C.A.N. CALIBRATOR

Fault Message Priorities

DRIVE FAULT IVIESSAGE PRIORITIES

"Accel Fault" 6FF 21 Accelerator wire off Accelerator OIC

"Capacitor Fault" 5FF 20 Main Caps not charging at power up Capacitor defect
"Coil SIC" 9FF 19 A contactor coil Sor
IC misconnected Cont. Coil SIC
"Regen SIC" 4FF 18 Regen contactor didn't open
"Rev Left SIC" 4FF 17
"Rev Right SIC" 4FF 16 -
REV contactor failed to
"Reverse SIC" 4FF 15 Reverse contactor didn't open
open
"Fwd Lefî SIC" 4FF 14 -
"Fwd Right SIC" 4FF 13 -
FWD contactor failed to
"Forward SIC" 4FF 12 Forward contactor didn't open
open
FWD or REV contactor
"Contactor SIC" 4FF 11 Fwd or Rev cont. short circuit
failed to open
"Regen olc" 4FF 10 Regen contactor didn't close
"Rev Lefi olc" 4FF 9 -
"Rev Right olc" 4FF 8 -
REV contactor failed to
"Reverse olc" 4FF 7 Reverse contactor didn't close
close
"Fwd Lefî olc" 4FF 6 -
"Fwd Right olc" 4FF 5 -
FWD contactor failed to
"Forward olc" 4FF 4 Forward contactor didn't close
close
FWD or REV contactor
"Contactor olc" 4FF 3 Fwd or Rev cont. open circuit
failed to close
"Thermal cutback" 8FF 2 Drive heatsink above 75°C Overheating
Controller self-check
"Testing" ON 1 Controller performing internal tests
operating

Messages with the highest number have the highest priority.

e.g. "Failed" 30 is the highest priority Drive diagnostic message.
When 2 or more errors occur at a time, only the message having a greater number is displayed.

CS-21
 C.A.N. CALIBRATOR
Fault Message Priorities (Cont'd)
POWER-UP FAILSAFE DIAGNOSTIC MESSAGE PRIORITIES
Message LED Status Priority Description
"Cap. Fault" Out 48 Caps not charged at keyswitch ON
"P. Up Trac. Weld" Out 47 Direction contactors SIC at KSW ON
"P. Up Trac. Mos" Out 46 Traction MOSFETs SIC at KSW ON
"Drive O on" Out 44 Failsafe cannot disable contactor drive O*
" ~ r i v e1 on" Out 43 Failsafe cannot disable contactor drive l*
"Traction on" Out 42 Failsafe cannot disable Drive MOSFETs
Contator drive O does not operate in failsafe
"Drive O off' Out 38
tests
Contactor drive O does not operate and Drive
"Drive O mos SIC" Out 37
MOSFETs Sin ICfailsafe tests
Contactor drive 1 does not operate in failsafe
"Drive 1 off' Out 36
tests

"Drive 1 mos slc" Out 35

I Contactor drive 1 does not operate and M.H.
MOSFETs SI
inC
failsafe tests
"Traction off' Out 34 Drive MOSFETs OIC in failsafe tests

Note 1: Power-up failsafe diagnostic messages have priority over any Drive or Material Handling fault mes-
sage.
Note 2: Drive O refers to Right traction motor drivers.
Drive 1 refers to Left traction motor drivers.
 .
TROUBLESHOOTING FLOWCHARTS

LED blinking once: CPU board exchange.

2FF
LED blinking twice: Operation procedure abnormality.

Calibrator Display
Check

.::i:: :::-i:
Calibrator
Display
"2 DIR FAULT" "SEAT FAULT"

Condition Forward and reverse direction SEAT switch is open during

switches selected simultaneously

f
Visual Set only forward or reverse Close SEAT switch to achieve
Check drive

Electrical Inspection 1: Inspection 1:

Check FWD.REV signa1 line continuity SEAT switch ON.OFF
inspection I inspection I

f
Logic PCB
t
Direction switch
T t
(ON: Oohm)

Logic PCB
t
(ON: 1M)

Harness defect
defect defect defect or SEAT switch
SIC
 TROLIBLESHOOTING FLOWCHARTS

LED blinking three times: TMD short circuit

Check

Calibrator
Display

Condition

Visual
l
I
o "MOSFET SIC"

Is the TMD short-circuited?

Motor cable shorted to B- I

Check

Electrical
Check

F1 wiring disconnection
F2 wiring disconnection

Inspection 1:
Voltage check between F1 and B-
Voltage check between F2 and B-

4-77 OK (8+1-IV)

Motor cable
NG (c7V)

Controller
defect defect
 TROUBLESHOOTING FLOWCHARTS

4FF
LED blinking four times: Contactor or motor abnormality (open or short circuit) <1/3>

Calibrator
Display

4 .t
Condition Forward (LefüRight) Reverse (LefüRight)
I
I
Contactor did not close I
I
I
I
Contactor did not close I
I

r
No Yes Yes No

Visual & Forward (LeftIRight)

t +
Inspection 1: I
f
Reverse (LefüRight) I
Electrical Contactor closes then Contactor coil continuity check: I Contactor closes then I

-t
Check immediately opens Forward (LefüRight) immediately opens
Circuit tester range <100ohm.
Approx. 52ohms.

lI II Reverse (LeftlRight):
Circuit tester range ~100ohm.
Approx. 52ohms.
I
l
I I

replacement replacement

Contactor power supply and motor cable

Inspection 1:
Drive motor continuity inspection (arma-
ture coil and field coil)

Controller replacement Drive motor replacement

 TROUBLESHOOTING FLOWCHARTS
4FF (Cont'd)
LED blinking four times: Contactor or motor abnormality (open or short circuit) <2/3>

<112> <313>
Check

F
Direction lever operation:
(forward tilt to neutral) F
Direction lever operation:
(backward tilt to neutral)

Calibrator
Display
"REVERSE
SIC" SIC" SIC"

Yes Yes Yes

f +
Condition I Forward or Reverse I I Forward Contactor ] Reverse Contactor
I Contactor short I I remains closed I I remains closed I
I circuit I II
Visual I * Contact welding I
Check check

* Contactor power
cable short circuit

Electrical * Armature field

Check coil short circuit
inspection

* Insulation check
between vehicle
chassis and con-
troller terminals
 TROUBLESHOOTING FLOWCHARTS
4FF (Cont'd)
LED blinking four times: Contactor or motor abnormality (open or short circuit) E 3 / 3 >

42/3> 4
Check

Calibrator

.
Display

I
Condition
X' Regen Contactor did not close
yes
Regen Contactor Welded

Visual &
Electrical
Check
I
1
It

irnrnediatelyyes ,
Regen Contactor closes then
opens 1 1 r
t
I I Inspection 1:
c o continuity
1 I
ll
+
Contact welding check

* Contactor power cable

short circuit
I I Regen:, 1
Circuit tester range
c100ohm.
Approx. lSohms.

+ + +
m Contactor]] 1 Armature field coil short I
I I replacement I I replacement I circuit inspection I
Insulation check between
Contactor power supply and vehicle chassis and con-
motor cable connection status troller terminals
check

Inspection 1:
Drive motor continuity
inspection (armature coil and
field coil)

l
Controller replacement
OK l NG
Drive motor replacement
 TROUBLESHOOTING FLOWCHARTS

5FF
Blinking five times: Capacitor abnormality

Calibrator Display
Check

Calibrator
Display

FAULT"

Condition
up at Keyswitch ON

Visual
Check
* External parts incorrectly
installed directly to control-
ler B+ terminal

Electrical
Check at Traction Fuse terminal
after KSW on

Logic PCB replace-

ment or controller
ASSY replacement
 TROUBLESHOOTING FLOWCHARTS

6FF
Blinking six times: Accelerator abnormality

Check

Calibrator Display

"ACCEL
FAULT"

Condition Accelerator cable disconnection

Visual Check 1. Accelerator cable disconnection

2. Acceleration potentiometer installation state

Electrical Check 1. Traction test by calibrator Confirmation of opera-

tion corresponding to accelerator operation under
condition NOS.1.3.1, 1.3.2, and 1.3.1 1.

2. Accelerator potentiometer individual check and

installation adjustment

1 3. Logic PCB replacement

 TROUBLESHOOTING FLOWCHARTS

7FF
Blinking seven times: Low battery voltage

/ Calibrator Display \
Check -)

Calibrator Display

I Yes

Condition Battery voltage at 14.4V or less

Visual Check
check

Electrical Check 1. Fuse OIC.

2. Inspection by calibrator:
Traction status mode 1.2.1
Battery voltage = 48V
3. Battery charging level
Actual, Measured value check.
4. Logic PCB replacement.
5. Controller replacement.
 TROUBLESHOOTING FLOWCHARTS

Blinking eight times: Overheating

Calibrator Display

Calibrator Display

Condition Traction heatsink

>75degC

Visual Check
l
t 1. Controller heatsink installation status

1 2. Fan operation status 1

Electrical Check l . Calibrator installation on vehicle.

2. Temperature check (status 1.2.4).
3. Personalities display check.
4. Calibrator status mode 1.2.3 OCL check.
Drive = 210A.
5. Motor inspection.
6. Controller replacement.

Note:
If "THERMAL CUTBACK" is displayed, travelling and material handling speeds are restricted. Immediately
..
stop the vehicle operation.
 'TROUBLESHOOTING FLOWCHARTS

9FF
Blinking nine times: Contactor Coil short circuit

Check

.::D
Calibrator Display

"COIL
SIC"

t
Condition l,Contactor coil short circuit
2. Contactor coil wiring incorrect

f
Visual Check 1. Contactor coil short circuit
2. Contactor coil power line incorrectly connected to
another pin

Electrical Check
1
Circuit tester range <100ohm

* Inspection
LF, LR, RF, RR contactors
Approx. 52ohms

RG contactor
Approx. l5ohms

BY contactor
Approx. l8ohms

PA contactor
Approx. l5ohms

FW contactor
Approx. 3Oohms

I Controller replacement
 'TROUBLESHOOTING FLOWCHARTS

LED Off
LED extinguished: Controller internal failure

Check

Calibrator Display

Indicated Not indicated

Condition
self-diagnostics upon
Keyswitch ON

+
Visual
Check
I 1. Keyswitch ON with
I battery connected I 1
l
2. Fuse normal
3. Keyswitch line inspec-
tion

t
Electrical Check L/ Controller replacement 1
Note:
In troubleshooting, when the rnain circuit is abnormal, a power-up failsafe diagnostic message wil1 be dis-
played when the)<eyswitch is recycled OFFION.
 SAFETY

Failsafe circuit should be checked at each service interval.

Procedure is thus:
e Ensure the front drive wheels are clear of the floor and free to rotate. Ensure the rear steer wheel is in
straightened position.
e KSW on / SWS switch selected 1 release handbrake / select FWD or REV / FS1 switch on:
e the front drive wheels should rotate.
e diagnostic LED should be on.
9 KSW off / Disconnect battery.
e Connect controller power terminals " Fl " and "B-" together with a 10mmsq cable.
(This effectively applies a short circuit across the drive mosfets).
e Re-connect battery / KSW on with direction in neutral."
e Regen Contactor should no close.
e LED should not be illuminated.
e If installed, CAN Calibrator wil1 indicate the messqge "P. Up Trac. Mos".
e Select FWD or REV.
e Direction contactors should not close.
e Front Drive wheels should not rotate.
e KSW off / disconnect battery.
e Remove short circuit from " F l " and "B-".
e Re-connect battery / KSW on.
e Select power-up sequence.
e Check LED illuminates.
e Truck drives OK.
e Repeat the procedure applying the short between "F2" and "B-".
* Note: If truck drives under this condition, the controller is faulty and must be replaced.
The SC2542 controller must NOT be used with permanently connected on-board chargers or damage to the
system may result.
Do not under any circumstances connect any Auxillary equipment (e.g. DC/DC Converters) directly to the
Controller "B+" terminal, otherwise damage to controller may occur.
May 2002 FCS 02-N01

Applied Model : N01 & GN01 (except TN01)

Applied From : Production in May, 2002

Subject : CONTROLLER SECTION (CS)

Introduction:
All NO1 and GN01 3-Wheel Forklift adopt a new controller system comprising of
two SEM traction controllers and one series pump controller.
These controllers are microprocessor based and use high frequency MOSFET that
can produce silent operation.
And these controllers have been designed to satisfy the requirements of the
relevant UL and EC standards.

Modification Notice:
In accordance with this change, Update the “CS” section in N01 Service manual
with attached new pages.

The information in this bulletin should not be interpreted as base for claims, unless so designated
 CONTROL SYSTEM

SECTION CS
CONTENTS
INTRODUCTION .................... 1 WORKING EXAMPLE .................... 31
Introduction .................... 1 Accelerator Adjustment .................... 31
Controller Specifications .................... 1 Steering Sensor Adjustment .................... 34
PRECAUTIONS .................... 2 DIAGNOSTICS .................... 39
CONTROLLER .................... 3 Fault Message .................... 39
Control system diagram .................... 3 Troubleshooting Flowcharts .................... 40
Construction .................... 4 LED Off .................... 40
Contactor Exploded Views .................... 6 1FF .................... 40
PANEL CONNECTORS .................... 7 2FF .................... 41
Harness Connection .................... 7 3FF .................... 42
CONTROL WIRING DIAGRAM .................... 9 6FF .................... 43
Control wiring diagram .................... 9 7FF .................... 44
C.A.N. CALIBRATOR .................... 11 8FF .................... 45
System overview .................... 11 9FF .................... 46
Outline .................... 11 12FF .................... 46
Function Map .................... 13
Traction Personalities .................... 14
Traction Status .................... 16
Traction Test .................... 17
Traction BDI .................... 18
Traction Fault log information .................... 19
Traction Setup .................... 20
Motor Setup .................... 22
Pump Personalities .................... 24
Pump Status .................... 26
Pump Test .................... 27
Pump BDI .................... 28
Pump Fault log information .................... 29
Pump Setup .................... 30
 INTRODUCTION
Introduction

All NO1 and GN01 3-Wheel Forklift adopt a new controller system comprising of two SEM
traction controllers and one series pump controller.
These controllers are microprocessor based and use high frequency MOSFET that can
produce silent operation.
And these controllers have been designed to satisfy the requirements of the relevant UL
and EC standards.

[ The SEM traction controller ]

The SEM controller has a totally different structure against former traction controller.
This SEM controller comprises an independently controlled half bridge Armature circuit
and an independently controlled full bridge Field circuit.
Armature and Field currents are both measured and are both controlled independently.

[ New series pump controller ]

The new series controller has a similar structure as former series controller.
But the logic board of this controller is designed with a same design policy as the SEM
traction controller.
A lot of information can be communicated between traction controller and pump
controller through CANbus.

[ CANbus ]
The traction and pump controllers have a serial communication interface CAN.
These controllers can communicate through CANbus for a data communication.
Therefore, the special function can work such as “proportional two motors control”.

Controller Specifications
Item (G)N01 with (G)N01 without
pump chopper pump chopper

Controller Input voltage 48V 48V

Control unit Traction Micropak(SEM)x2 Micropak (SEM)x2
Loading Powerpakx1 Contactorx1
Environmental Traction IP66 IP66
protection Loading IP66(Conector:IP55) ----
Current limit Traction 220A (Armature) 220A (Armature)
value 30A (Field) 30A (Field)
Loading 450A (Armature, Field) ----
Switching Traction 16kHz 16kHz
frequency Loading 16kHz ----
Main Type ALBLIGHT SW180 ALBLIGHT SW180
Contactor Coil voltage 24V 24V
Loading Type ---- ALBLIGHT SW200
Contactor Coil voltage ---- 24V

CS-1
 PRECAUTIONS
CAUTION
z Before removing or inserting each controller connectors, turn the key switch to
the OFF position and remove the battery plug.

z Make sure each controller connector wiring is free from twisting when the
connector is removed or inserted.
A twisted wiring may cause poor connector contact.
When removing the connector, always hold the connector body and do not pull
on the wiring.

z Before removing wiring harnesses and/or cable, connect the “B+” and “B-“
terminals by a 10 ohm 25 watt resistor to discharge the internal capacitors.
Then, make sure the voltage between the “B+” and “B-“ terminals is “ZERO”.
(10 ohm 25 watt)

“B-” 0V “B-”
Resistor

“B+” - + “B+”

z Do not make a short circuit between “B+” and “B-“ terminals before discharge.
Some spark might occur from the short circuit and might cause internal failure.

z When removing wiring harnesses and/or cable, note their relative locations so
they can be reinstalled in their original positions during re-assembly.

z When installing a controller, be sure to apply silicone-based grease to the

contacting surface of the controller and base plate.

z Before checking controllers during on-truck inspection, remove the wiring and
cable.
Inadvertent current flow may damage the element or other parts being checked.

z Before using flow charts as a guide to troubleshoot units and parts, become
familiar with the instructions outlined under “TROUBLE DIAGNOSTIC
PROCEDURES”.

CS-2
 CONTROLLER
Control system diagram

Battery

Key switch Main contactor

F/R control switch

Accelerator

Drive acceleration
volume
Traction controller Traction motor
Seat switch (SEM R.H) R.H

Pump-Cut
warning lamp
Traction controller Traction motor
Battery capacity (SEM L.H) L.H
meter

Brake switch
Steer angle
volume

Pump acceleration Pump motor

volume L.H
Pump speed
volume
Pump controller
Lift valve switch
: Main line
Tilt valve switch (Power line)
: Signal line
3,4,5 th valve
Construction : CAN BUS line
switch

CS-3
 CONTROLLER
CONTROLLER CONSTRUCTION ( N01 & GN01 with pump chopper )

Base plate Traction fuse (425A)

Traction controller (L.H) Pump fuse (325A)

Traction controller (R.H) EPS fuse (50A)
Main contactor Name plate

Pump controller

CS-4
 CONTROLLER
CONTROLLER CONSTRUCTION ( N01 & GN01 without pump chopper )

Base plate Traction fuse (425A)

Traction controller (L.H) Pump fuse (325A)

Traction controller (RH) EPS fuse (50A)
Main contactor Name plate

Pump contactor

CS-5
 CONTROLLER
Contactor Exploded Views

Main Contactor

Cover Screw And Washer

Top Cover
Terminal Contact Assembly
Return Spring
Moving Contact Assembly
Top Cover Base Moulding
Moving Contact Plunger
Coil And Magnet Frame Assembly
Spring Armature Cap

Pump Contactor

Top Cover Fixing Screw

Fixed Contact Assembly
Assembled Top Cover
Return Spring
Moving Contact Assembly
Coil And Magnet Frame Assembly
End Cap

CS-6
 PANEL CONNECTORS
Harness Connection [Chassis harness side]

GN01 & N01 with Pump chopper

To Chassis
Harness To Controller Pin Harness
No. Wiring contents ( From / To ) Note Color
1 N.C.
4 5 6
2 Battery Capacity Meter G
1 2 3 3 N.C.
4 Steer Angle VOL. Signal L
Connector 6 way 5 N.C.
AMP 35715-1 6 Steer Angle VOL. +Vcc G
(Connecting side view)
Pin Harness
No. Wiring contents ( From / To ) Note Color
1 F/R Control Switch F Switch L
3 6 9 12 15 2 F/R Control Switch R Switch GY
2 5 8 11 14 3 Accelerator FS1 Switch W
4 Traction Acceleration VOL. +Vcc Y
1 4 7 10 13 5 N.C.
6 Accelerator Signal PU
Connector 15 way 7 N.C.
AMP 350784-1
8 Power Supply ( Key Switch) OR
(Connecting side view)
9 N.C.
10 Seat Relay2 G
11 Ground B
12 Pump-Cut Warning lamp OR
13 Traction Acceleration VOL. Signal P
14 Brake Switch W
15 N.C.

Pin Harness
No. Wiring contents ( From / To ) Note Color
1 Lift valve Switch OR
3 6 9 12 2 Tilt valve Switch R
3 3rd valve Switch L
2 5 8 11 4 4th valve Switch G
1 4 7 10 5 5th valve Switch Y
6 Pump Acceleration VOL. Signal R/W
Connector 12 way 7 Pump Speed VOL. +Vcc W.R
AMP 350783-1 8 Pump Speed VOL. Signal B/W
(Connecting side view) 9 N.C.
10 N.C.
11 N.C.
12 N.C.

CS-7
 PANEL CONNECTORS
Harness Connection [Chassis harness side] (Cont’d)

GN01 & N01 without Pump chopper

To Chassis
Harness To Controller Pin Harness
No. Wiring contents ( From / To ) Note Color
1 N.C.
4 5 6
2 Battery Capacity Meter G
1 2 3 3 N.C.
4 Steer Angle VOL. Signal L
Connector 6 way 5 N.C.
AMP 35715-1 6 Steer Angle VOL. +Vcc G
(Connecting side view)
Pin Harness
No. Wiring contents ( From / To ) Note Color
1 F/R Control Switch F Switch L
3 6 9 12 15 2 F/R Control Switch R Switch GY
2 5 8 11 14 3 Accelerator FS1 Switch W
4 Traction Acceleration VOL. +Vcc Y
1 4 7 10 13 5 N.C.
6 Accelerator Signal PU
Connector 15 way 7 N.C.
AMP 350784-1
8 Power Supply ( Key Switch) OR
(Connecting side view)
9 N.C.
10 Seat Relay2 G
11 Ground B
12 Pump-Cut Warning lamp OR
13 Traction Acceleration VOL. Signal P
14 Brake Switch W
15 N.C.

CS-8
 CONTROL WIRING DIAGRAM
GN01 & N01 with Pump chopper

CS-9
 CONTROL WIRING DIAGRAM
GN01 & N01 without Pump chopper

CS-10
 C.A.N CALIBRATOR
System overview

C.A.N CALIBRATOR is a hand held adjustment unit and can be easily operated.
When the CALIBRATOR is connected with a controller as the following figure, many
functions can be used.

CAUTION : Key-Switch must be OFF when CALBRATOR is connected to controller

Outline

Operate the following procedure to avoid any damage to the controller and Calibrator.

1. Ensure that the front wheels are clear from the floor and are free to rotate.
Ensure that Fork and Mast are free from others.

2. Ensure that the Key-switch is OFF.

And then, connect the connector of the Calibrator to the connector of the SEM
controller. (Refer to above figure)

3. When the Key-Switch is turn on, the Calibrator’s screen shows some message.
1 Traction
- If truck condition has no problem, “OK” message is shown. OK

- If truck condition has some problem, failure message is shown. 1 Traction

Accel. Fault

4. The Calibrator has many functions and these functions can be selected and changed.
CS-8 Function Map shows all functions and the way to reach it.
All changed value only takes effort after Key-switch recycles.

“ Select the functions” “ UP and DOWN arrows buttons; ”

“ Select the items in function” “LEFT and RIGHT arrows buttons; ”

“ Change the value of item” “ + and - buttons; ”

CS-11
 C.A.N CALIBRATOR
Outline (Cont’d)

[Calibrator’s function]

1) Traction and pump personality adjustment.

1.1 Traction 2.1 Pump
Adjustment values for the traction and pump Personalities Personalities
control can be changed.

2) Traction and pump status information. 1.2 Traction 2.2 Pump

Voltage or current in the controller can be Status Status
monitored.

Caution : Truck can be moved.

3) Traction and pump Test information. 1.3 Traction 2.3 Pump

Switches or sensors can be checked. Test Test

Caution : Truck can be moved.

4) BDI (Battery Discharged Information) Information. 1.4 Traction 2.4 Pump

Adjustment values for the battery capacity can BDI BDI
be changed.

5) Traction and pump fault log information. 1.5 Traction 2.5 Pump
If some fault occurs, this function is activated Fault Log Fault Log
and fault information appears.
Normally, this function is not visible.

6) Traction and pump setup value adjustment. 1.6 Traction 2.6 Pump
Adjustment values for the controller setting can Setup Setup
be changed.

7) Traction motor setup adjustment. 1.7 Traction

Adjustment values for the traction motor can be Motor Setup
changed.

5. Turn off Key-switch.

And then, disconnect the Calibrator’s connector.

6. Turn on Key-switch.
Above changing only take effect after a key switch turned on.
Then, actual condition and operation of the truck can be checked.

CS-12
 C.A.N CALIBRATOR

Key-Switch ON Function Map

1 Traction 2 Pump
OK OK

2.1 Pump 2.2 Pump 2.3 Pump

Personalities Status Test
`

2.1.1 Pump Pers 2.1.34 Pump Pers 2.2.1 Pump Stat Service Log 2.3.1 Pump Test … 2.3.16 Pump Test
I.Max 400A
… Prot. Delay 0.5s Battery 48.0V
… + to reset log Accel1 0 % Ser No 000000

2.4 Pump 2.5 Pump 2.6 Pump

BDI Fault Log Setup

2.4.1 BDI 2.4.6 BDI 12*00F 123.6hr Fault Log 2.6.1 Pmp Setup … 2.6.12 Pmp Setup
80% Charge Left
… Cutout 15% CANbus Error
… + to reset log CANbus mode Econ CutS I Off

1.1 Traction 1.2 Traction 1.3 Traction 1.4 Traction

Personalities Status Test BDI

2.1.1A Trac Pers 1.1.48 Trac Pers 1.2.1 Trac Stat Service Log + to 1.3.1 Trac Test 1.3.30 Trac Test 1.4.1 BDI … 1.4.5 BDI
I.Max 220A
… Prot. Delay 0.5s Battery 48.0V
… reset log Accel1 0 %
… Type mp722 80% Charge Left Cutout 15%

1.5 Traction 1.6 Traction 1.7 Traction

Fault Log Setup Motor Setup

12*00F 123.6hr Fault Log 1.6.1 Trc Setup … 1.6.29 Trc Setup 1.7.1 Motor Setup 1.7.8 Motor Setup
… Mode Auto Detect Seat & Pump On Arm I low 70A
… Fld Res 0.61
CANbus Error + to reset log

CS-13
 C.A.N CALIBRATOR
Traction Personalities

The adjustable values for the traction control can be changed in this function.
Main purpose of this function is
for the checking each value after replacing a controller or parts.

These adjustable values can be changed by “+ and – buttons “.

1 Traction
OK

1.1 Traction
Personalities

1.1.1A Trac Pers

I.Max 220A
… 1.1.2 Trac Pers
Accel 1.5S
… 1.1.48 Trac Pers
Prot. Delay 0.5s

Increase Decrease Increase Decrease Increase Decrease

Adjustable values

Cal.Ref. Display Range Initial Remarks

: : : : :
1.1.2 Accel 0.1 – 5.0 s 1.5 s Time taken to ramp up from 0 to 100% on
: : : : :
1.1.4 Creep Speed 0 - 25 % 3% Min applied % on when drive first selected.
: : : : :
1.1.7 Ntrl Regen 0 – 220 A 0A Max Regen braking current in neutral position.
1.1.8 Foot Regen 0 – 220 A 40 A Max Regen braking current in foot braking.
: : : : :
1.1.14 Max Speed 0 - 100 % 100% Max allowable % of travel speed.
: : : : :
1.1.26 Accel Zero 0 – 10.00 V 0.12 V Input voltage for accelerator free position
1.1.27 Accel Full 0 – 10.00 V 4.52 V Input voltage for accelerator full pushing position
1.1.30 Econ. Zero 0 – 5.00 V 0.10 V Input voltage for Economy volume zero position
1.1.31 Econ. Full 0 – 5.00 V 3.40 V Input voltage for Economy volume full position
1.1.32 Str Zero 0 – 5.00 V 3.40 V Input voltage for full steering to counter-clockwise
position
1.1.33 Str Full 0 – 5.00 V 0.40 V Input voltage for full steering to clockwise position
: : : : :

Note : Changing only take effect after a key-switch recycle.

CS-14
 C.A.N CALIBRATOR
Traction Personalities (Cont’d)

All visible values ( For reference )

Cal.Ref. Display Initial Adjustable Remarks

1.1.1A I. Max 220 A X Armature I Max
1.1.1F I. Max 30 A X Field I Max
1.1.2 Accel 1.5 s O Traction Accel Delay
1.1.3 Decel 0.5 s X Traction Decel Delay
1.1.4 Creep Speed 3% O Traction Creep Speed
1.1.5 Driv Ramp 200 ms X Drive Ramp Time
1.1.5A* Plug Ramp 1000 ms X Plug Ramp Time
1.1.5B* Regen Ramp 356 ms X Regen Ramp Time
1.1.6 Dir. Regen 180 A X Direction Change Braking Current
1.1.7 Ntrl Regen 0A O Regen Neutral Braking
1.1.8 Foot Regen 40 A O Regen Foot Braking
1.1.9 Brake Start 0A X Brake Start Current
1.1.10 Brak Ramp 400 ms X Brake Ramp Time
1.1.11 Brk Init PWM 5 X Brake Initial PWM
1.1.12 Reg. Delay 260 ms X Traction Regen Time
1.1.12A* Foot Delay 80 ms X Foot Regen Delay Time
1.1.13 Reg Thresh 3.00 V X Brake Threshold
1.1.13A* Foot Thresh 4.00 V X Foot Regen Brake Threshold
1.1.14 Max Speed 100% O Traction Max Speed
1.1.15 Rolloff Fld 50% X Rolloff Field
1.1.16 Cut Speed1 50% X Traction Cut 1 Speed
1.1.18 Cut Speed2 30% X Traction Cut 2 Speed
1.1.25 Seat Delay 2.5 s X Traction Seat Delay
1.1.26 Accel Zero 0.12 V O Traction Accelerator Zero Voltage
1.1.27 Accel Full 4.52 V O Traction Accelerator Full Voltage
1.1.30 Econ. Zero 0.10 V O Economy Zero Voltage
1.1.31 Econ. Full 3.40 V O Economy Full Voltage
1.1.32 Str Left 3.40 V O Steer Zero Voltage
1.1.33 Str Right 0.40 V O Steer Full Voltage
1.1.34 Inner Angle 15 ° X Steer Inner Angle
1.1.35 Outer Angle 72 ° X Steer Outer Angle
1.1.43 Lo V Init 36.0 V X Low Battery Start
1.1.44 Lo V Cut 30.0 V X Low Battery Cutout
1.1.45 Hi V Init 65.0 V X High Battery Start
1.1.46 Hi V Cut 70.0 V X High Battery Cutout
1.1.47 Bat. Prot 30.0 V X Battery Protection Level
1.1.48 Prot. Delay 0.5 s X Battery Protection Delay
O : Adjustable, X : Not adjustable

Note *) : Cal.Ref. with “ * ” mark will appear by pushing a down arrow button .

CS-15
 C.A.N CALIBRATOR
Traction Status

The voltage or current can be monitored in this function.

These values are used for checking a condition of controller during truck operation.
Main purpose of this function is
for the checking the voltage or current in a trouble shooting.

Several items can be stored as a service log data. (minimum and/or maximum)
The items marked “+” or “+ -“ in “Log info column” have the service log.

1 Traction
OK

1.1 Traction 1.2 Traction

Personalities Status

1.2.1 Trac Stat

Battery 48.0V
1.2.2R Trac Stat
R. Armature 20V
… Service Log
+ to reset log

Max data Reset service Log

Monitoring Values

Cal. Ref. Display Min. Max. Log Remarks

Display Display Info.
1.2.1 Battery 0.0 V 127.5 V + Battery Voltage
1.2.2R R. Armature 0.0 V 127.5 V Right Armature Voltage
1.2.2L L. Armature 0.0 V 127.5 V Left Armature Voltage
1.2.3R R. Field 0.0 V 127.5 V Right Field Voltage
1.2.3L L. Field 0.0 V 127.5 V Left Field Voltage
1.2.4R R. Armature 0A 625 A + Right Armature Current
1.2.4L L. Armature 0A 625 A + Left Armature Current
1.2.5R R. Field 0.00 A 32.00A + Right Field Current
1.2.5L L. Field 0.00 A 32.00A + Left Field Current
1.2.6R R. Mosfet 0V 127.5 V Right MOSFET Voltage
1.2.6L L. Mosfet 0V 127.5 V Left MOSFET Voltage
1.2.7 Capacitor 0V 127.5 V Capacitor Voltage
1.2.8R R.Temp -30• +225• + - Right Controller Temp.
1.2.8L L.Temp -30• +225• + - Left Controller Temp.
1.2.10 Key 0 Hrs 65279.9 Hrs Key Switch Hours Count
1.2.11 Drive 0 Hrs 65279.9 Hrs Traction Pulsing Hours Count
- Service Log press + to reset service log Service Log Reset

Note : Log Info shows where the + and - keys can be used to
access the service max and min data.

CAUTION
Traction motor and pump motor can be operated during this procedure.
Make sure the following matters.
1)The drive wheels should be off the floor and free to rotate.
2) Loading equipment like as Fork or Mast should be free from others.

CS-16
 C.A.N CALIBRATOR
Traction Test

The switches and sensors can be monitored in this function.

Main purpose of this function is
for the checking the switches and sensors in a trouble shooting.

It is possible to observe the status of all the switches and sensors.

1 Traction
OK

1.1 Traction
Personalities
… 1.3
Test
Traction

1.3.1 Trac Test

Accel 0%
1.3.2 Trac Test
Accel 0V
… 1.3.30 Trac Test
Type mp722

Monitoring values

Cal. Ref. Display Min. Max. Remarks

Display Display
1.3.1 Accel 0% 100 % Accelerator %
1.3.2 Accel 0.00 V 5.00 V Accelerator Voltage
1.3.4 Footbrake Open Closed Footbrake Pot. Voltage
1.3.5 Economy 0% 100 % Economy Pot. %
1.3.6 Economy 0.00 V 5.00 V Economy Pot. Voltage
1.3.7 Steer Angle -90° 90° Dual Motor Steer Pot Angle (°).
1.3.8 Steer Pot. 0.00 V 5.00 V Dual Motor Steer Pot. V
1.3.9 Forward Open Closed Forward Switch
1.3.10 Reverse Open Closed Reverse Switch
1.3.11 FS1 Open Closed FS1 (Accelerator Switch)
1.3.13 Seat Open Closed Seat Switch
1.3.22 Trigger Open Close Power steer Trigger (not use)
1.3.23 Pump Trigger Off On Pump Trigger
1.3.28 Software 000.00 999.99 Software Version/Revision
1.3.29 Ser No 00000000 99999999 Controller Serial Number
1.3.30 Type mp722 Controller Type

CAUTION
Traction motor and pump motor can be operated during this procedure.
Make sure the following matters.
1)The drive wheels should be off the floor and free to rotate.
2) Loading equipment like as Fork or Mast should be free from others.

CS-17
 C.A.N CALIBRATOR
Traction BDI

The adjustable values for the battery capacity can be monitored in this function.
( Also the values can be changed. But normally, it is not necessary to change them.)
Main purpose of this function is
for the checking each value after replacing a controller or parts.

These values as “BDI warning level” and “BDI cutout level” are used to set the level of a
charge remaining, when the battery low warning and the battery low cutout occur.

For example
- When the battery remaining is reached to “BDI Warning level”, the BDI warning lamp
mounted in meter panel is flashed.

- When the battery remaining is reached to “BDI Cutout level”, the BDI warning lamp is lit
continuously.

- After that, every pump operation is inhibited and the traction speed is limited by the values
of personalities.
(1) Pump operation : stopped.
(2) Traction speed : Traction Cut 2 Speed (50% of maximum truck speed)

1 Traction
OK

1.1 Traction
Personalities
… 1.4
BDI
Traction

1.4.1 BDI
80% Charge Left
1.4.2 BDI
Reset 2.09V/cell
… 1.4.5 BDI
Cutout 15%

Increase Decrease Increase Decrease Increase Decrease

Adjustable values

Cal. Ref Display Range Initial Remarks

1.4.1 % Charge Left Display Only Percentage Charge Remaining
1.4.2 Reset V/Cell 2.00 - 2.50 V 2.09 V BDI Reset Level
1.4.3 Empty V/Cell 1.50 - 1.99 V 1.60 V BDI Discharge Level
1.4.4 Warning 0 % - 90 % 20 % BDI Warning Level
1.4.5 Cutout 0 % - 90 % 15 % BDI Cutout Level

Note : These information is used for both traction and pump operation even
if N01 has pump controller.

CS-18
 C.A.N CALIBRATOR
Traction fault log information.

If some fault occurs, this function is activated and fault information can be seen in this function.
This information show “LED flash fault code” and “fault message” that have occurred.
Main purpose of this function is
for the checking the fault history in the controller.

This fault log information can shows the fault data like as the following items.
- The total number of faults of this type.
- The Key hours count of the most recent fault.
- The text description of the fault.
For example
This fault log information shows
12*04F 12345.6hr - 12times of 4-Flash faults have occurred.
Contactor o/c
- The most recent at 12345.6 Key hours.
- This fault was a Contactor o/c fault.

However, the general faults during normal operation like as 2 flash “driver procedure error”
and 8 flash “thermal cutback indication” is not logged.

1 Traction
OK

1.1 Traction
Personalities
… 1.5 Traction
Fault Log

Fault Log
+ to reset log
2*00F 100.0hr
Drive 1 L … 12*04F 12.6hr
Contactor o/c

Reset Fault Log

Fault log information

Type of fault Description of fault Logged

LED off faults Internal controller power up check faults O
1 flash faults Personality/CRC faults O
2 flash faults Driver procedure/sequence/wiring type faults X
3 flash faults MOSFET/Motor wiring type faults O
4 flash faults Contactor o/c or s/c or wiring type faults O
5 flash faults Not used X
6 flash faults Potentiometer wire off type faults X
7 flash faults Battery low or high faults O
8 flash faults Thermal cutback faults X
9 flash faults Contactor coil s/c type faults O
12 flash faults CAN bus faults O

Note : Logged shows where the “O” can be logged.

CS-19
 C.A.N CALIBRATOR
Traction Setup

Adjustment values for the controller setting can be changed in this function.
Main purpose of this function is
for the checking each value after replacing a controller or parts.

Most items cannot be changed, because these values are very important for the controller.
But, N01 SEM traction controller is only one kind. (One parts number)
Therefore, It is necessary to select a controller type whether a truck has a pump chopper or not.

“Cal.Ref.1.6.3:Mode Pump/No Pump” item should be confirmed in a controller replacement.

If this item is not correct, this item should be change as bellow value.

-With pump chopper : “Cal.Ref.1.6.3:Mode Pump/No Pump” should be “Pump ”.

-Without pump chopper : “Cal.Ref.1.6.3:Mode Pump/No Pump” should be “No Pump”.

1 Traction
OK

1.1 Traction
Personalities
… 1.6 Traction
Setup

1.6.1 Trc Setup

Mode Auto Detect
… 1.6.3 Trc Setup
Mode Pump
1.6.29 Trc Setup
Seat & Pump On

Select Select Select Select Select Select

Adjustable value

Cal.Ref. Display Range Initial Remarks

: : : : :
1.6.3 Mode Pump / No Pump Pump Mode selection (with pump chopper)
No Pump Mode selection (without pump chopper)
: : : : :

Note : Changing only take effect after a key-switch recycle.

CAUTION
Traction motor and pump motor can be operated during this procedure.
Make sure the following matters.
1)The drive wheels should be off the floor and free to rotate.
2) Loading equipment like as Fork or Mast should be free from others.

CS-20
 C.A.N CALIBRATOR
Traction Setup (Cont’d)

All visible values ( For reference )

Cal.Ref Display Initial Adjustable Remarks

1.6.1 Mode Auto Detect X Can Mode

(Master/Slave/AutoDetect)
1.6.2 Mode Dual motor X Can Mode
(Dual motor/sigle motor)
1.6.3 Mode Pump O Mode ( with Pump chopper)

No Pump Mode ( without Pump chopper)

1.6.4 Mode no Input X CAN (input/ No Input)

1.6.5 Chop Select On X Chop Select (Off / On / 24V)

1.6.5A* BDI reg. 16 X BDI in Regen Chop Volts

1.6.6 Accel 2 * Slope X Accel Type

1.6.6A* Slope1 Ip 70 X 2*Slope End Slope1 Input %

1.6.6B* Slope1 Op 30 X 2*Slope End Slope1 Output %

1.6.7 BDI On X BDI (Off / On )

1.6.8 Str Trig None X Steering trigger

1.6.9 Economy Cuts I Off X Economy Cuts Current (Off / On )

1.6.10 SRO Off X SRO (Off / On )

1.6.11 Braking Prop X Braking (Const / Prop)

1.6.12 Control Torque X Control Mode (Torque / Speed)

1.6.13 Truck Ride On X Truck (Ride On / Walkie)

1.6.16 Dig 5 None X Digital i/p 5 config (Pin 6)

1.6.17 Dig 6 Pump X Digital i/p 6 config (Pin 7)

1.6.18 Dig 7 Speed 2 X Digital i/p 7 config (Pin 8)

1.6.19 Analog 1 Accel X Analog 1 i/p config (Pin 10)

1.6.20 Analog 2 Economy X Analog 2 i/p config (Pin 11)

1.6.21 Cont 2 Pump X Contactor 2 config

1.6.22 Fault Log On X Fault Log (Off / On )

1.6.23 Service Log On X Service Log (Off / On )

1.6.25 Steer Rev On X Steer reverse enable

1.6.26 Steer Pot X Steer input source

1.6.28 Battery Volt 48 V X System Battery Voltage

1.6.29 Seat & Pump On X Seatcut Pump Contactors

(Off / On )
O : Adjustable, X : Not adjustable

Note *) : Cal.Ref. with “ * ” mark will appear by pushing a down arrow button .

CS-21
 C.A.N CALIBRATOR
Motor Setup
Adjustment values for the traction motor can be changed in this function.
Main purpose of this function is
for the checking each value after replacing a controller or parts.

Most items cannot be changed, because these values are very important for the controller.
But N01 SEM traction controller is only one kind. (One parts number)
Therefore, It is necessary to select a controller type whether a truck is standard or HP.

“Cal.Ref.1.7.3: Field I Low” item should be confirmed in controller replacement.

If this item is not correct, this item should be change as bellow value.

- N01 standard : “Cal.Ref.1.7.3: Fld I Low” should be “7 A” .

- N01 HP (GN01) : “Cal.Ref.1.7.3: Fld I Low” should be “5 A” .

Note : Do not use other value in “Cal.Ref.1.7.3: Field I Low”.

1 Traction
OK

1.1 Traction
Personalities
… 1.7 Traction
Motor Setup

1.7.1 Trac Motor

Arm I low 70A
1.7.2 Motor setup
Fld I low 7.00A … 1.7.8 Motor setup
Fld Res 0.61•

Increase Decrease Increase Decrease Increase Decrease

Adjustable values

Cal.Ref. Display Range Initial Remarks

: : : : :
1.7.2 Fld I low 2.00A - 15.00A 7.00 A Motor filed current in low armature current.
( For N01 STD model)
5.00 A Motor filed current in low armature current.
( For GN01 HP model)
: : : : :

Note : Changing only take effect after a key-switch recycle.

CS-22
 C.A.N CALIBRATOR
Motor Setup (Cont’d)

All visible values ( For reference )

Cal. Ref Display Initial Adjustable Remarks

1.7.1 Arm I low 70 A X Armature I Low
1.7.2 Fld I low 7.00 A O Field I Low (N01 STD)
5.00 A Field I Low (N01 HP)
1.7.3 Arm I mid 90 A X Armature I Mid
1.7.4 Fld I mid 20 A X Field I Mid
1.7.5 Arm I high 140 A X Armature I High
1.7.6 Fld I high 30 A X Field I High
1.7.7 Arm Res 21 m• X Armature Resistance
1.7.8 Fld Res 0.61• X Field Resistance
O : Adjustable, X : Not adjustable

CS-23
 C.A.N CALIBRATOR
Pump Personalities

The adjustable values for the pump control can be changed in this function.
Main purpose of this function is
for the checking each value after replacing a controller or parts.

These adjustable values can be changed by “+ and – buttons “.

2 Pump
OK

2.1 Pump
Personalities

2.1.1 Pump Pers

I.Max 400A
2.1.2 Pump Pers
Ramp Up 0.2S
… 2.1.34 Pump Pers
Prot. Delay 0.5s

Increase Decrease Increase Decrease Increase Decrease

Adjustable values

Cal. Ref Display Range Initial Description

: : : : :
2.1.2 Ramp Up 0.1 - 5.0 s 0.2 s Time taken to ramp up from 0 to 100% on
: : : : :
2.1.5 Base Speed1 0 - 100% 100% Max allowable % of motor accelerator speed
: : : : :
2.1.9 Base Speed3 0 - 100% 100% Max allowable % of lift speed
: : : : :
2.1.11 Base Speed4 0 - 100% 85% Max allowable % of tilt speed
: : : : :
2.1.13 Base Speed5 0 - 100% 40% Max allowable % of 3rd attachment speed
: : : : :
2.1.15 Base Speed6 0 - 100% 100% Max allowable % of 4th attachment speed
: : : : :
2.1.17 Base Speed7 0 - 100% 100% Max allowable % of 5th attachment speed
: : : : :
2.1.25 Accel Zero 0 - 5.00 V 0.10 V Input voltage for pump accelerator
min. position
2.1.26 Accel Full 0 - 5.00 V 4.90 V Input voltage for pump accelerator
max. position
2.1.27 Accel2Zero 0 - 5.00 V 0.10 V Input voltage for pump economy
min. position
2.1.28 Accel2Full 0 - 5.00 V 4.00 V Input voltage for pump economy
max. position
: : : : :

Note : Changing only take effect after a key-switch recycle.

CS-24
 C.A.N CALIBRATOR
Pump Personalities (Cont’d)

All visible values ( For reference )

Cal. Ref Display Initial Adjustable Remarks

2.1.1 I. Max 400 A X Pump I Max
2.1.2 Ramp Up 0.2 s O Pump Ramp Up Delay
2.1.3 Ramp Down 0.2 s X Pump Ramp Down Delay
2.1.4 Creep Speed 10 % X Pump Creep Speed
2.1.5 Base Speed1 100% O Pump Speed 1 (Accelerator Speed)
2.1.6 Comp Speed1 0% X Pump Speed 1 Compensation
2.1.7 Base Speed2 0% X Pump Speed 2
2.1.8 Comp Speed2 0% X Pump Speed 2 Compensation
2.1.9 Base Speed3 100% O Pump Speed 3 (Lift)
2.1.10 Comp Speed3 0% X Pump Speed 3 Compensation
2.1.11 Base Speed4 85% O Pump Speed 4 (Tilt)
2.1.12 Comp Speed4 0% X Pump Speed 4 Compensation
rd
2.1.13 Base Speed5 40% O Pump Speed 5 (3 )
2.1.14 Speed5 Priority X Pump Speed 5 Mode
th
2.1.15 Base Speed6 100% O Pump Speed 6 (4 )
2.1.16 Speed6 Priority X Pump Speed 6 Mode
th
2.1.17 Base Speed7 100% O Pump Speed 7 (5 )
2.1.18 Speed7 Priority X Pump Speed 7 Mode
2.1.19 Steer Base 0% X Power Steer Speed
2.1.20 Steer Comp 0% X Power Steer Compensation
2.1.21 Steer Accel 0.3 s X Power Steer Ramp Up Delay
2.1.22 Steer Decel 0.3 s X Power Steer Ramp Down Delay
2.1.23 Steer Delay 2s X Power Steer Delay
2.1.24 Seat Delay 2.5 s X Seat Switch Delay
2.1.25 Accel Zero 0.10 V O Pump Accelerator Zero Voltage
2.1.26 Accel Full 4.90 V O Pump Accelerator Full Voltage
2.1.27 Accel2Zero 0.10 V O Economy Zero Voltage
2.1.28 Accel2Full 4.00 V O Economy Full Voltage
2.1.29 Lo V Init 36.0 V X Low Battery Start
2.1.30 Lo V Cut 30.0 V X Low Battery Cut-out
2.1.31 Hi V Init 65.0 V X High Battery Start
2.1.32 Hi V Cut 70.0 V X High Battery Cut-out
2.1.33 Bat. Prot 30.0 V X Battery Protection Level
2.1.34 Prot. Delay 0.5 s X Battery Protection Delay
O : Adjustable, X : Not adjustable

CS-25
 C.A.N CALIBRATOR
Pump Status

The voltage or current can be monitored in this function.

These values are used for checking a condition of controller during truck operation.
Main purpose of this function is
for the checking the voltage or current in a trouble shooting.

Several items can be stored as a service log data. (minimum and/or maximum)
The items marked “+” or “+ -“ in “Log info column” have the service log.

2 Pump
OK

2.1 Pump 2.2 Pump

Personalities Status

2.2.1 Pump Stat

Battery 48.0V
2.2.2 Pump Stat
Motor 20V
… Service Log
+ to reset log

Max data Reset service Log

Monitoring Values

Cal. Ref. Display Min. Max. Log Remarks

Display Display Info.
2.2.1 Battery 0.0 V 127.5 V + Battery Voltage
2.2.2 Motor 0.0 V 127.5 V Pump Motor Voltage
2.2.3 Motor 0A 625 A + Pump Motor Current
2.2.4 Mosfet 0V 127.5 V Pump MOSFET Voltage
2.2.5 Temp. -30 +225 + - Pump Controller Temp.
2.2.6 Key 0 Hrs 65279.9 Hrs Key Switch Hours Count
2.2.7 Pump 0 Hrs 65279.9 Hrs Pump Pulsing Hours Count
- Service Log press + to reset service log Service Log Reset

Note : Log Info shows where the + and - keys can be used to
access the service max and min data.

CAUTION
Traction motor and pump motor can be operated during this procedure.
Make sure the following matters.
1)The drive wheels should be off the floor and free to rotate.
2) Loading equipment like as Fork or Mast should be free from others.

CS-26
 C.A.N CALIBRATOR
Pump Test

The switches and sensors can be monitored in this function.

Main purpose of this function is
for the checking the switches and sensors in a trouble shooting.

It is possible to observe the status of all the switches and sensors.

2 Pump
OK

2.1 Pump
Personalities
… 2.3
Test
Pump

2.3.1 Pump Test

Accel 1 0%
2.3.2 Pump Test
Accel 1 0V
… 2.3.16 Pump Test
Ser No 0000

Monitoring values

Cal. Ref. Display Min. Max. Remarks

Display Display
2.3.1 Accel1 0% 100 % Accelerator %
2.3.2 Accel1 0.0 V 5.0 V Accelerator Voltage
2.3.3 Accel2 0% 100 % Economy %
2.3.4 Accel2 0.0 V 5.0 V Economy Voltage
2.3.5 Pswitch 3 Open Closed Pump Switch 3 (Lift)
2.3.6 Pswitch 4 Open Closed Pump Switch 4 (Tilt)
rd
2.3.7 Pswitch 5 Open Closed Pump Switch 5 (3 lever)
th
2.3.8 Pswitch 6 Open Closed Pump Switch 6 (4 lever)
th
2.3.9 Pswitch 7 Open Closed Pump Switch 7 (5 lever)
2.3.10 Trigger Open Closed Power Steer Trigger
2.3.15 Software 000.00 999.99 Software Version/Revision
2.3.16 Ser No 00000000 99999999 Controller Serial Number

CAUTION
Traction motor and pump motor can be operated during this procedure.
Make sure the following matters.
1)The drive wheels should be off the floor and free to rotate.
2) Loading equipment like as Fork or Mast should be free from others.

CS-27
 C.A.N CALIBRATOR
Pump BDI

The adjustable values for the battery capacity can be monitored in this function.
( Also the values can be changed. But normally, it is not necessary to change them.)
Main purpose of this function is
for the checking each value after replacing a controller or parts.
(Should be same as Traction BDI values.)

Traction BDI function monitor the battery remain capacity and control all BDI function.
Therefore, these pump BDI values should be same as Traction BDI values.
When Traction BDI values are changed, Pump BDI should be adjusted to the same value.
(Refer to Traction BDI for details.)

2 Pump
OK

2.1 Pump
Personalities
… 2.4
BDI
Pump

2.4.1 BDI
80% Charge Left
2.4.2 BDI
Battery Volt 48V
… 2.4.6 BDI
Cutout 15%

Increase Decrease Increase Decrease

Adjustable values

Cal. Ref Display Range Initial Remarks

2.4.1 % Charge Left Display Only Percentage Charge Remaining
2.4.2 Battery Volt 24 - 96 V 48 V BDI Battery Voltage
2.4.3 Reset V/Cell 2.00 - 2.50 V 2.09 V BDI Reset Level
2.4.4 Empty V/Cell 1.50 - 1.99 V 1.60 V BDI Discharge Level
2.4.5 Warning 0 % - 90 % 20 % BDI Warning Level
2.4.6 Cutout 0 % - 90 % 15 % BDI Cutout Level

CS-28
 C.A.N CALIBRATOR
Pump fault log information.

If some fault occurs, this function is activated and fault information can be seen in this function.
This information show “LED flash fault code” and “fault message” that have occurred.
Main purpose of this function is
for the checking the fault history in the controller.

This fault log information can shows the fault data like as the following items.
- The total number of faults of this type.
- The Key hours count of the most recent fault.
- The text description of the fault.
For example
This fault log information shows
12*04F 12345.6hr - 12times of 4-Flash faults have occurred.
Contactor o/c
- The most recent at 12345.6 Key hours.
- This fault was a Contactor o/c fault.

However, the general faults during normal operation like as 2 flash “driver procedure error”
and 8 flash “thermal cutback indication” is not logged.

2 Pump
OK

2.1 Pump
Personalities
… 2.5 Pump
Fault Log

12*00F 123.0hr
CANbus Error
2*03F 100.0hr
MOSFET s/c … Fault Log
+ to reset log

Fault log information

Type of fault Description of fault Logged

LED off faults Internal controller power up check faults O
1 flash faults Personality/CRC faults O
2 flash faults Driver procedure/sequence/wiring type faults X
3 flash faults MOSFET/Motor wiring type faults O
4 flash faults Contactor o/c or s/c or wiring type faults O
5 flash faults Not used X
6 flash faults Potentiometer wire off type faults X
7 flash faults Battery low or high faults O
8 flash faults Thermal cutback faults X
9 flash faults Contactor coil s/c type faults O
12 flash faults CAN bus faults O

Note : Logged shows where the “O” can be logged.

CS-29
 C.A.N CALIBRATOR
Pump Setup

Adjustment values for the controller setting can be only shown in this function.
Main purpose of this function is
for the checking each value after replacing a controller or parts.

All items cannot be changed, because these values are very important for the controller.

2 Pump
OK

2.1 Pump
Personalities
… 2.6 Pump
Setup

2.6.1 Pmp Setup

Canbus mode
2.6.2 Pmp Setup
Accel Canbus
… 2.6.11 Pmp Setup
PStr Actv Off

Select Select Select Select Select Select

All visible values ( For reference )

Cal.Ref Display Initial Adjustable Parameters

2.6.1 mode Canbus X Standalone / Canbus Mode
2.6.2 Accel Max Spd X Accelerator
2.6.3 Accel 2 Economy X Ecconomy
2.6.4 BDI On X BDI on/off
2.6.5 Fault log On X Fault log on/off
2.6.6 Service Log On X Service Log on/off
2.6.7 Seat & Pump On X Seat Cuts Pump on/off
2.6.8 Pin 5 P.Switch 6 X Digital Input 4 Configuration
2.6.9 Pin 6 P.Switch 7 X Digital Input 5 Configuration
2.6.10 Pin 7 Psteer X Digital Input 6 Configuration
2.6.11 PStr Actv Closed X Power Steer Active Sense
2.6.12 Econ Cuts I Off X Current cut in Economy mode

CS-30
 WORKING EXAMPLE
Traction Accelerator Adjustment

Outline

When the traction accelerator is replaced to new one, a function of accelerator needs to be
checked.
It is necessary to use a calibrator for the checking this accelerator function.
If the function is NOT OK, several values in controller need to be checked and adjusted.
The following procedure is a sample how to do in this check and adjustment.

Job Flow

[Replacement]
The traction accelerator need to be replaced.

Install the traction accelerator on the truck

Connect C.A.N CALIBRATOR Carry out the procedure in CS-11,12 in order

( Refer CS-11,12 ) to avoid any damage to the controller and
CALIBRATOR.

OK
Check the Accelerator output. The Accelerator output (1.3.1 Accel %)
should increase from 0 to 100 % as the
( Refer CS-32 for the detail)
Accelerator pedal is depressed.
NG
Accelerator output does not
increase correctly.

Adjust the movement of the Accelerator Pedal. In order to achieve a correct voltage, the
Accelerator Pedal should be adjusted.
NG
Cannot get a correct value
by the Adjustment
Check and write down the Accelerator
Measure the Acceleration Voltage voltage (1.3.2 Accel V) when the
( Refer CS-32 for the detail) Accelerator pedal is depressed or
pressed.

Adjust the Traction Personality value with

Adjust the Traction Personality values the measured value of the Accelerator
( Refer CS-33 for the detail) Voltage.

Confirm a Diagnostic Message The fault message as (Accel.Fault) should

not appear.
( Refer CS-33 for the detail)

OK

Finish

CS-31
 WORKING EXAMPLE
Description of each Job

Check the Accelerator output.

Check the values of “1.3.1 Accelerator Output” under the following conditions.
Condition
- Accelerator pedal in free position : Accelerator output should be 0 %
- Accelerator pedal in full depressed position : Accelerator output should be 100 %

Key-Switch ON

Accel pedal Accel Pot.

1 Traction
position Output
OK
Free 0%
Full press 100%

1.1 Traction
Personalities … 1.3 Traction
Test Check the Accelerator output

1.3.1 Trac Test

Accel 0%

Measure the Accelerator Voltage

Read and write down values of “1.3.2 Accelerator Voltage” under the following conditions.
Condition
- Accelerator pedal in free position : Accelerator Voltage is around 0-0.12 V
- Accelerator pedal in full depressed position : Accelerator Voltage is around 4.52-5 V

Key-Switch ON
Accel pedal Accel Pot.
1 Traction position Voltage
OK Free Vfree [v]
Full press Vfull [v]

1.1 Traction
Personalities … 1.3 Traction
Test Measure the accel voltage

1.3.1 Trac Test 1.3.2 Trac Test

Accel 0% Accel 0V

CAUTION
“Vfree” Accelerator Voltage in Accel pedal free position should be less than 0.12 V.
If not, adjust Accel pedal until “Vfree” achieves less than 0.12 V.

CS-32
 WORKING EXAMPLE
Description of each Job (Cont’d)

Adjust the Traction Personality values

Check the value “1.1.26 Accel Zero, 1.1.27 Accel Full” under the following conditions.
If the value is not correct, the value should be adjusted.
Condition
- “1.1.26 Accel Zero” : The value should not be changed from initial value (0.12V) .
- “1.1.27 Accel Full” : The value should be equal to “Vfull” or little less
(Vfull :Accel Voltage in Accel pedal full depressed position.)

Key-Switch ON

Accel pedal Accel Pot.

1 Traction position Voltage
OK
Free Vfree [v]
Full press Vfull [v]

1.1 Traction
Personalities Check and adjust the Traction
Personality value

1.1.1A Trac Pers 1.1.26 Trac Pers 1.1.27 Trac Pers

I.Max 220A … Accel Zero 0.12 Accel Full 4.52

Increase Decrease
Should not change

Confirmation of Diagnostic Message

Confirm the Calibrator message is “OK” when the Accelerator pedal is depressed to the
stroke end and free position.

Key-Switch ON

1 Traction
OK

CS-33
 WORKING EXAMPLE
Steering Sensor Adjustment

Outline

When the Steering Sensor is replaced to new one, a function of Steering Sensor needs to be
checked.
It is necessary to use a calibrator for the checking this Steering Sensor function.
If the function is NOT OK, several values in controller need to be checked and adjusted.
The following procedure is a sample how to do in this check and adjustment.

Job Flow

[Replacement]
The Steering Sensor need to be replaced

Check the actual steering tire angle Check the actual steering tire angle in both
( Refer CS-35 for the detail ) direction ( left end and right end)

Install Steering sensor on the bracket Install the steering sensor on the bracket of
( Refer CS-36 for the detail ) rear axle Boss.

Carry out the procedure in CS-11,12 in order

Connect C.A.N CALIBRATOR to avoid any damage to the controller and
( Refer CS-11,12 ) CALIBRATOR.

NG Check and write down the Steering Sensor

Measure the Steering Sensor Voltage voltage (1.3.8 Steer Pot.) when the
( Refer CS-36 for the detail ) steering tire is located at the left end or the
right end.
OK

Adjust the Traction Personality values Adjust the Traction Personality value with
the measured value of the Steering sensor
( Refer CS-37 for the detail )
Voltage.

The Steering Angle (1.3.7 Steer Angle) should

Confirm the Steering Angle. increase from around -90 to +90deg as the
( Refer CS-37 for the detail ) steering wheel is rotated from the left end to
the right end.
This value is not same as actual tire angle.
OK

Confirm a Diagnostic Message The fault message as (Steer Fault) should

( Refer CS-38 for the detail ) not appear.

OK

Finish

CS-34
 WORKING EXAMPLE
Description of each Job

Check the actual steering tire angle.

Check the actual steering wheel angle under the following conditions.

Condition
- Steering wheel rotated fully counter-clockwise :Steering Tire Angle is more then 85deg
(Steering tire is rotated to the left end)

- Steering wheel rotated fully clockwise :Steering Tire Angle is more then 85deg
(Steering tire is rotated to the right end)

Neutral position

BOSS- STRG
AXLE
The left end position The Right end position
(Steering wheel rotated (Steering wheel rotated
fully counter-clockwise) fully clockwise)

Steering Tire

BRKT CAM-STRG SW
Check the Check the
angle angle

Steering tire Angle of Steering tire

position
Left end More than 85 [deg]
Right end More than 85 [deg]

CAUTION
If there is big difference between the left end angle and the right end angle,
check the mechanical movement of the rear axle.

CS-35
 WORKING EXAMPLE
Description of each Job (Cont’d)

Install Steering sensor on the bracket

Install the Steering sensor on the bracket (BRKT-TRACTION, CONT SW) of BOSS-STRG
AXLE under following instruction.

Instruction
1) The Steering wheel and tire must be Neutral position
2) Install Steering sensor in the vertical position against the Front line.
3) The Steering Sensor Harness should be positioned to the truck front side.

BRKT-TRACTION, BOSS- STRG

CONT SW AXLE
Truck
Front

Steering Sensor
Harness

BRKT CAM-STRG
Neutral position Steering Sensor
SW

Measure the Steering Sensor Voltage

Check and write down values of “1.3.8 Steer Pot.” under the following conditions.

Condition
- Steering wheel rotated fully counter-clockwise : Steer Pot. is around 3.4 V (reference)
(Steering tire is rotated to the left end)
- Steering wheel rotated fully clockwise : Steer Pot. is around 0.4 V (reference)
(Steering tire is rotated to the right end)

Key-Switch ON

Steering tire Steer Pot.

1 Traction position Voltage
OK
Left end Vleft [V]
Right end Vright [V]

1.1 Traction
Personalities … 1.3 Traction
Test Measure the Steer Pot. voltage

1.3.1 Trac Test 1.3.8 Trac Test

Accel 0% … Steer Pot 0V

CAUTION
If Steer Pot. Voltage does not increase correctly, check the Steering sensor or
mounted position.

CS-36
 WORKING EXAMPLE
Description of each Job (Cont’d)

Adjust the Traction Personality values

Adjust the value “1.1.32 Steer Zero, 1.1.33 Steer Full” under the following conditions.

Condition
- “1.1.32 Steer left” : The value need to be equal to “Vleft - 0.04 [V] ” .
(Vleft : Steer pot in Steering wheel rotated fully counter-clockwise.)
- “1.1.33 Steer right” : The value need to be equal to “Vright + 0.04 [V] ” .
(Vright : Steer pot in Steering wheel rotated fully clockwise.)

Key-Switch ON
Steering tire Steer Pot.
position Voltage
1 Traction
Left end Vleft - 0.04 [V]
OK
Right end Vright + 0.04 [V]

1.1 Traction Adjust the Traction

Personalities Personality value

1.1.1A Trac Pers 1.1.32 Trac Pers 1.1.33 Trac Pers

I.Max 220A … Steer Left 3.4 Steer Right 0.4

Increase Decrease Increase Decrease

Confirm the Steering Angle.

Confirm the values of “1.3.7 Steering Angle” under the following conditions.
Condition
- Steering wheel rotated fully counter-clockwise : Steer Angle should be equal to –90deg

- Steering wheel rotated fully clockwise : Steer Angle should be equal to +90deg

Key-Switch ON
Steering tire Angle of
position Steering tire
1 Traction Left end - 90 [deg]
OK Right end +90 [deg]

1.1 Traction
Personalities … 1.3 Traction
Test
Confirm the
Steering angle

1.3.1 Trac Test 1.3.7 Trac Test

Accel 0% … Steer Angle 0

CS-37
 WORKING EXAMPLE
Description of each Job (Cont’d)

Confirmation of Diagnostic Message

Confirm the Calibrator message is “OK” when the Steering wheel is rotated fully counter-
clockwise or fully clockwise.

Key-Switch ON

1 Traction
OK

CS-38
 DIAGNOSTICS
Fault message

Traction and pump controller have a self Diagnostics function.

When some fault occur, LED of controller and C.A.N CALIBRATOR show error message.
In case of LED message, only high priority item is appeared by flashing LED.
The bellow table can show each fault message description and priority.

Calibrator Led Priority Description Check...

Message
OK on 19 All operational and OK. No action required.
CRC error 1F 6 One or more personalities have been Check all personalities.
corrupted.
Pers Error 1F 7 Personalities out of range at power up. Check all personalities.
2 Dir. Fault 2F 13 Directions ( F & R) selected together. Check Direction switch or wiring.
Seat Fault 2F 11 Drive selected and no seat sw. Check Seat switch or wiring.
Sequence Fault 2F 14 Direction or Accelerator switch at power Direction and Accelerator in neutral at
up. power up or wiring.

SRO Fault 2F 12 Direction ( F or R) switch selected after Direction ( F or R) switch should be

more than 2 sec of Accelerator selected before Accelerator switch
selected. selected.
Steer Fault 2F 10 Outer switch closing before inner. Check steering sensor or wiring.
Mosfet s/c 3F 4 MOSFET s/c Check power wiring(A / F1 / F2 / B) or
MOSFET of controller.

PU Trac Mos 3F 3 MOSFET s/c at controller power up. Check power wiring(A / F1 / F2 / B) or
MOSFET of controller.

Accel. Fault 6F 16 Accelerator sensor selected at power Check Accelerator or wiring or Accel
up. Zero & Full in traction personalities.

Line Cont o/c 4F 15 Line contactor coil or terminal o/c. Check line contactor and terminal
Battery High 7F 8 Battery > High battery in personality. Check battery voltage or + or - cable
or High battery in personality.

Battery Low 7F 9 Battery < Low battery in personality. Check battery voltage or + or - cable
or low battery in personality.

BDI Cut-out 7F 18 BDI enabled and cutout action initiated. Check battery voltage or + or - cable
or BDI Cut-out in personality.

Thermal 8F 17 Traction heat sink above 75°C. Check Heat sinking or Mounting
Cutback Surfaces.
Coil s/c 9F 5 Main contactor coil s/c. Check Main Contactor coil s/c.

CAN bus fault 12F 2 CAN bus failure. Check CAN bus wiring.
No message off 1 No supply Battery voltage or internal Check battery connection or wiring.
failed.

CS-39
 DIAGNOSTICS
Troubleshooting Flowcharts
Traction and pump controller have a self Diagnostics function.
When some fault occur, LED of controller and C.A.N CALIBRATOR show error message.
The following troubleshooting flowcharts are based on LED flash message.
These Flowcharts also include Calibrator fault messages.

LED Off
The possible main cause of “LED OFF” are
1) No supply from battery ( No Message in Calibrator display )
2) Internal failure of controller ( “FAIL “ in Calibrator display )

Calibrator Display
Check

No Message
FAIL

Check a battery Controller failure

connection and wiring

LED 1 Flash Fault

The possible main cause of “LED 1 Flash” are

1) Out of range Personalities ( “Pers error “ in Calibrator display )
2) One or more personalities have been corrupted ( “CRC error “ in Calibrator display )

Calibrator Display
Check

Pers error
CRC error

Check all personalities Check all personalities

then recycle key switch. then recycle key switch.

CS-40
 DIAGNOSTICS
LED 2 Flash Fault

The possible main cause of “LED 2 Flash” are

1) Directions ( F & R) selected together ( “2 Dir. Fault “ in Calibrator display )
2) Drive selected and no seat sw. ( “Seat Fault “ in Calibrator display )
3) Direction or Accelerator switch at power up ( “Sequence Fault “ in Calibrator display )
4) Direction ( F or R) switch selected after
more than 2 sec of Accelerator selected. ( “SRO Fault “ in Calibrator display )

Calibrator Display
Check

Sequence 2 Dir. SRO Seat

Fault Fault Fault Fault

Recycle direction, Recycle direction, Recycle direction, Recycle direction,

Accelerator switch Accelerator switch Accelerator switch Accelerator switch
or both. or both. or both. or both.

Check direction, Check direction, Check direction, Check seat,

Accelerator switch switch and wiring. Accelerator switch switch and wiring.
and wiring. and wiring.

If checks Ok,
Controller fault

CS-41
 DIAGNOSTICS
LED 3 Flash Fault

The possible main cause of “LED 3 Flash” are

1) MOSFET short circuit ( “MOSFET s/c “ in Calibrator display )

Calibrator Display
Check

MOSFET s/c

Power cable
problem

Check A/F1/F2/B- Power cable Correct Power cable

Power cable no
problem
MOSFET
s/c
Check MOSFET s/c by multi meter Controller failure
(MOSFET s/c)
MOSFET
no problem

Controller failure
(PCB fault)

CS-42
 DIAGNOSTICS
LED 6 Flash Fault

The possible main cause of “LED 6 Flash” are

1) Accelerator sensor selected at power up, ( “Accel.Fault “ in Calibrator display )
2) Steer sensor value is out of range. ( “Steer Pot Fault “ in Calibrator display )

Calibrator Display
Check

Accel.
Steer Pot
Fault
Fault

Check Accelerator adjustment. Check Steer pot adjustment.

(Refer to working example) (Refer to working example)

Problem Problem
still remain still remain

Check the Accelerator and Check the steer pot and

wiring wiring

Problem Problem
still remain still remain

Controller failure
(PCB fault)

CS-43
 DIAGNOSTICS
LED 7 Flash Fault

The possible main cause of “LED 7 Flash” are

1) Battery > High battery in personality ( “Battery High “ in Calibrator display )
2) Battery < Low battery in personality. ( “Battery Low “ in Calibrator display )
3) BDI enabled and cutout action initiated ( “BDI Cutout “ in Calibrator display )

Calibrator Display
Check

BDI Battery Battery

Cutout Low High

Check battery charge Check battery voltage Check battery voltage

remaining less than less than Low battery higher than high
BDI-cut level personality battery personality

Problem Problem Problem

still remain still remain still remain

Controller failure

CS-44
 DIAGNOSTICS
LED 8 Flash Fault

The possible main cause of “LED 7 Flash” are

1) Traction heat sink above 75°C ( “Thermal Cutback “ in Calibrator display )

Calibrator Display
Check

Thermal
Cutback

Temp. is not
high
Check traction controller
Temp. by Calibrator

Temp. is really
high

Check controller mounting

Surfaces clean

No
Problem
Check the Motor
Check controller after cool down current in the
actual operation
Problem
still remain Motor
Current is
really high

Controller failure
(Check each controller) Check the
operation.

CS-45
 DIAGNOSTICS
LED 9 Flash Fault

The possible main cause of “LED 9 Flash” are

1) Main contactor coil s/ ( “Coil s/c “ in Calibrator display )

Calibrator Display Check

Coil s/c

Check the Contactor Coil s/c or a

harness for Contactor.

Problem
still remain

Disconnect Contactor and then,

check the Calibrator Display.
Problem
still remain

Controller failure

LED 12 Flash Fault

The possible main cause of “LED 9 Flash” are

1) CAN bus failure ( “CAN bus fault “ in Calibrator display )

Calibrator Display
Check

CAN bus fault

Check the CAN

connector and wiring

Problem
still remain

Controller failure
(Check each controller
with Calibrator)

CS-46
WIRING DIAGRAM (with pump chopper)

CS-47
WIRING DIAGRAM (without pump chopper)

CS-48
 FRONT AXLE
(FA)

MODEL NOl SERIES

" "

CONTENTS

SERVICE DATA AND SPECIFICATIONS FA-2

TROUBLE DIAGNOSES AND CORRECTIONS FA-3
FRONT AXLE COMPONENTS FA-5
FRONT AXLE ASSEMBLY (Final drive assembly) FA-6
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT

Front axle type Full floating 4.4 - 5.4 N'm

Turning torque of axle hub (0.45 - 0.55 kg-m,
Suspension type Fixed to frame 3.3 - 4.0 ft-Ib)

Final drive assembly

Type RB3F250F

Input pinion and primary

reduction gear
Gear type Helical TIGHTENING TORQUE

Gear ratio 2.625 N.m kg-m ft-Ib

Number of teeth 42/16 Final drive assembly to 343- 392 35-40 253 - 289
frame
Secondary redu ction gear
Gear carrier 30 -40 3.1 - 4.1 22 -30
and third reduction gear
Gear type Helical Drain plug 20-29 2-3 14 - 22
Filler plug 20 - 29 2-3 14 -22
Gear ratio 3.714
Brake tube flare nut 15 -18 1.5-1.8 11 - 13
Number of teeth 52/14
Brake assembly to frame 54.74 5.5 - 7.5 40-54
Fourth reduction gear and Brake rotor fixing nut 44.59 4.5 - 6.0 33 - 43
final reduction gear
Road wheel nut 157 -176 16 - 18 116-130
Gear type Helical

Gear ratio 2.105

Number of teeth 40/19

Final gear ratio 20.526

Oil capacity
Q (US qt, Imp qt)
Right 0.8 (7/8,3/4)

Left 1.5 (1-5/8, 1-3/8)

Tire.size
Pneumatic-tire
1.25-ton model 18 x 7-8-14PR (I)

1.5-ton model 18 x 7-8-16PR (I)

Pneumatic type cushion-tire 18 x 7-8

Cushion-tire
1.25-ton model 18 x 6 x 12-1/8

1.5 & 1.75-ton model 18 x 7 x 12-1/8

8 x 4.33R TB (I)
Disc wheel size
(except cushion-tire models)

Tire pressure
kg/cm' (kPa, bar, psi)
1.25-ton model 9 (883,8.8,128)

1.5 & 1.75-ton model 1.0 (981,9.8,142)

FA-2
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

ROAD WHEEL TIRE AND AXLE HUB

Condition Probable cause Corrective action

Unusual noise
Before attempting a correction, make sure Loose final drive assembly mounting bolts. Tighten.
the noise is coming from the axle hub, not Loose axle hub nut. Tighten.
from the reduction gear.
Loose wheel nuts. Tighten.
Other retaining parts loose. Tighten.
Worn or damaged wheel bearing. Replace.
Wheel bearing not properly adjusted. Adjust.
Worn axle hub splines. Replace.
Insufficient lubrication. Lubricate.

Unstable driVing
Also refer to the Trouble Diagnoses and Loose wheel nut. Tighten.
Corrections in the RA section. Deformed road wheel. Replace.
Worn or damaged wheel bearing. Replace.
Loose final drive assembly mounting bolts. Tighten.
Wheel bearing not properly adjusted. Adjust.
Improper tire pressure. Adjust.

FA-3
 TROUBLE DIAGNOSES AND CORRECTIONS

REDUCTION GEAR (Final drivel

Condition Possible cause Corrective action

Oil leakage Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper
corrective action.
• Worn, faulty, or improperly installed oil Repair or replace.
seal.
• Loose gear carrier mounting bolts. Retighten, or replace gasket.
• Faulty gasket. Replace gasket .
• Loose filler plug or drain plug. Retighten.
• Clogged or faulty air breather. Repair or replace.
• Worn, faulty, or improperly installed axle Repair or replace.
hub oil seal.

Seizure Replace any seized or damaged parts. Check related parts for condition. Repair or replace them
if necessary.
• Bearing seizure. Replace.
• Too large axle hub preload. Disassemble, adjust or replace .
• Insufficient oil, or use of improper oil. Add or replace as specified.

Unusual noise • Pitted or worn gear tooth surface, or Replace.

broken tooth.
• Loose pinion nut, or any other bolts or Retighten.
nuts.
• Insufficient oil, or use of improper oil. Add or change oil as specified.
• Abnormally worn or broken gear. Replace.

FA-4
 FRONT AXLE COMPONENTS

FRONT AXLE COMPONENTS

~
C'II
C'II

~ ~
_
l'l'"0
c e
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=
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FFA009

FA-5
 FRONT AXLE COMPONENTS

FRONT AXLE ASSEMBLY 9. Support front axle assembly and

(Final drive assembly) traction motor with lifting device.
REMOVAL

1. Remove mast assembly. Refer to Matching mark

mast (Section LM) for removal.
2. Remove hydraulic pump motor
with pump. Refer to hydraulic pump
motor (Section HD) for removal.
3. Lift up truck front side and place
wooden blocks under both side FFA015
frames.
4. Removal front wheel tire.
S. Drain reduction gear oil. 1. Remove hub cap and axle hub
nut, then take out axle hub.

10. Disconnect traction motor cables.

11. Remove front axle assembly
mounting bolts and nuts.

6. Remove pad from disc brake as-

sembly. Remove brake assembly and 2. Separate gear case.
suspend it with lifting wires.

12. Remove front axle assembly and

traction motor as a unit.

3. Remove hub bearing inner race

7. Remove brake disc.
using puller.
8. Remove micron filter with
bracket, steering gear mounting
bracket and horn.
DISASSEMBL Y

Before separating traction motor and

front axle assembly, make matching
marks in order to install correctly.

FDA086

FA-6
 FRONT AXLE COMPONENTS

4. Remove hub bearing outer race, I. Tighten axle hub nut. • After installing front axle assembly,
using a brass drift. fill with gear oil.
~: 78-98N.m
(8 - 10 kg-m. Gear oil capacity:
Inspection after disassembly
58 - 72 ft-Ib) RH side 0.8 Q (7/8 US qt.
1. Clean the disassembled parts com- 2. Loosen hub nut completely. 3/4 Imp qt)
pletely. Repair or replace any damaged There should not be any axial play at LH side 1.5 Q (1-5/8 US qt.
or defective parts. hub. 1-3/8 Imp qt)
2. The following parts should be re- 3. Turn axle hub 4 to 5 times in
placed with new ones each time these both directions.
parts are removed. 4. Repeat steps I through 3 above .
• Gaskets 5. Adjust axle hub nut until speci-
• Oil seal fied turning torque of axle hub is
obtained.
ASSEMBLY
Turning torque:
Assembly should be performed in the 4.4 - 5.4 N.m
reverse order of disassembly. (0.45 - 0.55 kg-m.
Observe the following. 3.3 - 4.0 ft-Ib)

CAUTION: 6. Turn axle hub 4 to 5 times in

a. Apply gear oil when installing bear- both direction again.,
ings. 7. Measure turning torque of axle
b. Pack recommended multi-purpose hub again, and adjust tightening
grease cavity between lips when torque of axle hub nut.
fitting oil seal. 8. Lock axle hub nut with a lock
c. Apply a coat of molybdenum washer.
grease to axle hub and a coat of
gear oil to splines of traction
motor shaft.
INSTALLATION
To install, reverse the order of re-
Axle hub adjustment moval. Observe the following:
~ : Drain and filler plugs
Before performing axle hub adjust-
20 -29 N.m
ment. apply gear oil between gears
(2 - 3 kg-m.
without installing traction motor.
14 - 22 ft-Ib)

FA-7
 REAR AXLE
(RA)

MODEL NOl SERIES

" "

CONTENTS

SERVICE DATA AND SPECIFICATIONS " RA-2

TROUBLE DIAGNOSES AND CORRECTIONS " RA-2
REAR AXLE " RA-3
REAR AXLE ASSEMBLY RA-4
REAR AXLE HUB RA-5
 SERVICE DATA AND SPECIFICATIONS/TROUBLE DIAGNOSES AND CORRECTIONS

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT

Axle type Full-floating pivot type Support bearing of steering

axle bracket
Wheel alignment (deg.) Rotation starting torque
Camber 5 - 10 (0.5 .1.0,3.6 - 7.2)
N.m (kg-m, ft-Ib)

Caster 0° Axial play mm (in) 0(0)

Kingpin inclination Wheel bearing

Rotation starting force
86.4° - 87.9° Lessthan 29 (3,7)
Steering angle N (kg,lb)
(right and left)
0.01 .0.08
Tire size Axial play mm (in)
(0.0004 - 0.0031)
Pneumatic-tire'
1.25-ton model 18 x 7 - 8 - 14PR (I)

1.5-ton model 18 x 7 -8 . 16PR (I)

Pneumatic type cushion-tire 18 x 7-8

TIGHTENING TORQUE
Cushion-tire
1.25-ton model 18 x 6 x 12-1/8 Unit N.m kg-m ft.lb

1.5-ton and 1.75-ton model 18 x 7 x 12-1/8 Road wheel nut 157-177 16-18 116 -130

8 x 4.33 TB (I)
Disc wheel size
(except cushion-tire model)

Tire pressure
kg/cm1 (kPa, bar, psi)
1.25-ton model 9 (883, 8.8,128)

1.5-ton model 10 (981,9.8, 142)

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Unstable driVing. • Loose wheel nut. Tighten .

• Wheel bearing out of adjustment. Adjust.

• Support bearing out of adjustment. AdjUSt.

• Improperly adjusted chain tension. Adjust .

• Faulty steering system. Refer to ST section .

Noises. • Insufficient lubrication. Apply grease .

• Loose bolts and nuts. Tighten .

RA-2
_____________ -:::::R~EA~~RA:X~L;E~;_---------
REAR AXLE

Steering earn

Steering axle. upper -[

support bearing
e'~
~
~
~
I
@ ,
Steering axle. lower {
support bearing
9
Oilseal--~

Steering axle bracket

Axle hub

Lock nut

FRA018

RA-3
 REAR AXLE

REAR AXLE ASSEMBLY 6. Remove chain. 10. To install, reverse the order of re-
REMOVAL AND INSTALLATION moval carefully observe the following:

1. Loosen wheel nuts. • Support bearing adjustment

2. Lift up truck rear side and place (1) Apply a coat of grease to the fric-
wooden blocks under both counter- tional surface of support bearing and
weights. threads of lock nut before installing
them.
(2) Tighten support bearing lock nut
until steering axle bracket is hard to

J FRA020
turn with one hand. From that posi-
tion, back off lock nut approximately
1/6 turn.
(3) Turn steering axle bracket two to
7. Support steering axle with garage three turns.
jack. (4) Tighten lock nut again until steer-
ing axle bracket is hard to turn with
one hand.
FSA055 (5) Loosen lock nut until the rotation
starting torque of axle bracket is
within specifications. Then, install
lock washer.

3 Remove wheel tire. Rotating starting torque:

4. Remove top panel and controller 5 -10 N'm
upper cover, then remove controller (0.5 - 1.0 kg-m,
assembly from counterweight. 3.6 -7.2 ft-Ib)
S. Remove steering cam and switch • Steering switch assembly
assembly. adjustment

CAUTION: 8. Remove steering cam, lock (1) Align a square with the line drawn
Never attempt to remove steering washer, support bearing lock nut and on steering carn so that wheels are set
switch (microswitch) since its position axle mounting cap. in the straight-ahead position.
in relation to adjacent parts is pre. 9. Slowly lower garage jack and
adjusted at factory. withdraw steering axle.

Body
panel

Steering
earn

FRA022

RA-4
 REAR AXLE

(2) Align the punched mark on steer- to make light contact with each other. • Wheel bearing adjustment
ing switch assembly plate with the line With the two held in that position,
(1) Apply a coat of multi-purpose
longitudinally drawn on steering earn. install steering switch assembly.
grease to threaded area of wheel bear-
Allow the microswitch and cam profile
ing lock nut and bearing contact sur-
face.
(2) Tighten wheel bearing nut until
wheel hub can no longer be rotated
with one hand.
(3) From that position, turn bearing
lock nut back 1/6 turn.
(4) With wheel bearing lock nut held
in that position, turn wheel hub back
two or three rotations so that bearing
settles in.
(5) Again tighten wheel bearing nut
Steering earn until wheel hub no longer rotates with
one hand, then turn bearing nut back
1/6 turn.
(6) Install lock washer so that the
rotation starting force of the wheel
hub at hub bolt and the bearing's
axial play are within the range of spe-
cified values.

FRA023

REAR AXLE HUB 3. Remove wheel tire.

4. Remove hub cap.
REMOVAL AND INSTALLATION
S. Remove lock washer and lock nut.
1. Loosen wheel nuts. 6. Pull off hub assembly.
2.. Lift up truck rear side and place
wooden blocks under both counter- CAUTION: FSA061
weights. Be careful not to drop bearing cone.

Rotation starting force:

J 7. Remove inner bearing cone from

axle spindle.
At hub bolt
9.8 - 29.4 N
(1 - 3 kg, 2.2 - 6.6 Ib)
CAUTION:
Axial play
Be careful not to damage grease seal.
0.01 - 0.08 mm
(0.0004 - 0.0031 in)
8. To install, reverse the order of
removal. Carefully observe the follow-
ing:
FSA055

RA-5
 BRAKE SYSTEM
(BR)

MODEL NOl SERIES " "

CONTENTS

SERVICE DATA AND SPECiFiCATIONS BR- 2

TROUBLE DIAGNOSES AND CORRECTIONS BR- 3
AD~USTMENT BR- 5
SERVICE BRAKE BR- 5
SERVICE BRAKE BR- 7
BRAKE PEDAL BR- 7
MASTE R CY LI N DE R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B R- 8
FRONT DISC BRAKE BR- 9
FRONT DISC ROTOR BR-10
BRAKE PiPiNG BR-11
HAND BRAKE BR-12
SPECIAL SERVICE TOOL BR-12
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS TIGHTENING TORQUE
Service brake Unit N'm kg-m ft-Ib

Type Disc-FN28H Brake pedal bracket to

18 - 24 1.8 - 2.4 13 - 17
instrument panel
Pad dimensions 35 x 6 x 94.5
(Width x thickness x length) mm(in) (1.38 x 0.24 x 3.720) Master cylinder to brake
18 - 24 1.8 - 2.4 13 - 17
pedal bracket
Disc rotor
210 x 10 (8.27 x 0.39)
(Diameter x thickness) mm(in) Pedal shaft stopper plate
9 -12 0.9 -1.2 6.5 -8.7
fixing bolt
Wheel cylinder
Inner diameter mm(in) 19.05 (3/4) Stop lamp switch lock nut 19 -25 1.9 - 2.6 14 -19

Master cylinder Master cylinder to nipple 27 - 41 2.8 -4.2 20 - 30

Inner diameter mm (in) 19.05 (3/4)
Push rod lock nut 16 - 22 1.6 - 2.2 12 - 16
Stroke mm(in) 25 (0.98)
Air bleeder 7-9 0.7 - 0.9 5.1 - 6.5

Brake tube flare nut 15 -18 1.5-1.8 11 - 13

INSPECTION AND ADJUSTMENT Disc brake assembly 54 -74 5.5 -7.5 40-54
fixing bolt
Brake pedal
Brake pad fiXing bolt 18 - 26 1.8 - 2.7 13 - 20
Pedal play mm (in) 2.0 - 4.0 (0.079 - 0.157)
Disc rotor fixing nut 44 -59 4.5 -6 33 -43
Pedal height mm (in) 143 (5.63)
Hand brake bracket to
Pedal max. stroke mm (in) Less than 45 (1.77) 9 - 12 0.9 -1.2 6.5 -8.7
instrument panel

Hand brake lever to

9 - 12 0.9 -1.2 6.5 -8.7
Hand brake bracket

147-196 Hand brake cable lock nut 19 - 25 1.9 - 2.6 14 -19

Pulling force N (kg,lb)
(15 - 20, 33 - 44)

Master cylinder

Allowable clearance between cylinder

Less than 0.15 (0.0059)
and piston mm (in)

Front disc brake

Pad wear limit

1 (0.04) at pad end
(Minimum thickness) mm(in)

Disc rotor
Runout mm(in) Less than 0.07 (0.0028)

Parallelism mm(in) Less than 0.15 (0.0059)

Standard th ickness mm(in) 10 (0.39)

Minimum thickness mm (in) 9 (0.35)

BR-2
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Excessive pedal travel Low brake fluid level or empty master Fill and bleed as necessary. Test for source
cylinder reservoir. of leakage by examining all lines, connec-
tions and wheel cylinder.
Leakage in master cylinder. Overhaul master cylinder.
Deteriorated check valve. Replace check valve and bleed system.
Air in system. Bleed system.
Faulty brake adjustment. Adjust pad-to-rotor clearance.
Excessive lateral play on disc caused by Replace or adjust faulty parts.
loose or worn wheel bearings or steering
parts.

Spongy pedal Low fluid level in master cylinder. Top with fluid and inspect for leakage.
Air in system. Correct as necessary.
Faulty brake adjustment. Adjust pad-to-rotor clearance.
Reservoir filler cap vent hole clogged. Clean and bleed system.
Swollen hose due to deterioration or use of Replace hose and bleed system.
poor quality hose.
Use of a brake fluid with too low boiling Replace with specified brake fluid and bleed
point. system.

Poor braking effect Fluid leakage in brake lines. Check master cylinder, piping and wheel
cylinder for leaks, and repair.
Low brake fluid level or empty master cylin- F ill and bleed as necessary.
der reservoir.
Air in brake lines. Bleed system.
Grease, oil, mud or water on pads. Clean brake mechanism and check for cause
of problem. Replace pads.
Deterioration of pads. Replace.
Local fit of pads. Shave or replace.
Pads excessively worn. Replace.
Master cylinder or wheel cylinder in poor Repair or replace.
condition.
Binding mechanical linkage at brake pedal. Free up as required.

Unbalanced brakes Improper tire inflation. Inflate to correct pressure.

Improper adjustment of pad-to-rotor clear- Readjust.
ance.
Grease, oil, mud or water on pads. Clean brake mechanism and check for cause
of problem. Replace pads.
Mud in rotor. Clean.
Deterioration of pads. Replace.
Excessive wear of pads. Replace.

BR-3
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Unbalanced brakes Wheel cylinder in poor condition. Repair or replace.

Looseness of brake assembly securing bolts. Fasten or replace.
Scored or runout of brake rotor. Recondition or replace rotor as required.
Check for improper pad contact with rotor
and grind pad if necessary.
Incorrect adjustment of hub bearings. Adjust or replace.

Brakes fade Brake fluid has too low boiling point. Drain and fill system with approved flUid.
Use of improper pads. Replace.
Hydraulic connections, master cylinder and Repair as necessary.
wheel cylinders are corroded or damaged.
Bleed screw is open. Close screw and bleed system.

Brakes drag Pedal linkage is binding or push rod adjust- Lubricate linkage, check pedal return spring
ment is too long. for condition and adjust push rod as neces-
sary.
Master cylinder port is obstructed. Blowout foreign matter with compressed
air.
Seized master cylinder piston. Disassemble master cylinder and replace
piston. Bleed system.
Poor pad condition. Clean and repair.
Poor wheel cylinder condition. Repair or replace.
Deformation of piston cups. Replace.
Excessive runout of rotor. Repair or replace.
Hand brake will not return. Check and repair.
Clogged master cylinder port. Clean.
Clogged brake lines. Check and clean.
Incorrect adjustment of wheel bearings. Adjust or repair.
Improper pad-to-rotor clearance. Adjust.
No free travel in brake pedal return. Adjust pedal height.

Brake chatters Groove or runout of brake rotor. Grind or replace as required.

Distorted pads. Replace as necessary.
Grease or brake fluid on pads. Replace pads.

Brake squeals Dirty or scored rotor. Blowout assembly with compressed air or
refinish rotor.
Glazed or contaminated pads. Grind pad to eliminate glaze. If it doesn't
replace pad.

Pedal pulsates Lateral runout of brake rotor is excessive. Check with dial indicator, turning disc by
hand. If runout exceeds specifications, re-
place disc.
Excessive variation in thickness of brake Measure around disc face with micrometer.
rotor surfaces. Replace disc as reqUired.

BR-4
 ADJUSTMENT

ADJUSTMENT
SERVICE BRAKE Too small a free play pushes push
BRAKE PEDAL rod, blocking return port of master
cylinder and possibly resulting in
dragging brakes; too large a free
play will dislocate push rod.

3. After adjustment, check that

"pedal max. stroke" is less than 45
Pedal stopper bolt mm (1.77 in). If it is not, check brake
system.
Lock nut A
4. Depress and release pedal several
Lock nut B times to see if it travels smoothly over
Push rod its entire stroke without binding,
twisting or interfering with adjacent
parts.
5. Depress and release pedal several
times. Make sure stop lamp switch
Pedal play "a": comes on when pedal is depressed 7 to
2.0 - 4.0 mm (0.079 - 0.157 in) 13 mm (0.28 to 0.51 in) and goes off
Pedal height "H":
143 mm (5.63 in) when it is released.
Pedal max. stroke "S":
Less than 45 mm (1.77 in)

Floor board
FBR 530

I. Adjust pedal stopper until pedal Pedal play:

pad is 143 mm (5.63 in) above floor, At pedal pad
and tighten lock nut "A". 2.0 -4.0 mm
(f) : Pedal stopper lock nut "A" (0.079 - 0.157 in)
At push rod end
19 - 25 N'm
(1.9 - 2.6 kg-m, 0.4-0.8 mm
14 - 19 ft-Ib) (0.016 - 0.031 in)

(f) : Push rod lock nut "B"

2. Adjust push rod length until pedal
16-22N.m
play is within the specified value.
(1.6 - 2.2 kg-m,
Then tighten lock nut "B" securely.
12 - 16 ft-Ib)

BR-5
 ADJUSTMENT

DISC BRAKE c
Pad clearance adjustment
Depress brake pedal to operate brakes
when adjusting pad clearance.
1. Adjust bolt C until dimension L is
2 mm (0.08 in) and then tighten lock
nut.
2. Adjust bolt D until dimension M
is 1 mm (0.04 in) and then tighten
lock nut.
3. After above adjustments have
been made, release brake pedal to
make sure brakes do not drag.

+=~Wh,Lnfu
Unit: mm (in)
FBR399

HAND BRAKE
Before adjusting hand brake, make cD 9 - 12 (0.9 - 1.2,6.5 - 8.7)
sure that drive axle brake is function-
ing properly.
1. Adjust nut B until thread length L Inclination:
Less than Hand
is 27 mm (1.06 in) and then tighten 2 mm (0.08 in) grip
lock nut A.
2. Take off the hand grip and adjust
hand brake pulling force by turning Pulling
force
adjusting bolt. adjusting
B
bolt
Pulling force: A
147 - 196 N
(15.20 kg, 33 . 44lb) L

3. When hand brake lever is in the

lock position, make sure cable bracket
is not tilted. If it is, readjust dimen-
sion L.
4. After properly adjusting hand cD 19 - 25 (1.9 - 2.6, 14 - 19)
brake lever, release hand brake lever to l!J: N.m (kg-m, ft-lb)
make sure brakes release completely. FBR 531

BR-6
 SERVICE BRAKE

SERVICE BRAKE

BRAKE
REMOVAL
PEDAL

1. Remove floor board.

2. Disconnect reservoir tank hose
(0:t) ~
Bushing

from master cylinder. Pedal shaft

with bracket
To avoid splashing brake fluid on
~ -, Pedal
\ shaft
painted surfaces and other parts,
always place a container or rag under
Brake pedal -
brake tubes. assembly
FBR 534 FBR 536
3. Remove flare nut from master
cylinder.
When removing flare nut, using INSPECTION 2. After installing brake pedal to
Tool GG94310000. brake pedal bracket, adjust it.
Check the following parts, replac-
Never use open end or adjustable Refer to Adjustment for brake pedal.
ing or repairing as necessary.
wrench.
• Pedal bushing for wear, deforma- Make sure pedal travels smoothly
tion or other damage over its entire stroke without binding,
• Pedal shaft for bending or other twisting, etc. and makes no contacting
damage noise.
• Pedal arm for bending or other
3. After installing brake tube to
damage
• Return spring for weakness master cylinder, bleed air from brake
• Pedal pad for damage and wear. system.

Always replace pedal assembly if

pedal bushing is not suitable for
further use. Discard cotter pin after
removal; install new one.

4. Remove master cylinder.

(!J: Brake tube flare nut

rrrr{ Return spring 15 - 18 N.m
(1.5 - 1.8 kg-m,
FBR 535
11 - 13 ft-Ib)
Brake tube to brake hose
INSTALLATION 17 - 20 N.m
(1.7 - 2.0 kg-m,
To install, reverse the order of re-
12.14 ft-Ib)
moval. Observe the following:
5. Loosen bolts securing pedal shaft Brake pedal bracket to instrument
1. Apply a coat of multi-purpose panel
bracket and drive out pedal shaft with grease to all surfaces of pedal bushing 18 - 24 N.m
shaft bracket, then remove pedal as- and areas at clevis pin and contact
sembly. (1.8 - 2.4 kg-m,
points. Also grease outer periphery of 13 - 17ft-lb)
return spring.

BR-7
 SERVICE BRAKE

Master cylinder to brake pedal Pedal shaft stopper plate fixing DISASSEMBL Y
bracket bolt
1. Pull off push rod and remove dust
18 - 24 N-m 9 -12 N.m
cover.
(1.8 - 2.4 kg-m, (0.9 - 1.2 kg-m,
2. Pry snap ring and draw out piston
13 - 17 ft-Ib) 6.5 - 8.7 ft-Ib)
assembly, spacer, piston cup, spring
Stop lamp switch lock nut
seat, return spring and check valve.
19- 25 N'm
3. Remove secondary piston cup
(1.9 - 2.6 kg-m,
from piston assembly.
14 - 19 ft-Ib)
Discard piston cup after removal;
install new one.

MASTER CYLINDER 4. Disconnect nipple from cylinder

body.
When disassembling parts, select
a place that is clean and free from
dust, and arrange all parts orderly
to facilitate reassembly.

1 Air breather
2 Cylinder body INSPECTION
3 Nipple
4 Check valve Clean all parts in brake fluid and
5 Spring seat check their condition.
6 Return spring
7 Spring seat CAUTION:
8 Primary piston cup
9 Piston
Do not use any other cleaning solvent
10 Secondary piston cup to clean parts.
11 Spacer
12 Stopper ring When following conditions are
13 Dust cover detected, replace new one.
14 Push rod
• Scratched or worn sliding surfaces
of cylinder and piston
FBR290
• Cylinder-to-piston clearance ex-
ceeding 0.15 mm (0.0059 in)
Cylinder inner diameter:
REMOVAL 19.05 mm (3/4 in)
Remove following sections.
(1) Reservoir tank from instrument • Weak, worn or damaged primary
panel and/or secondary piston cups
(2) Push rod from brake pedal bracket • Weak, or deformed return spring
(3) Master cylinder from brake pipe • Damaged check valve
using Tool GG943 10000. • Deformed or damaged dust cover
(4) Master cylinder from brake pedal and/or push rod
bracket • Deformed or damaged reservoir
tank and/or hose
To avoid splashing brake fluid on
painted surfaces and other parts,
always place a container or rag under
brake tubes. ASSEMBLY
To assemble, reverse the order of
disassembly. Observe the following:
a. Clean all parts in clean brake fluid.
b. Apply coat of brake fluid to fric-
tional surfaces of piston and cyl-
inder.

BR-8
 SERVICE BRAKE

c. Be careful not to scratch them FRONT DISC BRAKE

when assembling.
d. Install new piston cups;discard old
ones.
1. Install piston cup on piston.

Wheel cylinder
assembly
Hand brake cable

[fJ 18 - 26
Make sure piston cup lip is facing 11.8 - 2.7.13 - 20)

return spring.
[fJ : N'm (kg-m, ft-Ib)
2. Install check valve, return spring,
FBR403
spring seat, primary piston cup, spacer
and piston assembly in cylinder body.
Retain with snap ring.
3. Install dust cover and push rod. REMOVAL AND INSTALLATION 5. Take off disc brake assembly, and
I. Lift up truck front side and place then disconnect hand brake cable.
a. Install check valve with its seat
wooden blocks under both side 6. To install, reverse the order of re-
facing return spring.
frames. moval. After installing, bleed air from
b. Install spring seat with its flange
2. Remove front tire. brake system.
facing return spring.
c. Make sure snap ring fits in groove. 3. Disconnect brake hose to brake
tube, then draw out lock spring. CAUTION:
[!J: Nipple When installing brake tube, use Flare
27-41 N'm Nut Torque Wrench GG94310000.
(2.8 - 4.2 kg-m,
20 - 30 ft-Ib) [!J : Brake hose to tube
17 - 20 N.m
(1.7 - 2.0 kg-m,
INSTALLATION
12 - 14 ft-Ib)
To install, reverse the order of re- Brake fixing bolt
moval. After installing, bleed air from 54- 74N.m
brake system. (5.5 - 7.5 kg-m,
[!J : Push rod lock nut 40 - 54 ft-Ib)
16- 22 N'm Pad fixing bolt
(1.6 - 2.2 kg.m, 18 - 26 N'm
12 - 16 ft-Ib) (1.8 - 2.7 kg-m,
4. Remove brake pad and disc brake
Brake tube flare nut 13 - 20 ft-Ib)
securing bolt.
15.18 N'm
(1.5 - 1.8 kg.m,
11 - 13 ft-Ib) DISASSEMBL V
Master cylinder to brake pedal 1. Wipe off dust and mud from disc
bracket brake assembly.
18.24 N.m
(1.8 - 2.4 kg-m,
13 - 17 ft-Ib)
Air breather
7 - 9 N.m
(0.7 - 0.9 kg-m,
5.1 - 6.5 ft.lb)

BR-9
 SERVICE BRAKE

2. Remove pad, pins and return PAD REPLACEMENT

springs. 1. Lift up truck front side and place
wooden blocks under both side
frames.
2. Remove front tire.
3. Remove brake pad and disc brake
securing bolts.

FBR406

4. Remove disc rotor.

3. Separate levers and wheel cylin-
Be sure to hold rotor in place when
der.
tightening or loosening its nuts. Do
4. Disassemble wheel cylinder.
not hold axle hub.

UIWPiston cup 4. Take off disc brake assembly and

remove pad.
(j(]I~PktO"
S. After replacing brake pad, make
~{f)) both pad clearance and hand brake ad-
justments. Refer to "Adjustment" for
Dust cover~~ instructions.
Locking hole
FBR407 FBR 538
Inspection
1. When pads are heavily fouled with
INSPECTION
oil or grease or when pad is deterio-
Clean all parts and check as follows: rated or deformed, replace it. S. To install, reverse the order of
2. If pad is worn to less than the removal.
CAUTION: specified value, replace. (!J : Disc rotor fixing nut
Use brake fluid to clean. Never use
Pad wear limit 44 -59 N.m
mineral oil.
(Minimum thickness): (4.5 . 6 kg-m.
1 mm 10.04 in) at pad end 33 - 43 ft-Ib)
• Check all parts for evidence of ab-
Pad fixing bolt
normal wear or damage, if neces-
3. Check rotor, referring to Rotor 54-74N.m
sary, replace faulty parts.
for inspection. (5.5 - 7.5 kg-m.
40 . 54 ft-Ib)

ASSEMBLY
To assemble, reverse the order of re-
moval.
Observe the following:
• Replace piston cup of wheel cylin-
der with new one. FRONT DISC ROTOR INSPECTION
• Before installing, apply a coat of REMOVAL AND INSTAllATION Check the following items and, if
brake grease to contact surfaces of
1. Lift up truck front side and place necessary, replace.
levers and pins. Do not grease fric- 1. Sliding surface
wooden blocks under both side
tion face of pad. If there are cracks or considerable
frames.
(!J : Brake pad fixing bolt 2. Remove front tire. chips, replace.
18.26 N'm 3. Remove pad from disc brake as- 2. Runout
(1.8 - 2.7 kg'm. sembly. Remove brake assembly and Place disc rotor on surface plate and
13.20 ft.lb) support it with lifting wires. measure runout using a dial gauge.

BR-10
 SERVICE BRAKE / BRAKE PIPING

Runout limit: 3. Parallelism 4. Thickness

Total indicator reading Measure thickness of rotor in circum- If rotor thickness is beyond wear limit,
Lessthan 0.07 mm (0.0028 in) ferential direction, using a micrometer. replace rotor.
at 162 mm (6.38 in) dia. Parallelism: Standard thickness:
Circumferential direction 10 mm (0.39 in)
Lessthan 0.15 mm (0.0059 in) Wear limit
at 162 mm (6.38 in) dia. 9.0 mm (0.354 in)

Surface plate'::>'

FBR408

FBR539

BRAKE PIPING
• To remove brake hose, first remove
flare nut securing brake tube to
hose, then withdraw lock spring.
Master cylinder Do not twist brake hose.
• After installation is completed,
bleed air from brake system.

Brake hose (R.H.)

Brake tube (L.H.) INSPECTION

Check brake lines (tubes and hoses)
for evidence of cracks, deterioration or
other damage. Replace any faulty
parts.
If leakage occurs at end around joints,
re-tighten or, if necessary, replace faul-
ty parts.

FBR 540

REMOVAL AND INSTALLATION

• To remove brake tube, disconnect
flare nut.

CAUTION:
When removing or installing brake
tubes, use Tool GG94310000.

BR-11
 HAND BRAKE / SPECIAL SERVICE TOOL

HAND BRAKE

r!J 19 - 25 (1.9 - 2.6,14 - 19)

"

r!J: N.m (kg-m, ft-lb)

FBR 541

Refer to "Adjustment" for adjustment

instructions.

SPECIAL SERVICE TOOL

Tool number Tool name

GG943 10000 Flare nut torque wrench

BR-12
 STEERING SYSTEM
(ST)

MODEL NOl SERIES

" "

CONTENTS

SERVICE DATA AND SPECIFICATIONS ST- 2

TROUBLE DIAGNOSES AND CORRECTIONS ST- 3
POWER STEERING CONTROLLER ST-15
POWER STEERING SYSTEM ST-19
POWER STEERING MOTOR ST-20
EPS SENSOR ASSEMBLy ST-21
I NPUT SHAFT ASSEMBLY ST-23
STEERING GEAR ST-24
STEERING CHAIN '" ST-25
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS TIGHTENING TORQUE

Type Electric power steering Item N.m kg-m ft-Ib

Steering wheel Steering wheel nut 26 - 32 2.7 - 3.3 20 - 24

Wheel diameter mm (in) 360 (14.17)
Steering column bracket 43 - 55 4.4 - 5.6 32 - 41
to instrument frame
Turn of steering wheel 7
Steering column assembly 41 - 52 4.2 - 5.3 30 - 38
Steering gear ratio 33.3 to bracket

13.17 Steering column to column 21 - 26 2.1.2.7 15 - 20

Overall gear ratio
shaft
Maximum steering angle 0 0
degree 86.4 - 87.7 Sprocket bracket to final 29 - 37 3.0 - 3.8 22 - 27
(right and left)
drive

Power steering motor Sprocket shaft lock nut 98 - 127 10 - 13 72 - 94

Rated voltage (V) 48
Sprocket bracket to frame 21 - 26 2.1 - 2.7 15 - 20
(rear lower side)
Rated output (kW/h) 0.3
Sprocket bracket to frame 76 - 98 7.7 - 10 56 -72
Power steering controller (rear upper side)
Control method F ET double converter
Steering gear to frame 43 - 55 4.4 - 5.6 32 - 41
Rated vOItage 48V,DC Sprocket to steering gear 43 - 55 4.4 - 5.6 32 - 41

Current limit 25A Relay lever bracket to 41 - 52 4.2 - 5.3 30 - 38

steer ing ax Ie

Chain adjusting bolt lock 25 - 32 2.6 - 3.3 19.24

INSPECTION AND ADJUSTMENT nut

Steering wheel play mm (in) 20 - 30 (0.79.1.18)

Power steering motor

Commutator wear limit mm (in) 29.5 (1.161)

Brush wear limit mm (in) 13.0 (0.512)

4.9 -7.8
Brush spring tension N (kg, Ib)
(0.5 - 0.8, 1.1 - 1.8)

ST-2
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

POWER STEERING CONTROLLER

SYMPTOM 1:
HARD STEERING/EFFORT REQUIRED AT STEERING WHEEL

Hard steering (effort required to

operate steering wheel) is
persistent after key switch is
turned ON.

Check if steering wheel turns

Yes
fully in each direction after key
switch is turned ON.

No
Turn key switch OFF and raise
steering wheel using a jack.

Check if steering wheel turns

No
properly when key switch is
turned ON.

Yes

Turn key switch OFF and lower Refer to Symptom 2 "Steering

steering wheel to ground. Wheel Locks".

Check if PS relay closes

No
circuit when key switch is turned
ON.

Yes

C C_h_e_C_k_p_S_r_el_ay_,)
Check if PS relay opens
circuit (turns OFF) soon.
Yes

No

Yes
Check if PS relay opens
circuit when steering wheel is
C C_h_e_ck_p_S_re_l_ay_, ~)

turned.

No

Refer to Symptom 3 upS Attach ammeter's leads to PS

Relay Turns OFF When motor leads.
Steering Wheel is Turned".
A
Check if current flow through No
PS motor is OA when steering
wheel is turned.

Yes
Refer to Symptom 5 upS System
Refer to Symptom 4 upS
is Set In Operation but Excessive
Relay Turns ON but PS System
Steering Effort is Required".
Does Not Operate",

ST-3
TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 2:
STEERING WHEEL LOCKS.

Steering wheel is locked.

Turn key switch OFF.

Remove PS motor.
No
Check to see if PS motor shaft
turns manually.

Yes

Refer to Symptom 10 "Steering

Sensor Check".
( Replace PS motor. )

ST-4
 TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 3:
PS RELAY TURNS OFF WHEN
STEERING WHEEL IS TURNED.

PS relay turns OFF when

steering wheel is turned.

Turn key switch OFF and dis-

connect PS motor connector.

Check if PS relay turns ON

to OFF quickly when steering No
wheel is turned with key switch
turned ON.
Check if voltage across motor
Yes
No terminals TP7 (+) and TP2 (-)
smoothly changes from 0 to 48V
when steering wheel is turned
clockwise.
Turn key switch OFF, remove PS
controller cover and turn key Yes
switch ON again.
Turn key switch OFF.

Check if voltage across terminals

TP4 (+) and TP2 (-) continuous- Check if PS motor brush Yes
No
ly changes from 6 to :1:3.1V when exceeds specified length.
steering wheel is slowly turned No
in both directions.

Yes
( Replace PS motor brush. )
Refer to Symptom 10 "Steering Replace PS controller.
Sensor Check". ( Replace PS motor. )

ST-5
 TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 4:
PS RELAY TURNS ON BUT PS SYSTEM
DOES NOT OPERATE.

PS relay turns ON but PS

system does not operate.

Check if PS system operates Yes

when key switch is turned ON
after PS relay turns OFF.
No ( Good condition )
Check if PS ceases operation Yes
while truck is in motion.
No Check battery voltage.
Turn key switch OFF and open
PS controller cover.

Check if voltage across terminals

Yes
TPS (+) and TP2 (-) is greater
than 20Y.
No
No
Check if voltage across terminals Check if voltage is OY.
TP4 (+) and TP2 (-) continuous-
Yes
ly changes from 6 to 9.1 Y when
steering wheel is turned clock-
( Charge battery. )
wise and from 2.9 to 6Y when Check if voltage across reactor No
turned counterclockwise. assembly PS controller terminal
No (+) and TP2 (-) is OY.
Yes Replace PS controller.
Turn key switch OFF and dis-
connect steering sensor connector. Check if voltage across reactor
No
assembly terminal (+) on PS
relay side and TP2 (-) is OY.
Check if resistance between blue Replace reactor assembly.
and green leads of connector (on Yes
steering sensor side) is in 2 to 3 Check if voltage across terminal No
kn range when steering wheel is (+) on PS relay side and TP2 (-)
released. isOY.
Yes Yes Replace PS relay.

Check if resistance between blue Check fuse and harness (on body
and green leads of connector (on side ).
steering sensor side) continuously
changes when steering wheel is Disconnect steering sensor con-
released. nector.
Yes

Replace PS controller.
Check if resistance between blue
No
and green leads (on steering Check harness between steering
sensor side connector) is in 2 to sensor and PS controller.
3 kn range.
Replace steering sensor.

ST-6
TROUBLE DIAGNOSES AND CORRECTIONS

1
Turn key switch OFF.

I
Check if continuity exists between Yes
terminals TP6 and TP7.
No Replace PS controller.
Check if PS motor brush length Yes
is in specified range.

No

Replace PS motor brush. Replace PS motor.

ST-7
 TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 5:
PS SYSTEM IS SET IN OPERATION BUT
EXCESSIVE STEERING EFFORT IS RE-
QUIRED.

PS system is set in operation but

excessive steering effort is reo
quired.

Turn key switch OFF and attach

ammeter indicates at least 22.5A
lead.

Turn key switch ON. Check if

ammeter indicates at least 22.5A Yes
when steering wheel is turned to
limit.
Turn key switch OFF and dis-
No
connect one of motor leads. Also
Replace PS motor brush or check Check if PS motor brush length remove PS control motor cover.
PS motor. is in specified range.

Yes
Turn key switch ON and attach
a spring scale to steering wheel.
Check if voltage across terminals
Yes
Turn key switch OFF and dis- TP4 (+) and TP2 (-) is more than
connect power supply leads 2.9V when spring scale is pulled to
(Red). Also remove PS con- the left with a force of 14.7 N
troller cover. (1.5 kg, 3.3 lb).

No

Turn key switch ON. Check if Check and repair actuator.

voltage across terminals TP4 (+)
and TP2 (-) continuously No
changes from 0 to 6:!:3.l V when
steering wheel is turned from one
end to the other. Refer to Symptom 10 "Steering
Sensor Check".
Yes

( Replace PS controller. )

ST-8
TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 6:
STEERING WHEEL VIBRATES AND CANNOT
BE TURNED.

Steering wheel vibrates and

cannot be turned.

Check if connector and harness No

between PS controller and steer-
ing sensor are in good condition.
Repair faulty connector or
Yes harness.
Check if connector and harness No
between PS controller and PS
motor are in good condition.
Repair faulty connector or
Yes harness.
Refer to Symptom 10 "Steering
Sensor Check".

ST-9
 TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 7:
PS SYSTEM IS SET IN OPERATION BUT
VEHICLE KNOCKS WITH EXCESSIVE
STEERING EFFORT IS REQUIRED.

PS system is set in operation but

vehicle tends to knock with exces-
sive steering effort is required.

Check if battery voltage is greater No

than 20V.
Yes

Attach ammeter leads to PS

( Recharge battery. )
motor leads for current measure.
ment.

Measure current while turning

steering wheel slowly. Check if
Yes
current on ammeter indicator
drops abruptly when steering
wheel drags.
Turn key switch OFF.
No Check if PS motor brush is
greater than specified length.
Turn key switch OFF, disconnect
Yes
motor connector and remove PS
controller cover.
Replace PS motor.

Turn key switch ON. Check if

voltage across terminals TP4 (+)
No and TP2 (-) continuously
Replace PS motor brush.
changes from 6 to 9.1 V when
steering wheel is slowly turned
Refer to Symptom 10 "Steering clockwise and from 2.9 to 6V
Sensor Check". when turned counterclockwise.

Yes

Turn key switch OFF and jack

up vehicle so that wheels clear
ground. Disconnect motor
connector.

Yes Check if steering wheel drags or

is heavy when turned slowly.
No
Refer to Symptom 10 "Steering
Sensor Check". ( Replace PS controller. )
ST-10
TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 8:
STEERING WHEEL STEERS BY ITSELF.

Steering wheel steers by itself.

Turn key switch OFF and dis.

connect motor connector.
Also remove PS controller cover.

Turn key switch ON. Check if

voltage across terminals TP4 (+) No
and TP2 (- ) is in 6:t3.1 V range
when steering wheel is turned
slowly in each direction.

Yes

Check if voltage across terminals

TP4 (+) and TP2 (-) continuous-
ly changes from 6 to 9.1 V when No
steering wheel is slowly turned
clockwise and from 2.9 to 6V
when turned counterclockwise.

Yes
Refer to Symptom 10 "Steering
Replace PS controller.
Sensor Check".

ST-11
 TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 9:
PS MOTOR EXCESSIVELY OVERHEATS.

PS motor excessively overheats.

Check if PS motor overheats Yes

when key switch remains ON.
No
Turn key switch OFF.
Turn key switch 0 FF and jack Remove PS controller cover and
up vehicle so that wheels clear turn key switch ON.
ground. Attach ammeter leads to
PS motor leads and turn key
switch ON again. Check if voltage across
terminals TP4 (+) and TP2 (-)
is outside 6:t3.IV.

Check if indication on ammeter No

Yes is continuously less than :t5A
when steering wheel is turned to Refer to Symptom 10 "Steering
Sensor Check".
its limits.
Good condition
No

Turn key switch OFF and

remove PS motor. Replace PS controller.

Turn key switch ON. Check if

current is :t3A when steering No
wheel is turned and PS motor
runs idle (under no-load).

Yes ( Replace PS motor. )

Check and repair actuator.

ST-12
TROUBLE DIAGNOSES AND CORRECTIONS

SYMPTOM 10:
STEERING SENSOR CHECK

Check steering sensor.

Turn key switch "OFF".

Disconnect joint between steering
sensor and motor.

Check if steering wheel rotates No

smoothly.
Yes
Remove steering sensor.
Check if steering sensor Check if steering sensor shaft
connection is tight and secure. rotates smoothly with your
Open EPS controller cover. hand.
Yes

Check if bearing (on vehicle

body side) rotates properly.

Check if voltage across

terminals TP4 (+) and TP2 (-) No
is 6:tO.5V when key switch is
turned ON.
Yes

Prevent motor-to-steering
sensor joint from rotating when
turning steering wheel.

Check if voltage across terminals

TP4 (+) and TP2 (-) continuous- No
ly changes in 6:!:3.1V range when
steering wheel is turned.

Yes

Check vehicle body and joints. Replace steering sensor.

ST-13
 TROUBLE DIAGNOSES AND CORRECTIONS

STEERING SYSTEM

Condition Probable cause Corrective action

Shaking, shocking Unbalanced or deformed wheel. Correct or replace.

or unstable steering Uneven tire wear. Replace.
wheel.
Wheel bearing improperly adjusted or worn. Adjust or replace.
Loose steering gear housing. Tighten.
Looseness or play in steering gear and Adjust or replace.
linkage.

Hard steering or Steering gear and linkage improperly lu- Lubricate.

poor returnability bricated.
of steering wheel. Steering gear and linkage improperly ad- Adjust or replace.
justed or worn.
Wheel bearing at driving wheel or caster axle Adjust or replace.
improperly adjusted or worn.
Improper adjustment of chain tension. Adjust.
Faulty bearing at steering gear and linkage or Replace.
caster wheel.
Universal joint damaged or worn. Replace.

Excess play in Steering gear and linkage damaged or worn. Replace.

steering wheel. Wheel bearing at driving wheel or caster axle Adjust or replace.
improperly adjusted or worn.
Loosen steering gear housing. Tighten.
Improper adjustment of chain tension. Adjust.
Pin or key deformed or damaged. Replace.
Serration portion of steering gear and link- Replace.
age damaged or worn.
Universal joint damaged or worn. Replace.

ST-14
 POWER STEERING CONTROLLER

POWER STEERING CONTROLLER

SCHEMATIC

Seat
relay Fuse lOA Key switch Fuse lOA
cf\..O

~APNB 1246
~l Fuse SA
o I ~
0
L__
~ Seat switch

Steering torque
sensor Reactor
assembly
T
Battery :
PS controller
I
..L

Fusible
link

FST476

SPECIFICATIONS 2. Before the inspection, check that • The steering wheel vibrates and
the fuse is not burnt out. cannot be steered.
Type 1077-4302
3. Make sure that the low voltage • The steering wheel does not operate
Control method FET double converter lock lamp is not lit before the inspec- smoothly and is abnormally heavy.
tion. 3. Hold the steering wheel turned all
Rated voltage 48V, DC
the way (at full steering) and check if
Current limit 2SA INSPECTION the assistance force disappears in
I . Check if the PS relay turns ON 12:t2 seconds and that the steering
Control element FET
when the key switch is turned ON. wheel turns back a little.
Control frequency 16 kHz 4. With the key switch set to OFF,
2. Check that following does not
occur when the steering wheel is check that the assistance force de-
PRECAUTIONS turned. creases gradually and the PS relay
• The power steering does not work. opens within 6.5 sec. (:t2 sec.)
1. Be sure to apply the hand brake
• Operation of the steering wheel is If problems are discovered during
before beginning the inspection be-
exceptionally heavy. the inspection, refer to "TROUBLE
cause inspection is performed while
DIAGNOSES AND CORRECTIONS".
electrical current is flowing through
the system. Also place blocks of wood,
etc., in front of the front wheels of the
vehicle to prevent it from accidentally
moving.
During the inspection, do not allow
anyone except inspectors near the
vehicle.

ST-15
 POWER STEERING CONTROLLER

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-...'"
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lZl lZl lZl lZl lZl

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Cf.)
....
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u
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u
2
Q
i=
u
w
....
o o
Z
a:
Cl..

ST-16
 POWER STEERING CONTROLLER

REMOVAL AND INSTAllATION before starting the inspection. Also f. When the tester is used for check-
I. Disconnect battery connector. place blocks of wood, etc., in front ing, be sure to set the correct
2. Disconnect connector and remove of the front wheels of the vehicle ranges (such as A. V. n) and
controller. so that the vehicle does not ac- correct polarities (+, -) for the
cidentally roll. tester.
During the inspection, do not allow
anyone other than inspectors near Insulation resistance
the vehicle. Measure insulation resistance between
b. When inspection is performed by terminal P and aluminum plate, then
measuring insulation resistance, terminal N and aluminum plate.
etc., without current flowing
through the system, be sure that Normal value: con
following is observed.
1) Disconnect the battery connector
after the PS relay opens by setting
the key switch to OFF.
2) Wait approx. 10 seconds after
3. Install controller in the reverse removing the battery connector.
order of removal. c. Before the inspection, be sure to
check that fuse is not burnt out.
d. Make sure that the low voltage
lock lamp is not lit beforehand.
INSPECTION
e. When inspection is performed using
A WARNING: the tester, be careful that the tester
FST478

a. If the inspection is performed with does not come into contact with
current flowing into the system, be other parts around it, as this may
sure to apply the hand brake cause a short circuit.

Measurement of voltage at each section

Tester measurement
point Measurement
Normal value Remarks
condition
(+) (-)
~Check item terminal terminal

TP2 Key switch ON Same voltage as battery

Key switch power supply TPI
(GND) 48V

TP2 Key switch ON Same voltage as battery

Main power supply TP5
(GND) 48V

Stabilizer TP2
+12V TP3 Key switch ON 12:tIV
power supply (GND)

Neutral 6:tO.5V

Voltage should be varied

Right continuously within 6 to
turn TP2 9.1 V while turning the
Sensor signal TP4 Key switch ON
(GND) steering wheel slowly.

Voltage should be varied

Left
within 2.9 to 6.0V con-
turn
tinuously.

Right TP2
TP7
turn (GND) Voltage varied from OV
Motor voltage Key switch ON
Left TP2 to the battery voltage.
TP6
turn (GND)

ST-17
 POWER STEERING CONTROLLER

TPI
TP7 TP4
TPS

TP2
Output voltage
adjusting switch
TP3

TPI: Key switch power supply

TP2: GND
TP3: Stabilizer power supply
TP4: Sensor signal input
TP5: Main power supply
TP6:
} Motor output
TP7:
FST479

REACTOR ASSEMBLY 2. If insulation resistance is less than

1 MD, clean terminal and bracket
using a dry, clean cloth.

Inspection
PS RELAY
Insulation resistance check Inspection
1. Remove reactor assembly. Using a
500-V megger, measure resistance be-
tween each terminal and bracket.
Specification: 5
Greater than 1 MD

0-0: on

When 48V is applied between CD and @

When no voltage is applied between

CD and @
FST482

ST-18
 POWER STEERING SYSTEM

POWER STEERING SYSTEM

..
(8

FST483

ST-19
 POWER STEERING SYSTEM

POWER STEERING MOTOR

1 Armature assembly
2 Bearing
3 Armature
4 Bearing
5 Shim
6 Rear bracket assembly
7 Brush
8 Brush spring
9 Rear bracket
10 Oil seal
11 Front bracket
12 Yoke assembly
13 Brush cover

FST462

REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY

I . Disconnect battery connector. 1. Remove brush cover.

2. Disconnect motor harness con- 2. Using a brush spring holder, pull
nector, and remove motor. brush spring back just enough to lift
brush approximately halfway off
brush holder. With brush held in that
position, secure brush spring to the
side surface of brush.

FST464

FST484
4. Separate front bracket assembly,
yoke assembly and rear bracket as-
sembly.
3. Install motor in the reverse order
of removal. Observe the following FST378 /~
/ S. Remove front and rear bearings
from armature assembly using a
instructions.
puller.
• Remove traces of sealant from
6. Assemble power steering motor
mating surfaces of motor and gear 3. Make mating mark, then remove
in the reverse order of removal.
case. Apply a coat of liquid packing through-bolts.
to the mating surfaces and install
motor.

ST-20
 POWER STEERING SYSTEM

INSPECTION • Rough ... Sand lightly with Insulation resistance

Brush
No. 500 to 600 sandpaper. 1. Remove motor. Using a soo-v
2. Check commutator diameter. megger, measure resistance between
Check brush wear.
Commutator minimum diameter: each terminal and yoke.
Wear limit: 13 mm (0.51 in)
29.5 mm (1.161 in) Specification:
• Excessive wear ... Replace. • Less than specified diameter ... Greater than 1 MD.
Replace.
2. If resistance is less than I MD.,
3. Check depth of insulating mica
clean commutators and brushes using
from commutator surface.
a dry, clean cloth
• Less than 0.2 mm (0.008 in) ...
Undercut to 0.6 to 0.8 mm
(0.024 to 0.031 in).

FST417

Commutator
Check commutator when replacing
Commutator undercut
motor brushes.
1. Check commutator surface. FST419

EPS SENSOR ASSEMBLY

Input shaft assembly

[fl 5 - 20
(0.5 - 2, 3.6 - 14.5)
Snap ring
ViewC

EPS motor
Power steering
sensor assembly
Power steering sensor
assembly fixing
O-ring C!J 3 -4
(0.3 - 0.4, 2.2 - 2.9)

[fl17 - 27
(1.7 - 2.8,12 - 20)

C!J : N'm (kg-m, ft-lb)

FST485

ST-21
 POWER STEERING SYSTEM

REMOVAL AND INSTAllATION DISASSEMBLY AND ASSEMBLY 4. Neutral adjustment of sensor

For removal and installation of steer- Sensor disassembly
ing gear assembly, refer to "Steering I. Remove screws securing power
Gear" . steering sensor assembly.
2. Remove power steering sensor as-
sembly.

Resistance in neutral position:

2 to 3 kD.

Fully right Fully left

Measuring
turn turn
terminal
position position

1 and 2 1 kD. 4kD.

2 and 3 4kD. lkD.

FST486

Sensor assembly
I. Clean surfaces of power steering 3. Set power steering sensor assem-
sensor assembly and mating part. bly arm horizontal and position
2. Install G-ring on power steering bearing at end of the arm into groove
sensor assembly. in mating part.

Potentiometer
arm
FST467

ST-22
 POWER STEERING SYSTEM

5. -After making sensor neutral ad.

justment, secure power.steering sensor
assembly using screws.
Cf) : 3-4 N.m
(0.3 . 0.4 kg-m. 2.2 - 2.9 ft-Ibl

Power steering sensor assembly

mounting screw

FST468

INPUT SHAFT ASSEMBLY

REMOVAL
2. Remove oil seal, O-ring and cover.
1. Remove snap ring. 3. Remove input shaft assembly.

o-Snapring
PS motor @---Oil seal
e--cover
o--0-ring
Input shaft
assembly

FST488

To install, reverse above removal CAUTION:

procedure. Ensure power steering sensor assembly
when removing or installjng input
shaft assembly.

ST-23
 POWER STEERING SYSTEM

STEERING GEAR

FST459

REMOVAL AND INSTALLATION • Remove traces of sealant from • After installing power steering
1. Disconnect battery connector. mating surfaces of gear case and motor, check that both starting and
2. Disconnect motor harness and cover. Apply a coat of liqUid pack. operating torque values are within
sensor harness connectors. ing to the mating surfaces and the following ranges:
3. Remove chain from steering gear. install cover. Starting torque:
4. Remove steering gear assembly t!l : Cover 5.4.6.9 N.m
with power steering motor. 17.27 N.m (55 • 70 kg-em, 48 - 61 in-Ib)
S. Install steering gear assembly in (1.7 .2.8 kg-m, 12 .20 ft-Ib) Operating torque:
the reverse order of removal. 4.9.6.4 N.m
• After assembling parts, check that
(50 - 65 kg-em, 43 - 56 in-Ib)
shaft end play is within specifi.
DISASSEMBLY AND ASSEMBLY Gear grease quantity:
cations:
Approx. 50 g (1.76 oz)
1. Remove power steering motor. End play:
2. Remove gear case cover. 0.0.4 mm (0.0.016 in)
3. Draw out spacer and gears from
gear case.
4. Remove snap ring, then draw out
gear shaft.
S. Assemble steering gear in the
reverse order of removal. Observe the
following instructions.
• Check gears for breakage, bearings
for improper operation and oil seals
for damage. Replace faulty parts.
• Clean gears and bearings in clean
oil before assembling.

ST-24
______ :- POWER
~~~..;S~T!:!E:.!E!R~I~NG~S~Y~S~T~E~M!..... ~

STEERING CHAIN i
~
:!il

:; c
~
~ Z
E
III

"":
:!
18

......

N
....
In
c:;
...

....
....
<B

ST-25
 HYDRAULIC SYSTEM
(HD)
MODEL NOl SERIES " "

CONTENTS

SERVICE DATA AND SPECIFICATIONS HD- 2

GENERAL SPECIFICATIONS HD- 2
INSPECTION AND ADJUSTMENT HD- 2
TIGHTENING TORQUE HD- 3
TROUBLE DIAGNOSES AND CORRECTIONS HD- 4
01 L PUMP MOTOR HD- 4
HYDRAULIC 01 L PUMP HD- 5
CONTROL VALVE HD- 6
TI LT CY LI NDE R HD- 7
LI FT CYLINDER HD- 8
OIL PUMP HD- 9
OIL PUMP MOTOR HD-12
MOTOR AND OIL PUMP ASSEMBLy HD-14
CONTROL VALVE HD-15
T ILTC Y L IN D E R. .. .. . . . . . .. . . .. .. . .. . . . . .. . . .. .. .. . . . . .. . . . . H D- 18
LIFT CyLINDER HD-20
OIL AND FILTERS HD-22
HYDRAULIC HOSES HD-23
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS TILT CYLINDER

OIL PUMP Stroke mm (in) 60 (2.36)

Pump model 1S x 146 Cylinder 1.0. mm (in) 65 (2.56)

Discharge Cylinder 0.0. mm (in) 80 (3.15)

14.6 (0.49,0.51)
mQ (US fl oz, Imp fl oz)/Rev.
Piston rod diameter mm (in) 30 (1.18)

Tilt angle Forward

Backward

01 L PUMP MOTOR
LIFT CYLINDER
Self-ventilating,
Type
DC compound wound Model 2-stagewide view mast

Model 3439 TMS 721 Unit mm in

Maker B.K.B. Cylinder

Bore diameter -0 -0
Rated voltage v 48 45+0.13 1.77+0.005

Rated output kW/5 min. 7.4 Outside diameter 55 2.17

36+0 +0
Piston rod diameter 1.42_0.004
-0.1

INSPECTION AND ADJUSTMENT

CONTROL VALVE
01 L PUMP MOTOR
1.25 - 1.5 ton 1.75 ton
models models Minimum length of brush
19 (0.75)
mm (in)
Valve type HUSCO5000
Brush spring pressure 8.14 -12.65
14,711 15,691 N (kg,lb) (0.83. 1.29, 1.83 - 2.84)
Main relief valve set pressure
(147.1,150, (156.9,160,
kPa (bar, kg/cm' , psi!
2,133) 2,275) Commutator diameter mm (in)
Initial 73 (2.87)
Relief valve type Cartridge type
Limit 68.5 (2.70)
Cylinder type,
Plunger type
spring return system Insulation resistance M.!1 More than 1

Rated flow rate Commutator undercut 0.5.0.75

65 (17-1/8, 14-1/4)
Q (US gal, Imp gal)/min. mm (in) (0.0197 - 0.0295)

HD-2
 SERVICE DATA AND SPECIFICATIONS

TIGHTENING TORQUE
Unit N'm kg-m ft-Ib

Oil pump
Inside through bolt 46-51 4.7 - 5.2 34-38
Pump to motor 25-31 2.5 - 3.2 18 - 23

Control valve
Control valve to chassis 34 - 39 3.5 - 4 25-29
Tie rod nut (3/8 - 24) 45 4.6 33
(5/16 - 18) 19 1.9 14
Oil pump motor
Motor to bracket 16 - 22 1.6 - 2.2 12 - 16
Motor bracket to chassis 25-32 2.6 - 3.3 19 - 24
Tilt cylinder
Rod head tightening nut 108-147 11 - 15 80 - 108
Cylinder head 275 - 343 28 - 35 203-253
Pivot pin retaining screws25 - 32 2.6-3.3 19-24
Hydraulic piping 20 - 39 2-4 14 - 29
adapters
Lift cylinder
Cylinder head 235-304 24-31 174 - 224
Upper nuts 29 - 39 3-4 22 - 29
Lower bolts 43 - 55 4.4-5.6 32 - 41
Intermediate U-bolts 74 -94 7.5 - 9.6 54 - 69
Hydraulic hoses
Adapters 59 -98 6 - 10 43 -72

HD-3
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

OIL PUMP MOTOR

Condition Probable cause Corrective action

Motor does not rotate. • Poor contact of brush • Correct.

• Disconnected lead • Check bent portion or connected portion

of lead for disconnection.
Replace lead or repair by soldering.

• Disconnected field winding • Repair or replace .

• Disconnected armature winding • Repair or replace .

Motor rotates slowly. • Lead on verge of disconnection,

nection, or connection is poor
or con- • Check bent portion or connected portion
for disconnection.
Replace lead or repair by soldering.

Temperature rises
abnormally.
• Dust accumulation • Repair or replace.
• Shortcircuit between field coil layers • Repair or replace.
• Shortcircuit between armature coil • Repair or replace.
Motor makes
abnormal noise.
• Loose bolts • Retighten .
• Foreign matter caught in motor • Repair or replace.
• Faulty bearing • Repair or replace.
• Foreign matter caught in bearing • Repair or replace.
• Insufficient grease in bearing • Repair or replace.
Abnormal tempera-
ture rise in bearing.
• Faulty bearing, or insufficient grease • Repair.
• Poor installation • Repair.
Poor rectification. • Excessively large load • Stop overloaded operation .
• Excessive armature shaft runout • Repair or replace .
• Excessively worn brush • Replace brush.
• Rough commutator • Polish with emery paper.
• Projected mica • Replace armature assembly.
• Commutator
dust
contaminated with oil or • Clean with dry cloth.
• Poor brush contact • Correct brush contact.
Correct brush spring.

• Shortcircuit or disconnection
winding
in armature • Repair or replace .

Excessive vibration. • Faulty installation • Retighten .

• Loose armature winding • Repair or replace .

• Poor rotary balance • Repair or replace .

• Disengaged core • Repair or replace .

HD-4
 TROUBLE DIAGNOSES AND CORRECTIONS

HYDRAULIC OIL PUMP

Condition Probable cause Corrective action

No oil from oil pump Low oil level in tank Add oil to specified level.

Clogged suction pipe or strainer Clean oil line and tank. If oil is dirty, change.

Low discharge Worn bearing or faulty backup ring or O-ring Replace faulty parts.
pressure on oil
pump Maladjusted relief valve Readjust to specified pressure using pressure
gauge.

Air in the system Retighten suction side piping.

Add oil.
Check pump oil seal.
Do not operate pump until bubbles in tank
disappear.

Noisy oil pump Cavitation due to crushed suction hose or Clean strainer and repair crushed hose.
clogged strainer

Air being sucked from loose suction side Retighten each joint.
joint

Cavitation due to too high oil viscosity Replace with new oil having proper viscosity
for temperature at which pump is to be oper-
ated.

Bubbles in hydraulic oil Determine cause of bubbles and remedy such

as air bleeding and replace oil.

Oil leaking from oil Faulty oil seal on pump, faulty O-ring on Replace faulty parts.
pump body, or worn sliding surfaces on pump

HD-5
 TROUBLE DIAGNOSES AND CORRECTIONS

CONTROL VALVE NOTE: Refer to page HD-16 for location of parts.

Condition Probable cause Corrective action

Plunger sticks Foreign matter between valve housing and Clean valve housing and plunger.
plunger

Dirty oil Change oil.

Faulty return spring Replace.

Distorted valve housing Replace.

Bent plunger Replace valve housing and plunger as an

assembly.

Oil leaks from oil Loose seal plate Clean seal plate and retighten bolts.
seal
Scratched or worn seal Replace seal.

Lift cylinder lowers Worn valve housing and plunger Replace valve housing and plunger as an
without control lever assembly.
operation
Oil leaking from cylinder Check cylinder.

Lift cylinder lowers Foreign matter caught in load check valve Disassemble check valve and clean.
when changing control
lever from NEUTRAL Damaged on poppet or check valve seat Replace poppet or repair poppet seat by
to LIFT lapping.

Fork tilts forward Worn or damaged tilt lock valve Replace plunger and tilt lock valve as an
when control lever is assembly.
used while key switch
is "OFF". Broken tilt lock spring Replace spring.

Oil leaking from O-ring around tilt plunger Replace O-ring.

Lifting speed is slow. Scratched relief valve seat Replace relief valve assembly.

Worn relief valve Replace relief valve assembly.

Foreign matter caught in relief valve Clean or replace relief valve.

Faulty oil pump Refer to "Oil pump".

Mast is unstable when Malfunctioning tilt relief valve Replace tilt relief valve assembly.
tilting forward.

Mast will not tilt Scratched tilt lock valve Replace plunger and tilt lock valve assembly.
forward when control
lever is moved to Foreign matter caught between valve and Disassemble and clean the valve.
"forward tilt" while plunger, making valve inoperative.
motor is running.

HD-6
 TROUBLE DIAGNOSES AND CORRECTIONS

TILT CYLINDER

Condition Probable cause Corrective action

Oil leak between Packing biting foreign matter on sliding Remove foreign matter.
cylinder head and portion
piston rod
Scratched V-ring Replace V-ring.

Wiper ring lip biting foreign matter Remove foreign matter.

Damaged lip of wiper ring Replace wiper ring.

Damaged sliding face of piston rod Repair minor nicks or scratches with oil stone.
If damage is irreparable, replace piston rod.

Oil leak between Damaged O-ring Replace O-ring.

cylinder head and
cylinder tube

Oil leak from welded Damaged welded portion of cylinder tube Replace cylinder tube.
portion of cylinder
tube

Cylinder tilts forward Damaged sliding portion of cylinder tube Replace cylinder tube. (Repair minor damage
without control lever with oil stone.)
operation
Damaged sliding portion of piston Replace piston.

Damaged O-ring Replace O-ring.

Air in cylinder Slightly loosen connector between high pressure

side of cylinder tube port and hose, and gradual-
ly apply oil pressure to cylinder to bleed air.
If connector emits continuous flow of oil, tight-
en connector and operate cylinder for about five
minutes (10 to 20 strokes).

HD-7
 TROUBLE DIAGNOSES AND CORRECTIONS

LIFT CYLINDER

Condition Probable cause Corrective action

Oil leak from packing V-ring biting foreign matter on sliding Remove foreign matter.
around cylinder head portion

Damaged inner or outer lip of V-ring Replace V-ring.

Wiper ring lip biting foreign matter Remove foreign matter.

Damaged lip of wiper ring Replace wiper ring.

Damaged sliding face of piston rod Repair with oil stone if damage is minor.
Replace piston rod if damaged heavily.

Lowering of cylinder V-ring biting foreign matter Remove foreign matter.

without control lever
operation or insuf. Damaged inner or outer lip of V-ring Replace ring.
ficient power due to
faulty packing on Damaged sliding face of piston ring Replace piston ring.
piston side
Damaged sliding face of cylinder tube Replace cylinder tube.

HD-8
 OIL PUMP

OIL PUMP

There are three different possibilities

for removal of the motor and oil pump Rotation shown anticlockwise
assembly:
a) Remove only oil pump.
b) Remove only oil pump motor.
c) Remove motor and oil pump to-
gether.

REMOVAL
1. Raise top panel.
2. Remove driver's side floor panel.
1 Bolt 6 Bush seal 11 Balance plate
3. Remove battery from unit. 2 Spring washer 7 Bush 12 Driven gear
4. Prepare a container to collect the 3 End cover 8 Bush 13 Drive shaft and gear
oil from the hose between oil tank and 4 D-ring 9 Body 14 Key
pump. Prepare a 27 mm (1.06 in) dia. 5 Back-up seal 10 Gear 15 Mounting flange
plug for closing the hose after dis- 16 Shaft seal
connecting it from the pump.
5. Put a rag under the pump to
collect oil that will drip out when
pump is removed. DISASSEMBL Y 7. Before removing the internal
6. Loosen and remove clamp from
Before starting work ensure that the components, mark the bushes on the
lower hose between pump and oil
unit, work area and all tools are other side of bush seal location to
tank.
thoroughly clean to prevent contami- denote the location in the body.
Disconnect hose from pump.
7. Loosen and remove upper adapter nants from entering the unit. FD Bush (8) on drive shaft
that connects pump to control valve. flange end
1. Lightly mark the end cover, body FI Bush (7) on driven gear
and mounting flange (3, 9 and 15) to flange end
ensure reassembly in the correct posi- CD Bush (8) on drive shaft
tion. cover end
2. Remove bolts and springs washers CI Bush (7) on driven gear
(1 and 2). cover end
3. Remove end cover (3), O-ring (4), 8. With the unit lying on its side,
bush seal and back-up seal (6 and 5). hold the drive shaft and pull it square-
4. Turn the unit over and lightly tap ly out of the body bringing with it
the mounting flange (15) to disengage the bushes (7 and 8) and complete
it from the locating dowels and slide gear pack (10, 11, 12, 13 and 14).
the flange squarely off the shaft. 9. Remove gears, key and plate (10,
5. Push the shaft seal (16) squarely 14 and 11) from the drive shaft and
out of the mounting flange taking driven gear journals, note the position
8. Loosen and remove the two care not to damage any sealing sur- of plate (11) to ensure reassembly in
screws that hold oil pump to. motor. faces. the same position.
9. The upper screw is only accessible 6. Remove O-ring (4), bush seal and 10. Remove the two remaining bushes
from the battery compartment. back-up seal (6 and 5). from the body bores.

HD-9
 OIL PUMP

INSPECTION AND REPAIR material. Often there are half-moon ASSEMBLY

shaped scratches where the tips of the
Assessment Ensure all parts are perfectly clean
opposing gears have worn. There must
Each component should be thoroughly and lubricated bushes and gears with
be no noticeable wear step as it is
cleaned, carefully examined and assess- clean hydraulic fluid (ensure O-ring
critical that the bush side face and
ed for suitability of re-use. Below is recess and end faces of body remain
balance plate are completely flat
a guide for inspecting the various com- dry). This will assist assembly of
to the gear side face.
ponents. components into the body bores.
The bush bearing liners are acceptable 1. Refit cover end bushes (CD and
proViding that they are not scored or CI) into the undowelled end of the
Body
show other damage. The general body from where they were removed.
Inspect the body bore cut-in where outside area of the bush should not The "C" shape cut-out in the bushes
gears wear into the body. show any prominent signs of wear. must match the end cover.
The body can only be re-used if the
2. Place the end cover (3) against
cut-in is bright and polished in ap-
the undowelled end of the body (9)
pearance and depth does not exceed Gears
and stand the assembly on the cover
0.08 mm (0.0031 in). The gear side faces should be ex- so the dowels are towards the top and
The body should be replaced if the amined for bruising of scoring. to the left hand side.
surface is scored, has a matted ap- Contaminated fluid may show scoring
3. Hold drive shaft and driven gear
pearance or shows signs that the tips between the root of the gear and the
(13 and 12) together and refit plate
of the gears have dug in or torn away journal undercut, which leaves a wear
step. If a wear step can be felt, coinci- (11) in its original position. The two
the surface material.
dental with the root diameter, by grooves in the plate must be to the low
The body should be inspected to
drawing a sharp pointed tool across pressure side of the pump so that the
ensure that there is no superficial
the surface from the undercut out- drive shaft nearest to you these
damage which may adversely effect
wards towards the tip of the gear, then grooves will be on the left hand side.
performance or sealing. Pay particular
the gear is unusable. 4. Fit key (14) to keyway in drive
attention to the port threads and
The gear teeth should then be care- shaft and then carefully fit gear (10)
O-ring seal recesses.
fully examined to ensure that there to locate on the key, fit the second
are no signs of bruising or pitting. gear to the extended plain journal of
Mounting flange and end cover
The journal bearing surfaces should be the driven gear.
The inner surfaces should be inspected completely free from scoring or 5. Keeping the gear pack together
to ensure that there is no unusual bruising. The surface should appear carefully feed the assembly into the
wear or scoring in the regions where highly polished and be smooth to the body bores with the drive shaft
the O-rings and bush seals contact, touch. positioned to suit the required direc-
which could result in external leakage. Examine the area where the shaft tion of rotation, i.e. for clockwise
Check the shaft seal recess for scoring seal lips run on the drive shaft; this rotation the drive shaft in top bore
or damage that could result in oil shows up as polished rings. If a noti- and for anticlockwise rotation the
leakage around the outer diameter of ceable groove can be felt or there is bottom bore.
the shaft seal. Replacement shaft scoring, the shaft should be replaced. 6. Refit flange end bushes (FD and
seals can be refitted with Loctite Examine drive keyway in drive shaft FI) into their original bores remember-
hydraulic sealant to overcome slight journal extension to ensure it is not ing the "C" cut-out must match the
damage in this area. damaged or chipped. cover end bushes.
Provided the drive shaft is not 7. Fit new O-ring (4), bush seal and
Bushes and balance plate damaged from the drive coupling and back-up seal (5 and 6) ensuring that
The gear side faces should be perfect- the gears have not been harmed as the seals are located correctly in the
ly flat showing no sign of scoring. described above, then the gears can seal grooves.
Characteristically there are bright be re-used. If, however, the gears are
polished areas on this surface caused damaged they must be replaced as a
by loading against the gear side faces, matched set.
which is often more pronounced on As a matter of good practice, when
the low pressure side. These should be pumps have been dismantled, all the
replaced if there is any general scoring seals should be replaced. It is most
or fine scoring with a matted ap- important that only genuine Ultra
pearance or tearing of the surface seals are used.

HD-10
 OIL PUMP

8. Fit new shaft seal into the recess over drive shaft and carefully refit O-ring (4), bush seals and back-up
in the mounting flange with the mounting flange (I5) ensuring that seals (6 and 5).
"garter" spring facing into the pump. it is located squarely onto the dowels 12. Replace the end cover, refit bolts
Remember that if the seal recess was in the body, then remove assembly and spring washers. Tighten bolts to
scored then Loctite hydraulic sealant sleeve. 46 - 51 N.m (4.7 - 5.2 kg-m, 34 - 37
must be applied to the outer dia- 10. Holding the whole unit together, ft-Ib).
meter of the seal. Apply a coat of carefully turn it over ensuring it is 13. Pour a small amount l.of clean
high melting point grease to the shaft supported on the mounting flange and hydraulic fluid into the port and
seal lips. not drive shaft. check that the shaft can be rotated
9. Fit shaft seal assembly sleeve 11. Remove end cover (3) and fit new without undue force using a smooth
jawed vice.

Typical pump test circuit

Pressure gauge

INSTALLATION from the body cut-in arrested by

Install in reverse order of removal. filters.
Bear in mind that: It is recommended that the unit is
Be careful not to install the oil pump run-in at 1,500 rpm, initially, at zero
on upside down. The inlet is larger pressure for one minute then in
than the outlet. The inlet must be at stages with the pressure increased by
the bottom and is clamped to the 3,500 kPa (35 bar, 36 kgjcm2, 508
hose. The outlet is threaded for an psi) every minute, until maximum
adapter and must be at the top. rated pressure has been attained.
Frequently check the system temper-
ature, ensuring that it does not ex-
ceed the maximum permissible figure
Running-in of 80°C (176°F). If the temperature
A unit which has been re-assembled exceeds the system or unit specifi-
with either new gears, bushes or body, Ideally, this should be done a test rig cation, the test must be delayed and
must be carefully run-in before it is (see figure above.) where pressure can operated off-load until acceptables
subjected to full working conditions. be gradually applied and any wipings temperatures are obtained.

HD-11
 01 L PUMP MOTOR

OIL PUMP MOTOR

REMOVAL

The oil pump motor can be removed

without taking off the pump.
1. Raise the top panel.
2. Remove battery from unit.
3. Put a rag under the pump to
collect oil that will drip out when
pump is removed.
4. Loosen and remove screws that
hold oil pump to motor.
The lower screw is only accessible
from the battery compartment.

1 Brush cover 5 Brush 9 Circlip

2 Rear cover 6 Brush spring 10 Front cover
3 Terminal assembly 7 Spring washer 11 Fan
4 Brush holder assembly 8 Bearings 12 Stator
13 Armature

DISASSEMBLY • Bearings
1. Remove motor from oil pump • Spring washers
motor assembly bracket. • Terminals
Mark position on mounting insulator. • Circ1ip

5. Loosen and remove bolts that Brush disassembly Checking brush

hold oil pump motor assembly bracket Check brushes for pressure and wear.
2. Remove brush cover.
to chassis. 1. Brush pressure should be meas-
3. Loosen screws that hold brushes
ured with a spring balance.
to collectors.
4. Lift brush springs and remove
brushes.

Opening the motor

Before opening the motor, matchmark

both sides so as to ensure reassembly
in the original position.
Mark the brush side with one line (I),
and the opposite side with two lines
(II).

INSPECTION Spring pressure:

6. Loosen and remove bolts that Carefully inspect all components of 8.14 -12.65 N
hold motor to its bracket. the motor assembly. (0.83 - 1.29 kg, 1.83 . 2.84 Ib)

HD-12
 OIL PUMP MOTOR

2. Wear limit of brush Measure insulation resistance between Checking for discontinuity
Brush has a line which indicates its one of negative or PA terminals, and
wear limit. If the motor fails to rotate, its lead
yoke.
wire(s) may have discontinued. Use a
Insulation resistance: tester to closely check for discon-
More than 1 Mil tinuity in the wires or poor connec-
If insulation resistance is less than 1 tions.
Abrasion Mil, clean carbon brush by using dry
limit line Replace any component that might
compressed air.
be considered defective.
Removing dust
If motor is operated under dusty con-
ditions, occasionally clean its interior ASSEMBLY
I. ., using dry compressed air. This will Assembly is the reverse of disassembly.
32 (1.261 Unit: mm (in)
help in maintaining insulation resist-
ance.

INSTALLATION
3. Replace if necessary. Checking and maintenance of
commutator Install in reverse order of removal.
Be careful not to tighten the bolts
The commutator is the heart of a
that hold oil pump motor assembly
motor. If oil or dirt comes in contact
bracket to the chassis until the motor
with the commutator, undue wear
CLEANING AND INSPECTION is secured to the oil pump.
may occur on the brushes during oper-
Clean all disassembled parts, but do ation, resulting in a motor malfunc-
not use grease dissolving solvents for tion. It is, therefore, advisable to
cleaning armature assembly and field occasionally remove dirt or dust with a
coils, since such a solvent would clean, dry cloth or by using dry com-
damage coils or other insulators. pressed air. @ 25-31
Check them for excessive damage or @ 25-32 (2.5 - 3.2.18 - 23)
Rough commutator surfaces should be (2.6 -3.3.
wear, and replace if necessary. smoothly filed with sandpaper (No.
500 or 600) and cleaned using dry
compressed air. Dirt or dust which
19-11~
Measuring insulation resistance may have accumulated in the undercut
of the commutator should also be
cleaned. If the commutator surface is
excessively rough, it should be ground
until smooth.

Diameter limit: @ 16- 22

68.5 mm (2.697 in) (1.6 - 2.2.12 - 161

The wear limit of commutator dia-

meter is 4.5 mm (0.177 in). If the dia-
meter of commutator is less than
specified value, replace armature as-
~ : N.m (kg-m, ft-Ib)
sembly.

HD-13
 MOTOR AND 01 L PUMP ASSEMBLY

MOTOR AND OIL PUMP ASSEMBLY

REMOVAL 5. Loosen upper adapter that con- bracket to chassis.

1. Raise top panel. nects pump outlet to control valve Lift and remove the assembly.
2. Remove driver's side floor panel. pipe.
3. Prepare a container to collect 6. Check marks of motor cables and
oil from the hose between oil tank and terminals. In case of doubt, mark
pump. Prepare a 27 mm (1.06 in) dia. position of cables and terminals to
plug for closing the hose after dis- avoid erroneous connections later.
connecting it from the pump. Disconnect terminals.
4. Loosen and remove clamp from
lower hose between pump and oil
tank.
Remove hose from pump.

INSTAllATION
Install in reverse order of removal.
Be careful not to tighten the bolts
that hold the bracket to the chassis
until the lower hose and upper adapter
7. Loosen and remove the four bolts have been secured to the pump inlet
that hold oil pump motor assembly and outlet ports.

HD-14
 CONTROL VALVE

CONTROL VALVE

REMOVAL 5. Remove driver's side floor panel.

1. Turn off key switch. 6. Prepare a container to collect oil
2. Eliminate pressure in circuit by that will drip out from the valve
moving the mast lift and tilt levers in outlet hose.
back and forth; then set levers in the 7. Disconnect hydraulic connections
"NEUTRAL" position. from control valve.
3. Loosen and remove the three • Disconnect high-pressure pipe
screws that hold control valve protec- adapter from port (1).
tion cover to chassis. • Disconnect low-pressure hose from
port (2).
• Disconnect pipe adapters from tilt
cylinder ports (3 and 4).
3. Backwards.
4. Forwards.
• Disconnect pipe adapter from lift
cylinder port (5).

4. Remove lever or levers.

• Take out pin that connects lever 8. Loosen and remove bolts (T) that
to control valve . hold control valve to chassis.
• Disconnect electrical connector (5)
from control valve.

INSTALLATION

Install in reverse order of removal.

rD : Control valve to chassis bolts (T)
34 - 39 N.m
(3.5 - 4 kg-m, 25 - 29 ft.lb)

HD-15
 CONTROL VALVE

DISASSEMBL Y

1 Tie rod
2 Tie rod
3 Inlet housing
4 Relief valve
5 D-ring
6 Coring
7 Wiper ring
8 D-ring
9 Tilt valve housing
10 Poppet
11 Poppet spring
12 Poppet seal
13 Tilt lock valve spring
14 D-ring
15 Cap screw
16 D-ring
17 Seal plate
18 Wiper ring 21 Spool cap
19 Spring seat 22 Screw
20 Return spring 23 Socket screw
24 Valve housing
25 Cap screw
26 Plug
27 D-ring
28 Nut
29 Nut
30 Valve housing
31 Plug
32 D-ring
33 Dutlet housing

Relief valve Control valve housing Plunger

Using wrench, loosen relief valve as- 1. Remove tightening nuts and dis- 1. Remove cap.
sembly from valve housing. assemble valve into component
sections.

FHD374

FHD314
2. Remove spring and spring seat.

If relief valve is faulty, replace as an

assembly. Clean inside of relief valve
before reusing.
2. Do not overlook load check pop-
pet and spring, located at mating sur-
face of plunger section. M"2
~ Plunger

o?~ '\ Spring seat

FHD375

HD-16
 CONTROL VALVE

3. Remove plunger assembly from • Do not wash O-ring in cleaning oil. 3. Turn key switch ON. Set control
valve housing. Clean it in soapy water, and replace lever to the following position and
4. Take out O-ring and wiper. if damaged. read indication of pressure gauge.
At backward position of tilt
Control lever ASSEMBLY control lever:
1.25 - 1.5 ton models
Disassemble ball joint, proceeding To assemble, reverse the order of
14,711 kPa
as follows: disassembly procedures, adding the
(147.1 bar, 150 kg/cm2,
1. Pull off lock pin, remove plug, following operation:
2,133 psi)
and take out joint seat. I. Coat O-ring, plunger and O-ring
1.75 ton models
2. Remove control lever joint. groove with grease or hydraulic oil
15,691 kPa
3. Remove joint seat and spring. before assembly.
(156.9 bar, 160 kg/cm2 ,
4. Loosen control rod joint with a 2. Tighten tie rods with specified
2,275 psi)
wrench. torque.
4. If pressure will not reach the spec-
CfJ : Tie rod nut (3/8 - 24)
45 N.m ified value, turn adjusting screw of
main relief valve until specified pres-
(4.6 kg-m, 33 ft-Ib)
sure can be obtained. To lower pres-
Tie rod nut (5/16 - 18)
19 N.m
sure, turn adjusting screw counter-
clockwise.
(1.9 kg-m, 14 ft-Ib)
One rotation of adjusting screw can
3. Grease control lever ball joint.
change pressure by 6,865 to 7,846 kPa
(68.6 to 78.5 bar, 70 to 80 kg/cm2,
HYDRAULIC PRESSURE TEST 995 to 1,138 psi). Therefore, adjust
AND ADJUSTMENT pressure carefully, observing pressure
FHD315
1. Turn key switch to OFF. gauge indication.
1 Lock pin 2. Remove plug on hose joint of con- S. After completing adjustment,
2 Plug
trol valve and attach pressure gauge. tighten lock nut while holding adjust-
3 Joint seat
4 Control lever joint ing screw, and tighten cap nut.
5 Control rod joint 6. Repeat pressure test to make sure
6 Spring set pressure is correct.
7 Control lever

INSPECTION
• Clean disassembled parts in cleaning
oil, and use compressed air to re-
move all foreign matter.

Item Assembly standard Service limit Repair

1. Valve housing and Lowering of cylinder without

- control lever operation
Replace as an assembly.
plunger

2. Relief valve - Hydraulic pressure drop Replace relief valve assembly.

3. Tilt relief valve Mast unsteady when tilted Replace tilt relief valve assem-
(anti-cavitation valve)
- forward bly.

4. O-ring and oil seal - Damage or deformation Replace.

5. Clearance between 0.01 mm

0.02 mm (0.0008 in) Replace.
plunger and valve (0.0004 in)

HD-17
 TILT CYLINDER

TILT CYLINDER

CD

1 Piston head 6 Wiper ring 11 Cylinder tube

2 Bush 7 Cylinder head 12 Piston rod
3 Pivot pin 8 Bush 13 Wear ring
4 Pivot pin retaining screw 9 D-ring 14 D-ring
5 V-ring 10 D-ring 15 Bolt

REMOVAL DISASSEMBL Y 3. Withdraw piston rod assembly

1. Tilt mast forward to its limit. If 1. Hold cylinder in a vise, and apply (12).
forks are installed, rest them on the compressed air alternatively to the 4. Loosen piston head bolt (15).
floor. two orifices while moving piston rod
2. Turn off key switch. back and forth; this will force the oil
3. Eliminate pressure in circuit, by out of the cylinder.
moving tilt lever in back and forth; 2. Loosen cylinder head (7). Use
then set tilt lever in the "NEUTRAL" lubricant if necessary.
position.
4. Remove driver's side floor panel.
5. As a safety measure, support the
weight of the two masts with a hoist.
As long as the tilt cylinders are re-
moved from the fork lift truck, ex-
treme care must be exercised so as
to avoid the mast from falling for-
wards.
5. Loosen and remove piston head
(1) from piston rod.
6. Loosen the two hydraulic pipe
adapters. Any U-ring, wiper ring, O-ring or
7. Loosen and remove cylinder front wear ring that comes out of its hous-
and rear pivot pin retaining screw (4). Be careful not to damage the cylinder ing, should be discarded and replaced
8. Take out the cylinder. head U-ring, wiper ring and O-rings. with a new one.

HD-18
 TILT CYLINDER

ASSEMBLY portion of cylinder tube. 2. Fit screws that secure front and
Assemble in reverse order of dis- Cfl : Piston head (1) rear pivot pins to chassis.
assembly. Be sure to: 108 -147 N'm Cfl : 25 - 32 N.m
• Lubricate each part with clean (11 - 15 kg-m, 80 - 108 ft-Ib) (2.6 - 3.3 kg-m, 19 - 24 ft-Ib)
hydraulic oil. Cylinder head (7)
• Never allow dust to enter cylinder 275 - 343 N.m 3. Secure the two hydraulic pipe
during assembly. (28 - 35 kg-m, 203 - 253 ft-Ib) adapters to cylinder.
• Be careful not to damage V-ring,
Cfl : 20 . 39N.m
wiper ring, O-rings or wear ring. INSTAllATION (2 - 4 kg-m, 14 - 29 ft.lb)
• When inserting piston rod assem-
1. Place cylinder in its housing.
bly, be careful not to damage 0- 4. Remove hoist.
Fit front and rear pivot pins.
ring or wiper ring with threaded

HD-19
 LIFT CYLINDER

LIFT CYLINDER

6. Using the hoist, raise inner mast

about I m (3 ft).
Put a support in place and lower mast
on to it. Keep weight of the mast
supported with the hoist.

I
I

lJ I~
m-{J IJ '"I
Support
1 Cylinder tube assembly 7 G-ring 13 Cylinder head
2 Bush 8 Inner valve 14 Bushing holder assembly
3 V-ring 9 Inner piston 15 G-ring
4 Piston ring 10 Retainer 16 Stop
5 Circlip 11 Wiper ring 17 Piston
6 Washer 12 V-ring 18 G-ring
19 Adapter

7. Loosen and remove lower cylin-

REMOVAL der bolt.
8. Remove protection cover from
1. If forks are installed, rest them on
connecting hose between both cylin-
the floor.
ders.
2. Turn off key switch.
9. Prepare a container to collect oil
3. Eliminate pressure in circuit by
that will drip out when the connect-
moving lift lever in back and forth.
ing hose is disconnected.
then set lift lever in the "NEUTRAL':
• Disconnect adapter that connects
position.
hose to R.B. cylinder.
4. Support weight of inner mast
with a hoist. L.H. cylinder
S. Remove split pin, then loosen and • Disconnect high pressure hose.
remove upper nut from cylinder. • Raise inner mast and remove high
pressure valve.
10. Remove intermediate U-bolt that
holds cylinder to mast.
11. Remove cylinder.

HD-20
 LIFT CYLINDER

DISASSEMBL Y 3. Remove piston. ASSEMBLY

Loosen and remove adapter (19) to
1. Hold cylinder assembly in a vise. Assemble in reverse order of dis-
make removal of piston easier.
Prepare a container to collect oil assembly. Be sure to:
Release retainer (10) and withdraw
that will come out when the cylinder • Lubricate each part with clean
piston assembly. hydraulic oil before assembly.
is opened.
Loosen and remove cylinder head. • Clean V-rings with petroleum-base
hydraulic oil.
• Never allow dust to enter the lift
cylinder.
• Be careful not to damage the
V-rings, gasket, O-rings or bush,
etc.
cP : Cylinder head
235 - 304 N.m
(24 - 31 kg-m, 174 - 224 ft-Ib)

FHD504

4. Remove inner piston (9).

Disassemble inner valve (8), taking
out O-ring (7), washer (6) and circlip
2. Take out V-ring (I2), wiper
(S) from inside 0 f valve.
ring (I 1), bushing holder assembly INSTALLATION
If necessary, remove piston ring (4),
(I4) and O-ring (IS).
V-ring (3) and bush (2) from outside Install in reverse order of removal.
Replace V-ring, wiper ring and 0-
of inner valve. Be sure to:
rings.
Always replace wiper ring, gasket,
cP : Cylinder upper nuts
O-rings and bush of inner valve.
29 - 39 N.m
(3 - 4 kg-m, 22 - 29 ft-Ib)

Tighten nuts to their limit, then back

them off so as to align the slot with
the split pin hole.
cP : Cylinder lower nuts
43 - 55 N.m
(4.4 - 5.6 kg-m, 32 - 41 ft-Ib)
Cylinder to mast U-bolts
74 - 94 N.m
(7.5 - 9.6 kg-m, 54 - 69 ft-Ib)

HD-21
 OIL AND FILTERS

OIL AND FILTERS

CHANGING THE HYDRAULIC the maximum and then contract 4. Loosen and remove the 8 screws
OIL them. that hold filter to oil tank.
Contaminated or deteriorated hydrau- Allow the oil to settle in the tank; S. Remove filter through underside
lic oil can cause problems in the oil then check the level. of oil tank.
pump. Therefore, the oil should be The correct level is half way between Remove sediments from inside oil
changed every 6 months or 1,200 the two marks on the dipstick. tank. Clean suction filter and dipstick.
hours, whichever comes first. 6. Install filter.
1. Open and remove R.H. cover. 7. Reconnect lower hoses.
Prepare a container of sufficient 8. Refill oil tank with fresh oil.
capacity to collect oil from the oil 9. Start motor and operate control
tank. lever so that the oil flows through the
OIL TANK SUCTION FILTER entire circuit. Extend lift cylinders to
The maximum height of this container
should be 90 mm (3.54 in). Change the oil tank suction filter at the maximum and then contract them.
the intervals shown in section MA. 10. Allow the oil to settle in the tank;
HYdraulic oil capacity:
1. Open and remove R.H. cover. then check the level. The correct level
18 Q (4-3/4 US gal, 4 Imp gal)
Prepare a container of sufficient is half way between the two marks on
capacity to collect oil from the oil the dipstick.
2. Set control lever to "LOWER"
position, and allow lift cylinder to tank.
The maximum height of this con-
contract gradually, thus returning oil
tainer should be 90 mm (3.54 in).
in cylinder to oil tank.
3. Release the clamps and remove Hydraulic oil capacity:
the two lower hoses from the oil tank. 18 Q (4-3/4 US gal, 4 Imp gal) FRONT OIL FILTER
Drain the oil tank. Change the oil filter at the intervals
4. Remove sediments from inside oil 2. Set control lever to "LOWER" shown in section MA.
tank. Clean suction filter and dipstick. position, and allow lift cylinder to 1. Prepare a container to collect oil
S. Reconnect lower hoses. contract gradually, thus returning oil when the filter is removed.
6. Refill oil tank with fresh oil. in cylinder to oil tank. 2. Loosen and remove filter.
7. Start motor and operate control 3. Release the clamps and remove 3. Apply oil to gasket and install
lever so that the oil flows through the the two lower hoses from oil tank. the new filter.
entire circuit. Extend lift cylinders to Drain the oil tank. Hand-tighten the filter.

HD-22
 HYDRAULIC HOSES

HYDRAULIC HOSES

q"
\ I~
,~ >"1
" ./ /' I

.~:} ',,' \
~,~';t':1 I

~~J~'~Y
~ "" 1 ";/

Al

REPLACING HYDRAULIC HOSES Hose (A2) from intermediate Hose (B2) from front filter to
Before removing either of the hydrau- connection to oil pump intermediate connection
lic circuit's main hoses (hose (A) be- • Loosen clamp that secures hose 1. Raise top panel.
tween oil tank and pump, and hose to oil pump inlet. 2. Remove driver's side floor panel.
(B) between oil tank and front filter), • Remove hose. 3. Loosen and remove upper adapter
the oil tank must be drained. that connects oil pump to control
Line (8) from oil tank to front filter valve inlet pipe.
Line (A) between oil tank and pump 4. Loosen and remove the four
This line is formed by two hoses: (Bl)
This line is formed by two hoses: from oil tank to intermediate connec- screws that hold oil pump motor
(A 1) from oil tank to intermediate tion; and (B2) between intermediate assembly bracket to chassis.
connection; and (A2) from inter- connection and front filter. 5. Lift and separate oil pump motor
mediate connection to oil pump. assembly.
I. Remove battery from unit. Hose (BI) from oil tank to 6. Loosen and remove clamp that
2. Loosen intermediate connection intermediate connection secures hose to intermediate connec-
clamp of hose to be removed. tion, which is located below the oil
1. Remove battery from unit.
pump motor assembly.
2. Loosen clamp that secures hose
Hose (AI) from oil tank to 7. Loosen and remove clamp that
to oil tank.
intermediate connection secures hose to front oil filter.
3. Loosen clamp that secures hose
8. Remove hose.
• Loosen clamp that secures hose to intermediate connection.
to oil tank. 4. Remove hose.
• Remove hose.

HD-23
 HYDRAULIC HOSES

Line (e) from oil pump to control moving the control levers in both 2. Loosen adapters on ends of hose,
valve directions; then set them in the which connects distributor lines and
I. Eliminate pressure in circuit, by "NEUTRAL" position. tilt cylinders.
moving the control levers in both 2. Loosen the two adapters on ends 3. When installing hose, tighten to
directions; then set them in the of hose between high-pressure valve the following torque:
"NEUTRAL" position. and control valve. l!l :59 . 98N.m
2. Loosen the two adapters on ends 3. When installing hose, tighten to (6 - 10 kg.m. 43 - 72 ft.lb)
of hose between control valve and the following torque:
oil pump. l!l :59.98 N.m Return line (F) from control valve to
3. When installing hose, tighten to (6.10 kg.m. 43 - 72 ft.lb) front filter
the following torque:
1. Eliminate pressure in circuit, by
l!l :59 . 98 N.m Distributor pipe lines (E) to tilt moving the control levers in both
(6. 10 kg-m. 43 - 72 ft-Ib) cylinders directions; then set them in the
I. Eliminate pressure in circuit, by "NEUTRAL" position.
moving the control levers in both 2. Loosen clamps on both ends of
High pressure hose (D)
directions; then set them in the hose, which connects control valve
I. Eliminate pressure in circuit, by "NEUTRAL" position. with front filter.

HD-24
 Hydraulic System
FHD 00-N01

APPLIED MODEL: N01 series

APPLIED FROM: September, 2000

HYDRAULIC SYSTEM

MODIFICATION NOTICE:
To accommodate minor changes made on N01 series forklift trucks, outside pulley type 2W mast has been
adopted.

Please file this bulletin in the binder.

The information in this bulletin should not be interpreted as the basis for claims unless so designated.

Issue date: September 5th, 2000 (01)

Printed in the Netherlands Publication No. TB00E-N01SE0

Page 1 of 12
 HYDRAULIC SYSTEM

SECTION HD
CONTENTS
PRECAUTIONS .................................................................. 2 Attachment Piping .......................................................... 5
SERVICE DATA AND SPECIFICATIONS (SDS) .............. 3 LIFT CYLINDER ................................................................. 6
General Specifications ................................................... 3 Construction ................................................................... 6
HYDRAULIC SYSTEM ....................................................... 4 Removal.......................................................................... 7
Mast Piping..................................................................... 4 Installation ...................................................................... 8
PRECAUTIONS

● Remove hydraulic fluid if necessary.

● Before disconnecting the hydraulic piping, discharge residual
pressure inside the piping.
● For tilt piping, first place the fork horizontal (tipped slightly
forward) and turn the ignition switch off. Next, loosen the
piping and let set while the remaining pressure escapes.
● To lift piping, turn the ignition switch off, and operate the lift
lever several times downward.
● Before removing the hydraulic piping and hydraulic unit, remove
dirt and dust.
● Before disconnecting the piping, cover the surrounding area with
waste to prevent contamination of other parts by hydraulic fluid.
● Block the ends of disconnected piping with stoppers to prevent
leakage of hydraulic fluid.
● When removing the harness connector, turn the ignition switch off
and disconnect the battery cable negative terminal from the bat-
tery.
● Before removing the harness connector, check its mounting posi-
tion.
● Seal the taper threads with a seal tape securely. Prevent chips
of the seal tape or other foreign objects from entering into the
hydraulic piping.
● O-rings are used at the connectors which connect the hydraulic
units. When assembling, be careful not to damage the O-rings.
● When installing the piping or hydraulic unit, prevent foreign
objects from entering into the piping.
● Tighten the connecting section of piping to the specified torque.
● Place the disassembled parts of the hydraulic unit on clean paper
or cloth. Make sure that the parts are free from contamination,
damage, and dents.
● Before assembling the hydraulic unit, clean each part by deter-
gent oil and blow air to prevent foreign objects from entering into
the unit.
● Before assembling the hydraulic unit, apply hydraulic fluid if nec-
essary.
● Lifting should be performed only by a technician who has
received the proper training for slinging or hoisting.
● Operation involving heavy load should be performed by two per-
sons.

HD-2
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
TILT CYLINDER
Stroke mm (in) 60 (2.36)
Cylinder ID mm (in) 65 (2.56)
Cylinder OD mm (in) 80 (3.15)
Piston rod diameter mm (in) 30 (1.18)

LIFT CYLINDER
Mast name 2W2700 2W3000 2W3300 2W3500 2W3700 2W4000 2W4500 2W5000
1,350 1,500 1,650 1,750 1,850 2,000 2,250 2,500
Stroke mm (in)
(53.51) (59.06) (64.96) (68.90) (72.83) (78.74) (88.58) (98.43)
Cylinder ID
45 (1.77)
mm (in)
Cylinder OD
52 (2.05)
mm (in)
Piston rod diameter
35 (1.38)
mm (in)

HD-3
 HYDRAULIC SYSTEM

Mast Piping

Lift cylinder (RH)

Lift cylinder (LH)

12.7 - 15.7
(1.3 - 1.6, 10 - 11)
Hose guard

Front Flow regulator valve

39.2 - 58.8
(4.0 - 6.0, 29 - 43)

34.3 - 39.2
34.3 - 39.2 (3.5 - 4.0, 25 - 29)
(3.5 - 4.0, 25 - 29)
Lift hose
: Nvm (kg-m, ft-lb)
29.4 - 58.8 (3 - 6, 22 - 43) HDM0052A

HD-4
 HYDRAULIC SYSTEM

Attachment Piping

LIFT HEIGHT: 2,700 - 3,500 mm

Attaching hose

26 - 32
(2.6 - 3.3, 19 - 23)

74 - 94
(7.5 - 9.6, 55 - 69)

LIFT HEIGHT: 3,700 - 5,000 mm

13 - 15
(1.3 - 1.6, 10 - 11)
13 - 15
(1.3 - 1.6, 10 - 11)

13 - 15
(1.3 - 1.6, 10 - 11)

13 - 15
(1.3 - 1.6, 10 - 11)

Attaching pipe

13 - 15
(1.3 - 1.6, 10 - 11)

13 - 15
(1.3 - 1.6, 10 - 11)

Attaching pipe

Attaching hose

Carriage 13 - 15
(1.3 - 1.6, 10 - 11)

: Nvm (kg-m, ft-lb)

HDM0056A

HD-5
 LIFT CYLINDER

Construction

ADD OIL TO THIS CAVITY

IN THE AMOUNT AND TYPE
INDICATED ON 196 - 245 Nvm
CPS_ _ _ _ _ _ _ _ _57.00
___ (20 - 25 kg-m,
145 - 181 ft-lb)

Stamp 35 (1.38) dia.

part No.

45 (1.77) dia.

52 (2.05) dia.
LABELCUSTOMER
---------------------------
PART NO.
---------------------------
IN THIS LOCATION

Unit: mm (in)
HDM0083A

V
1 Shell assembly V7 O-ring V
13 Pull-in wire
V
2 Plunger V8 Spacer V
14 Check valve
V
3 Retainer V9 Piston V
15 O-ring
V
4 Wiper V
10 Buck-up ring V
16 Washer
V
5 Rod seal V
11 Piston seal V
17 Circlip
V
6 Buck-up ring V
12 Wear ring V
18 Label

HD-6
 LIFT CYLINDER

Removal
CAUTION:
Be sure to keep hands and feet out of danger.

PREPARATION
1. Remove from mast carriage assembly with fork.
2. Jack up the front of vehicle to keep about 120 mm (4.72 in) of
clearance from lower end of outer mast to floor (refer to GI sec-
tion).
3. After setting mast vertical and turning ignition switch OFF, lower
lift cylinder at the lower end using joystick (control) lever.
CAUTION:
Be sure to lower lift cylinder fully to discharge remaining pres-
sure in pipes.

LIFT CYLINDER
Lift hose
1. Remove lift hose from lift cylinder.
CAUTION:
Oil tends to spill if hoses are disconnected, so be sure to block
the end with stoppers.
2. Disconnect the hose between the lift cylinders.

HDM0086A

3. Remove lock nut and stud bolt on the upper plane of lift cylinder
to separate lift cylinder from inner mast.
4. Remove spacer and lift up inner mast with lifting wire/nylon sling.

HDM0085A

HD-7
 LIFT CYLINDER
Removal (Cont’d)
5. Remove lift cylinder attaching bolt and U-bolt, then remove lift
cylinder from the front.
CAUTION:
● Because lift cylinder is very heavy, two people should per-
form this task.
● When removing U-bolt, support lift cylinder to prevent it
from falling.

HDM0087

Installation
Installation is in the reverse order of removal. Pay attention to the
following points.
● Tighten bolt at the lower end of cylinder.
: 43 - 54 Nzm (4.3 - 5.6 kg-m, 32 - 40 ft-lb)

● Fit the U-bolt into the cylinder, tighten the nut by hand, and fix
Adjusting nut
Stopper with the double nuts.
U-bolt : 26 - 32 Nzm (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
Lock nut ● Fit the stopper into the hole at the end of the adjusting bolt.
● Tighten the adjusting bolt, and check that the stopper contacts
Adjusting bolt with the cylinder. Then, further tighten for 1/2 to 1 turn and tighten
the lock nut.
: 74 - 94 Nzm (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
Lock nut
● When tightening the lock nut, make sure that the adjusting
Cylinder nut does not turn.
HDM0094

Set nut ● Tighten the stud bolts on the set nuts to the bottom of the threads.
Pin Apply thread lock to the threads of the stud bolt on the spacer
side. And then tighten and fasten the stud bolt on the top of the
spacer. So that the set nut does not become loose, secure the
stud bolt with a cotter pin.
Stud bolt ● Perform the shim adjustment so that the clearances between the
piston rod of the mast cylinder on the right and left and the mast
Spacer
cylinder mounting section become the same.
Shim: 1.0 mm (0.039 in)

HDM0093A

● Securely wrap seal tape around tapered threads of pipes. Never

allow pieces of seal tape to enter hydraulic pipes.
● O-rings are used in the connectors to couple each hydraulic unit.
Before assembling, attach a guide to connector threads and
insert O-ring along with it so as not to damage O-ring.
● Tighten connector by hand and after determining connector
position, tighten lock nut to the specified torque.

HD-8
LIFT CYLINDER
Installation (Cont’d)
HEIGHT ADJUSTMENT
1. Park the forklift on solid, level ground. Set the mast assembly in
the vertical position.
2. Raise the mast assembly and hold it just before it reaches the
fully extended position.
3. Slowly raise the mast assembly. When the mast assembly
reaches the fully extended position, check for movement (swing-
ing left or right) in the middle or inner rail.

BLEEDING AIR
1. Add hydraulic oil up to the upper limit of level gauge.
2. Raise and lower mast slowly.
3. Lower mast fully and check the hydraulic oil capacity in tank. If
hydraulic oil level is reduced, fill up to the upper limit of level
gauge.
4. Repeat steps 2 and 3 until the hydraulic oil capacity is not
reduced.
5. Check that cylinder moves smoothly up and down.

HD-9
 LOADING MECHANISM
(LM)

MODEL NOl SERIES " "

CONTENTS

SERVICE DATA AND SPECIFICATIONS LM- 2

TROUBLE DIAGNOSES AND CORRECTIONS LM- 3
LOADING MECHANISM LM- 4
FORKS AND CARRIAGE LM- 5
MAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. LM- 8
LI FT ROLLER AND BACK-UP METAL LM-11
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

INSPECTION AND ADJUSTMENT TIGHTENING TORQUE

Item mm (in) N.m kg-m ft-Ib

Mast to lift roller 0.1 - 0.6 (0.004 - 0.024) Lift chain lock nut 108 -147 11 - 15 80 - 108
Mast support cap bOlt 89 - 118 9.1 - 12 66 - 87
Shims 0.5, 1.0 (0.020, 0.039)
Backrest bolt 72 -98 7.3 -10 53 -72
Mast to back-up
0- 1.0 (0 - 0.039) Tilt cylinder lock nut 25 - 32 2.6 - 3.3 19 - 24
metal
Clearance
Lift cylinder Bolt 29 - 39 3-4 22.29
Shims 0.5, 1.0 (0.020,0.039)
Nut 43 - 55 4.4 - 5.6 32 - 41
I nner mast to U-bolt 74 - 94 7.5 - 9.6 54 - 69
0.1 - 0.6 (0.004 - 0.024)
carriage side roller
High pressurevalve 59 - 98 6 - 10 43 -72
Shims 0.5, 1.0 (0.020, 0.039)

Lift chain deflection 25 - 30 (0.98 - 1.18)

LM-2
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Forks are lifted or Carriage bracket out of adjustment. Adjust clearance at side roller/lift roller to
lowered unsmoothly. inside of inner mast. Replace worn or faulty
parts with new ones as required.
Insufficient clearance between inner and Adjust clearance with shims.
outer masts.
Insufficient lubricant. Apply grease on contact swfaces of sliding
parts.
Biting foreign materials between moving Remove foreign materials.
parts.
Skew inner mast. Repair.
Bent lift bracket. Repair or replace.

Forks are lifted Lift chains out of adjustment. Adjust lift chains.
unevenly.

Lift roller does not Grease stiffened or dirt accumulated on lift Clean. Do not apply grease on rolling sur-
rotate. roller and mast sliding surfaces. faces of lift rollers.
Improperly adjusted lift roller. Adjust.

Excessive mast noise. Insufficient lubricant. Lubricate.

Improperly adjusted lift roller, side roller Adjust.
and back-up metal.
Worn chain wheel, lift roller, side roller and Replace.
back-up metal.

LM-3
 LOADING MECHANISM

LOADING MECHANISM

CD
~ '"
oj
u
.......
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~~ 0 ...
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t:;
oj ,0
E ....... 5l
... 0
t:;
S
<l.l

8 ....5l'"'" ~
oj
......
CICl

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oj ."
CICl
~ (8

...
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...
<t:
;:l

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0

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CICl

...
Ltl
E ...
...
o:t'

CDN
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='... .5 ~,0
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CICl
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LM-4
 LOADING MECHANISM

FORKS AND CARRIAGE 2. Remove carriage bracket and

backrest assembly.
REMOVAL
• Put slings in place and, using a

A WARNING:
hoist, raise assembly about 1 m
(3 ft).
Be careful when removing and install- • Put a support in place and lower
ing the forks and carriage as they are assembly on to it.
heavy.

1. Remove forks.
• Place two wooden blocks under
each mast column. Remove bolt
from carriage bracket.
• Release retaining pins at top of
4. By means of the lift cylinders,
forks, and slide forks towards
raise mast and pull the carriage bracket
center of carriage bracket.
and backrest assembly out in a for-
• Lift bottom of fork and separate it
wards direction.
from carriage bracket.

A WARNING:
a. Keep hands and feet away from
forks. (When removing and install-
Support
ing forks carefully, keep feet and
hands clear.)
b. Do not remove forks from the end
of the fork bar. Severe injury can
result if the fork is dropped.

3. Remove lift chains.

Remove split pin from castellated
nut and loosen and remove lock nut
and nut from end of chain.

LM-5
 _ LOADING
____________ ~~~~M~E~C~H~A~N~~IS~M=~---------~
DIS
ASSEMBLY \" 1 26
Side roller
1.75<00 mode" 11iliJl
0<";", "'''k''. ""\\ '()~ (fJ
(2.1. . •
2 . 27 15.20)

.r~~snapring

'~I&I
J~0 <{D-Side thrust metal

Lift roller

Fork

1.25- an d 1 .s -ton mdoels

Carna. ge bracket Side roller

~l '()
(fJ2(2.1

Shim
1.2627
..•
15.20)

.~ --Snap ring
']~ ~ <{D- Side thrust metal

Lift roller

(fJ: N.m (kg-m, ft-Ib)

LM-6
 LOADING MEeHAN ISM

INSPECTION
Check condition of all components of Carriage bracket assembly
carriage bracket and backrest assem-
B
bly.
• Lift rollers and side rollers
• Possible deformation of roller pins
• Forks
Replace any component that might be
considered defective.
Shim

ASSEMBLY AND ADJUSTMENT

Roller clearance
1. Measure inside width "A" be-
tween inner masts. Make measure.
ments at the top, bottom and center B'
(cross beam) sections.

I /I III [III II I
Clearance: the rollers on the inner mast.
A-B Inner mast to side 3. Rest inner mast on floor.
roller 4. Using a hoist, raise carriage
A-B' Inner mast to bracket and backrest assembly about
carriage roller 1 m (3 ft).
A -B" Inner mast to 5. Put a support in place and lower
A thrust metal assembly on to it.
0.1 - 0.6 mm
(0.004 . 0.024 in)

Adjustable range with shim:

2. Measure right and left pitches, B, 1.0.4.0 mm (0.039 - 0.157 in)
B', B" of carriage side roller, carriage
roller and thrust metal. Shims:
0.5 mm (0.020 in)
3. Calculate A - B, A - B' and
A - B". 1.0 mm (0.039 in)

Each result shows clearances between

each roller and inner mast. a. Number of shims must be the same
Adjust shims of each roller evenly on on the right and left sides.
the left and right and make clearances b. After clearance adjustment, push
between smallest part of inner mast carriage assembly to see if it oper-
and carriage side roller, carriage roller ates properly.
and thrust metal, 0.1 to 0.6 mm Support
(0.004 to 0.024 in). Lift chain
Refer to page LM-8 for instructions of
lift chain adjustment.

INSTALLATION
Carriage bracket and backrest assembly
1. Using the lift cylinders, raise
inner mast.
2. Fit assembly under inner mast. As a safety measure, do not remove
Gradually lower inner mast, centering hoist yet.

LM-7
 LOADING MECHANISM

6. Install lift chains. after the forks are installed in place. 2. Hold mast assembly with slings;
• Secure chains with castellated nuts Operate lift control lever until fork is raise forklift truck, put wooden
and split pins. in contact with the floor; then turn blocks underneath, and lower forklift
adjusting nut until obtaining the on to them.
specified dimension "e" when pres-
sure is applied with one finger.
Dimension "e":
25 - 30 mm
(0.98 - 1.18 in)

FLM203
o
o
o o
o
o
(fJ : Lift chain
to carriage bracket and o I

backrest assembly retaining nut

108 -147 N.m 3. Remove front wheels.
c
(11 -15 kg-m, From this time onwards, and as long
80 - 108 ft-Ib) as the mast assembly is connected
to forklift truck, use extreme caution,
• Tighten nut to its limit, then back
because the lift truck is out of balance.
it off so as to align slot of nut with
split pin hole.
• Fit split pin.
7. Secure chains to inner mast, by
means of nut, lock nut and split pin.
8. Using the hoist, lift carriage
bracket and backrest assembly; remove
support and lower assembly to the
floor. Remove hoist.
9. Adjust length of chain.
With mast in the vertical position,
adjust length of chain until the
carriage bracket and backrest assembly MAST
is at a distance of 76 mm (2.99 in)
REMOVAL
from the floor.
1. Disconnect high pressure hose. 4. Separate tilt cylinder head from
Move mast lift and tilt levers in both mast.
directions; then set them in the With the weight of the mast supported
NEUTRAL position. By means of this by the hoist, remove pivot pin of tilt
operation, any possible pressure in the cylinder head.
mast cylinders is eliminated. Put a If necessary, move mast slightly with
suitable container in place to collect hoist, so as to make removal of pivot
the oil that will drip out from inside. pin easier.

10. This distance is obtained by

tightening or loosening the nut and
lock nut that connect lift chain to
outer mast.
11. Tension lift chains.
This adjustment must be carried out

LM-8
 LOADING MEeHAN ISM

S. Remove mast support caps.

INSPECTION

Check condition of all mast assem-

bly components.
• Correct alignment and parallelism
of inner and outer masts
• Rollers and shims of both masts
• Possible deformation of roller pins
• Condition of back-up metals and
shims
• Lift cylinder, connecting hose, high
• Slide top of mast so as to free pressure hose, etc.
cylinder head. Replace any component that might
• Remove cylinders. be considered defective.
6. Using the hoist, lift mast and 3. Remove inner and outer mast
remove assembly. rollers.
• Slide inner mast backwards, so
that the four rollers (two on inner
mast and two on outer mast) are
ASSEMBLY AND ADJUSTMENT
completely exposed to view.
• Using a puller, remove rollers.
A WARNING:
Be careful when assembling the
masts as they are heavy.
DISASSEMBL Y

A WARNING:
Assembly is the reverse of disassem-
bly.
Be careful when disassembling the
I. Place inner mast in outer mast.
masts as they are heavy.
Using the hoist, lift mast so as to
clear the roller pins.
1. Place mast assembly on a flat
2. Install inner and outer mast
surface.
rollers.
2. Remove the two lift cylinders
The same shims removed during
from mast assembly.
disassembly should be used again.
• Remove split pins from upper
nuts of lift cylinders.
• Loosen and remove bolts that
hold lower end of cylinders to
mast.
• Remove protection cover from
connecting hose between both 4. Remove back-up metals installed
cylinders. at top inner end of outer mast.
• Remove connecting hose from be- 5. Withdraw inner mast.
tween cylinders. When arriving to the end, the mast
• Loosen and remove U-bolts that Outer mast
should be lifted with a hoist so as to
hold cylinders to masts. clear the roller pins.

LM-9
 LOADING MECHANISM

3. Adjust clearance between mast • Recheck that clearance "A" is with- 7. Apply a coat of grease to back-up
rollers and guides. in the specified limits. metals.
Place inner and outer masts, so that 5. Apply a coat of grease to the 8. Install lift cylinders.
roller pitch is as shown in the table areas indicated below. Installation is the reverse of removal.
below:

Front
ME MI

:q I
J
L
L ____
0
U L:1J

ME: Outer mast

MI: Inner mast

Unit: mm (in) • After adjustment and greasing, slide

Max. fork height "L" dimension inner mast inside outer mast, so as
2,700 - 3,300 to check that there is nothing to
254 (10.00)
(106.3 - 129.9) prevent its movement.
3,500 (137.8) 289 (11.38) 6. Install and adjust back-up metals.
3,700 (145.7) 314 (12.36) • The back-up metals are installed at
4,000 - 5,000
top inner end of outer mast.
354 (13.94) • To adjust the clearance between
(157.5 - 196.9)
back-up metals and inner mast,
4. Check clearance "A". raise the latter and check dimension
"B" . [fJ: Lift cylinder upper nuts
Clearance "A": 29- 39 N.m
0.1 - 0.6 mm Dimension "8"
(3 - 4 kg-m,
(0.004 - 0.024 in) 0- 1.0 mm (0 - 0.039 in)
22 - 29 ft-Ib)

Tighten nuts to their limit, then back

IMPORTANT:
them off so as to align slot of nut
Clearance "A" must be equal at right
with split pin hole.
and left sides of mast.
[fJ : Lift cylinder lower nuts
Outer mast 43 - 55 N.m
(4.4 - 5.6 kg-m,
Lift roller 32 • 41 ft-Ib)
Lift cylinder to mast U-bolts
74- 94 N.m
(7.5 - 9.6 kg-m,
54 - 69 ft-Ib)

A
INSTALLATION
• If necessary, remove back-up metal Installation is the reverse of removal.
again and fit suitable shims so as to Refer to SERVICE DATA AND
obtain the required dimension SPECIFICATIONS for tightening tor-
• A shim repair kit is available, which "B"; then reinstall guide. que.
permits adjustments from 1.0 - 4.0
Adjustment range with shims: 1. Using a hoist, lift mast assembly
mm (0.039 - 0.157 in).
0.5 - 2.5 mm and put it in place on front of fork-
• Two classes of shims with the
(0.020 - 0.098 in) lift truck.
following thicknesses are available.
• The forklift truck must be standing
Shim thickness: • Two classes of shims with the
on a flat surface.
0.5 mm (0.020 in) following thicknesses are available.
• If wheels are still mounted on fork-
1.0 mm (0.039 in) Shim thickness: lift truck, lift it with the hoist and
• If necessary, remove roller, fit the 0.5 mm 10.020 in) place it on wooden blocks.
necessary shims and reinstall roller. 1.0 mm (0.039 in) Remove wheels.

LM-10
 LOADING MECHANISM

• As a safety measure, support weight 4. Install front wheels.

of mast assembly with the hoist.
• Use extreme caution, since when
l!J : 157 - 177 N'm
(16 - 18 kg-m,
fitting mast assembly on lift truck,
116-130ft-lbl
the latter will be out of balance.
2. Install tilt cylinders.
5. Using the hoist, raise forklift
l!J : Tilt cylinder to chassis and mast truck and remove wooden blocks.
pivot pin retaining screws • Lower forklift truck to floor,
25 - 32 N.m leaving it standing on its wheels.
(2.6 - 3.3 kg-m, • Before removing the hoist, check
19 - 24 ft-Ibl that forklift truck is resting correct-
ly on all wheels, and perfectly
stable in all directions.
6. Connect high pressure hose. • Support weight of inner mast with
the hoist.
l!J: 59 - 98 N'm
2. Disconnect high pressure hose.
(6.10 kg-m,
Move mast lift and tilt levers in both
43 - 72 ft-Ibl
directions; then set them in the
NEUTRAL position. By means of this
operation, any possible pressure in the
mast cylinders is eliminated. Put a
suitable container in place to collect
the oil that will drip out from inside.

Loosen cylinder adapters so as to

make cylinder head to mast alignment
easier.
3. Install mast support caps that
connect lower end of outer mast to
chassis.
l!J : 89 - 118 N'm 7. Operate mast tilt control lever,
(9.1 - 12.0 kg-m, tilting the mast completely forwards
66 - 87 ft-Ibl and backwards.
Check mast tilt angle.
Forward 4°
Backward 6°
3. Remove lift cylinders.
As a safety measure, support weight
of inner mast with the hoist, all the
time that lift cylinders are removed.
• Take out split pins from cylinder
LIFT ROLLER AND upper nuts, and remove nuts.
BACK-UP METAL • Lift inner mast [about 1 m (3 ft)] ,
put support under inner mast.
REMOVAL
• Remove bolts that hold lower end
1. Remove carriage bracket and of cylinders to outer mast.
backrest assembly. • Remove protection cover from
See Page LM-5. connecting hose between both
• Tilt mast assembly backwards to its cylinders.
limit. • Using a hoist. raise inner mast.
• Using a hoist, raise forklift truck • Release upper head of lift cylinders.
[about 250 mm (9.84 in)] and • Loosen and remove cylinder to
place wooden blocks under front outer mast U-bolts.
end. • Remove lift cylinders.
Place a wooden wedge under rear • Remove support from under inner
wheel. mast.

LM-11
 LOADING MECHANISM

4. Lower inner mast until it rests on INSTALLATION

the floor.
1. Replace defective parts.
Remove defective parts. Adjust tolerance.
• Use a puller to remove rollers. Adjust clearances. See Page LM-lO.
2. Installation is the reverse of
removal.

• If necessary, remove back-up

metals.

LM-12
 BODY & FRAME
(BF)
MODEL NOl SERIES
" "

CONTENTS

SERVICE DATA AND SPECIFICATIONS BF-2

BODY AND FRAME BF-3
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

APPROXIMATE WEIGHT TIGHTENING TORQUE

NOl N.m kg-m ft-Ib

Counterweight to frame 490 - 618 50 - 63 362 - 456

1.35-ton 1.5-ton 1.75-ton
Overhead guard upper to 137 - 167 14 - 17 101 - 123
Overhead guard including rear pillar and instrument
rear pillar & instrument 94 (207) frame
frame kg lib)
Rear pillar to frame 137-167 14 - 17 101 - 123
600 600 650 Instrument frame to frame 93 - 108 9.5 - 11 69 -80
Cou nterweight kg lib)
(1,323) (1,323) (1,433)
Back mirror 13.16 1.3 - 1.6 9 - 12
Top stay ball stud 13 - 16 1.3.1.6 9 - 12
Top panel hinge 13 - 16 1.3 - 1.6 9 - 12
Top panel mounting 13 - 16 1.3 - 1.6 9.12
bracket
Floor board 13 - 16 1.3 - 1.6 9 - 12
Top panel lock 5.1 - 6.5 0.52 - 0.66 3.8 - 4.8
Seat mounting 13 - 16 1.3 - 1.6 9 - 12
Top side cover 13 - 16 1.3 - 1.6 9 - 12
Top panel strap 5.1 - 6.5 0.52 - 0.66 3.8-4.8
Top panel catch 13 - 16 1.3 - 1.6 9 -12
Side cover lock and 5.1 - 6.5 0.52 - 0.66 3.8 - 4.8
striker

BF-2
 Over head guard upper
CfJ 137 - 167 (14. 17 , 101 -123)

Instrument frame

CfJ 137. 167 .123)

(14 - 17, 101

l!J 93 - 108 (9.5 -1 1, 69 - 80)

Seat
Top panel
mounting
bracket

Controller upper
cover
Seal cover

CT" 5 1 . 6.5
'V U).52 _0.66,
3.8 -4.8)

Counter we]'ght
Toppa?nl
catch ./ ,~,
rT' 13 - 16 )
'V (1. 3 - 16
" 9 -12
l!J

. ~f£To:';:~'..
13 - 16
(1.3 -1.6, r!J 13 - 16 12)
9 -12)
'9
r!J 13 - 16
(1.3 -1.6,
9 -12)
r!J 13 -16~)
(1.3-1.6,9 '1J~.[ tfJ ;:.~ '~~. 9 121

Frame ~Sidecover

Floor board rear

Floor board front Step mat

r!J: N.m (kg-m, ft-lb)

FBF049

BF-3
 BODY ELECTRICAL
(BE)

MODEL NOl SERIES " "

CONTENTS

TROUBLE DIAGNOSES AND CORRECTIONS BE- 2

BATTERY BE- 2
BODY ELECTRICAL WIRING BE- 4
DESCRIPTION BE- 4
FUSE BLOCK BE- 4
FUSIBLE LINK BE- 4
WI RING HARNESS BE- 5
LIGHTING SYSTEM BE- 9
BULB SPECIFICATIONS BE- 9
CHECKING WARNING LAMP BE- 9
HEADLAMP BE- 9
FRONT TURN SIGNAL LAMP BE- 9
REAR COMBINATION LAMP BE- 9
BACK OPERATION LAMP BE- 9
KEY SWITCH BE- 9
LIGHT/BACK OPERATION LAMP SWITCH BE-lO
TURN SIGNAL SWITCH BE-l0
STOP LAMP SWITCH BE-lO
METERS BE-ll
BATTERY CAPACITY METER AND HOUR METER BE-ll
ELECTRICAL ACCESSORIES BE-ll
BACK-UP WARNING BUZZER BE-ll
CO NT R 0 L VA LV E SWI TC H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. B E-ll
LOCATION OF ELECTRICAL UNIT BE-12
BATTERY BE-13
REMOVAL AND INSTALLATION BE-13
CHECKING ELECTROLYTE LEVEL BE-13
CHECKING SPECIFIC GRAViTy BE-13
PRECAUTIONS WHEN CHARGING BE-14
WIRING DIAGRAM BE-16
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

BATTERY
Trou-
Condition Probable cause Corrective action
ble

Typical indications are listed below 1. Short-circuiting due to broken Replace faulty cell.
although they depend upon the de- or holed separator.
grees of shorting. (Warping of elements due to
repetition of overcharging and
1. Cell voltage and specific gravity are
overdischarging will be effective
-
"'C
Q.l

'S
u
....
low in open-circuit state as well as
during charging and discharging.
to accelerate such fault.)

-
0c;3

....
0
..s::
tI)
2. Gassing is retarded at the end of
charging .
3. Excessive rise of electrolyte tempera-
2. Presence of impurities (a piece of
lead, etc.) dropped in during
fabrication of battery .
3. Short-circuiting due to sediment
ture during charging.
of active materials.
4. Sp. Gr. quickly drops when stand-
ing in storage in charged state.

1. Voltage and electrolyte tempera- 1. Repetition of overcharging and 1. If the indication is light, remove
ture is higher during charging. discharging. the probable cause and carryon
equalization charging.
2. Gassing is accelerated during charg- 2. Plates is exposed in air for a long
ing and Sp. Gr. is lower at the end time due to lack of electrolyte. 2. Replace faulty cell if damage
c::
-
.
9 of charging .
~ 3. Voltage quickly drops during dis-
='
tI)
3. Careless storage without
tional charging.
addi-
cannot be remedied by step 1.

charging. (Battery capacity is

4. Let the battery alone at high Sp.
lower.)
Gr.
4. Plates are whitened in an extreme
S. Excessive self-discharging due to
case.
the presence of impurities.

Q.l
Self-discharge arises more or less in 1. Use of impure water other than 1. Take daily care of the battery.
....
tlO
every battery even if it is not in faulty distilled water .
2. Remove probable causes.
'"
..s::
u state. However, too much tendency
en 2. Presence of impurities.
:a
to:..
accompanied by the following indica- 3. Replace faulty cell if it is ex-
Q) tions should be remember as abnormal. 3. Too high Sp. Gr. ceedingly damaged.
en
..s::
u 1. Sp. Gr. qUickly drops when standing 4. Too high ambient temperature .
='
S in storage in charged state. S. Insufficient cleaning of container.
0
0 2. Charging capacity is considerably
Eo-<
reduced.

->.
'':
e'"
1. Polarity of some cells in a battery is
exchanged during discharging caus-
1. Due to qUick discharge without
caution to the extremely re-
1. Replace cell.

c.. 2. Keep daily inspection and proper

'- ing high electrolyte temperature. duced capacity of some cells.
0 handling of battery.
Q.l
tlO 2. Sometimes emission of gas arises 2. Lack of necessary preparative
c::
'"
..s:: due to dissolving of electrolyte. means such as equalization
u
>< charge.
~
1. Electrolyte becomes brown. 1. Due to corroded active dropped 1. Check for voltage and Sp. Gr.
from fatigued positive plates and If normal, use the battery for
....
en
mixed into clecrolyte. the time being .
-
Q.l
..s::
0 2. Smell of chlorine dUring charging. 2. Sea water mixed in electrolyte. 2. Replace electrolyte and charge
battery at low-rate with enough
time to extinguish smell.

BE-2
 TROUBLE DIAGNOSES AND CORRECTIONS

Trou-
ble Condition Probable cause Corrective action

3. Electrolyte decreases rapidly. 3. a. Cracked battery cells. 3. a. Replace.

b. High electrolyte temperature. b. Adjust.
c. Excessive sulfation. c. See above.
'"...
Q) 4. Electrolyte temperature is too high . 4. a. Lack of electrolyte. 4. See above topics as applicable.
.=:
0 b. Shorted cells.
c. Polarity reversed.
5. Connector is hot or heated. 5. Poor contact of connector with 5. Solder.
binding posts.

BE-3
 BODY ELECTRICAL WIRING

BODY ELECTRICAL WIRING

A WARNING: 3. No cable covering shows any evi- FUSIBLE LINK

Before starting to work on any part of dence of cracks, deterioration or other
electrical system, remove rings and damage.
jewelry to prevent an accidental short 4. Each terminal is a safe distance
circuit, and turn off ignition switch away from any adjacent metal parts.
and then disconnect battery ground 5. Each cable is fastened to its
cable. proper connector or terminal.
6. Wiring is kept away from any
adjacent parts with sharp edges.
DESCRIPTION
7. Wiring is kept away from any
Cables are covered with color-coded rotating or moving parts.
vinyl for easy identification. In the 8. Cables between fixed portions and
wiring diagram, colors are indicated by moving parts are long enough to
one or two alphabetical letters. withstand shocks and vibrations.
It is recommended that the battery be
disconnected before performing any A melted fusible link can be detected
electrical service. either by visual inspection or by feel-
FUSE BLOCK ing with finger tip. If its condition is
CABLE COLORS questionable, use circuit tester or test
lamp.
Cable colors are indicated by one or
two alphabetical letters: CAUTION:
B: Black, BR: Brown, G: Green, a. If fusible link should melt, it is
L: Blue, LG: Light green, possible that critical circuit (power
R: Red, W: White, Y: Yellow, supply or large current carrying cir-
OR: Orange, P: Pink, cuit) is shorted. In such a case, care-
GY: Gray, V: Violet fully check and eliminate cause of
The main cable is generally coded with problem.
a single color. The others are coded b. To ensure heat radiation from the
with a two-tone color as below: FBE565 fusible link, never wrap it with
B/W: Black with white stripe vinyl tape. Extreme care should be
G/Y: Green with yellow stripe taken with this link to ensure that
a. If fuse is blown, be sure to elimi- it does not come into contact with
nate cause of problem before in- any other wiring harness or vinyl or
INSPECTION rubber parts.
stalling new fuse.
Inspect all electrical circuits, referring b. Never use fuse higher than specified
to wiring diagrams. Circuits should be rating.
tested for continuity or short circuit c. Check condition of fuse holders. If
with a conventional test lamp or cir- rust or dirt is found, clean metal
cuit tester. Before inspecting circuit, parts with fine-grained sandpaper
ensure that: until proper metal to metal contact
1. Each electrical component part or is made.
cable is securely fastened to its con- Poor contact in any fuse holder will
nector or terminal. often lead to voltage drop or heat-
2. Each connection is firmly in place ing in the circuit and could result in
and free from rust and dirt. improper circuit operation.

BE-4
 BODY ELECTRICAL WIRING

WIRING HARNESS
HARNESS LAYOUT

Guard harness

Tail harness

Meter harness

Chassis harness
FBE567

TAIL HARNESS

To back
operation
lamp

To chassis
harness

FBE568

BE-5
 BODY ELECTRICAL WIRING

GUARD HARNESS

To meter
harness

FBE569

BE-6
 BODY ELECTRICAL WIRING

METER HARNESS

>,

...'"
" >,

".,'"...
..I<
u
..::
u
Po.
S
~
0
f-<

--.... ...
P:::'O
o I::
f-< 8

FBE570

BE-7
C~H~A~S~SI:S~H:A~R;'N:E~S~S-- ~BO~~D~Y~E~L~E~C~T~R~1C:A~L
~W~I
R~I~N~G~ _

~
;::::
~
;t, fl
Z.<;; ~0 .~
..z ;:J bl)

0
0
<:: .s
E-< u Ii)

~ ~

FBE571

BE-8
 LIGHTING SYSTEM

LIGHTING SYSTEM
A WARNING: BULB REPLACEMENT BULB REPLACEMENT
Before starting to work on any part of
1. Remove lens retaining screws. 1. Remove lens retaining screws.
electrical system, remove rings and
2. Remove bulb. 2. Remove bulb by pushing it in and
jewelry to prevent an accidental short turning it left.
circuit, turn off key switch and then

Ai1
disconnect battery connector.

BULB SPECIFICATIONS

Item
Wattage
S b'lli ~o"",,

48V

Headlamp

Front turn signal lamp

23W

23W
""'-- F_B_E_3_7....l9 i Stop/ r
Rear combination lamp Tail bulb
Back-up lamp lOW
FRONT TURN SIGNAL LAMP
T,m b'lli L I

OW

n
Rear turn signal
25W REMOVAL AND INSTAllATION
lamp
1. Remove lens retaining screws.
Stop and tail lamp 25W/lOW
2. Disconnect lead wires from
Back operation lamp 23W harness at connections. Rear Pillar~
3. Installation is in the reverse order
of removal.
FBE573

CHECKING WARNING LAMP BULB REPLACEMENT

When the key switch is turned past 1. Remove lens retaining screws.
ON position, all warning lamps come 2. Remove bulb by pushing it in and BACK OPERATION LAMP
on unless they are blown out. Check turning it left. Bulb replacement procedure is the
the lamps and replace if necessary.
same as for headlamp.

j
I

(<V)

~I (CD)

Brake fluid level

Low voltage warning lamp ~ Bock 'P,mU,"
warning lamp FBE572 lamp
FBE574

HEADLAMP REAR COMBINATION LAMP

REMOVAL AND INSTAllATION REMOVAL AND INSTALLATION KEY SWITCH
1. Remove lens retaining screws. REMOVAL AND INSTAllATION
1. Remove retaining bolts.
2. Disconnect headlamp wires from 2. Disconnect lead wires from har- 1. Disconnect battery connector.
harness at connections. ness at connections. 2. Remove front upper panel and
3. Install headlamp in reverse order 3. Install rear combination lamp in front lower panel of meter panel.
of removal. the reverse order of removal.

BE-9
 LIGHTING SYSTEM

3. Remove ring nut from key switch. INSPECTION

Test continuity through turn signal
switch with ohmmeter or test lamp.

(waSher
(;;fJiRing"UI
3

LMmu~" , N

L
FBE383

INSPECTION FBE388
4. Disconnect harness connector, Test continuity through lighting
and remove key switch. switch with ohmmeter or test lamp.
5. Install key switch in reverse order
of removal. STOP LAMP SWITCH
The stop lamp switch is integral
part of the brake pedal. After instal-
INSPECTION ~ lation, adjustment is required.
Test continuity through key switch
~
with ohmmeter or test lamp.
REMOVAL AND INSTALLATION

1. Disconnect battery connector.

2. Disconnect lead wires at connec-
~~ ~'" no,","
tors.
FBE576
~ OFF0@ 3. Loosen lock nut. Switch assembly
can then be taken out by rotating

A~,on
switch.
TURN SIGNAL SWITCH 4. Install in the reverse order of
removal.
REMOVAL AND INSTALLATION
1. Disconnect battery connector.
FBE384
2. Remove front upper panel and
front lower panel of meter panel.
3. Disconnect harness connector.
4. Loosen turn signal switch re-
taining screws and then remove turn
signal switch.
LIGHT/BACK OPERATION 5. Install turn signal switch in reverse
LAMP SWITCH order of removal.
REMOVAL AND INSTALLATION
1. Disconnect battery connector.
2. Remove front upper panel and
front lower panel of meter panel.
3. Remove switch knob by pushing INSPECTION
it in and turning it left. Test continuity through stop lamp
4. Remove switch retaining nut. switch with test lamp or ohmmeter.
S. Pull switch downward and dis- When plunger is pressed into switch
connect. assembly, stop lamp switch contact
6. Install lighting switch in reverse are open. Contacts are closed when
order of removal. plunger is projected.

BE-10
 METERS / ELECTRICAL ACCESSORIES

METERS

BATTERY CAPACITY METER 5. Remove hour meter and battery

AND HOUR METER capacity meter.

REMOVAL AND INSTALLATION

1. Disconnect battery connector.
2. Remove front upper panel.

FBE394
4. Remove front lower panel.

6. Install hour meter and battery

capacity meter in reverse order of
removal.

3. Disconnect harness connectors

and remove rear upper panel with rear
lower panel. FBE392

ELECTRICAL ACCESSORIES

BACK-UP WARNING CONTROL VALVE SWITCH Clearance between roller and dog:
BUZZER REMOVAL 0.5 -1.0 mm
REMOVAL AND INSTALLATION (0.020 - 0.039 in)
Remove control valve switch.
1. Remove retaining screw.
2. Disconnect lead wires from har- ~Dog
ness connector. rI
,, .. ;-RoUer

Control
valve
switch

0.5.1.0mm
FBE122
(0.020 .0.039 in)
FBE579

INSTALLATION INSPECTION
1. Install control valve switch. Be sure that continuity exists between
2. Adjust nuts so that clearance the two terminals on the switch when
3. Install back-up warning buzzer in between roller and dog is within speci- the roller is pushed down by the
reverse order of removal. fications. dog.

BE-11
 LOCATION OF ELECTRICAL UNIT

LOCATION OF ELECTRICAL UNIT

SEAT RELAY, POWER STEERING
RELAY

Seat
relay

Power
steering
relay

FBE581

HORN RELAY, BULB CHECK

RELAY, FLASHER UNIT
'----
Horn relay
I
Bulb check relay
(g9J

HORN, PARKING BRAKE BUZZER

BE-12
 BATTERY

BATTERY

REMOVAL AND CHECKING SPECIFIC When miXing, always pour sulfuric

INSTAllATION GRAVITY acid into distilled water. If this is
reversed, not only heating and break-
1. Disconnect battery connector. ELECTROL YTE
age of container can occur but it is
2. Open top panel and securely hook
The battery unit used in forklift trucks also very dangerous. Therefore, use
it to overhead guard. Then remove side
is essentially the same as those for utmost care when mixing.
panels.
conventional motor vehicles, except
3. Align hoist with center of notch
that it contains more liquid and is
in overhead guard provided for battery
composed of more cells. It is, there-
removal, and then lift battery with a
fore, recommended to keep ready a
hanger. Move the hoist to the right
mixture with specific gravity of 1.400.
until battery is away from forklift
truck, and carefully lower battery.
MIX1NG AMOUNT OF SULFURIC ACID AND
DISTILLED WATER

Quantity of sulfuric acid Quantity of sulfuric acid

Specific gravity of per one liter (2-1/8 US pt, (S.G. 1.400) per one liter
sulfuric acid 1-3/4 Imp pt) of (2-1/8 US pt, 1-3/4 Imp pt)
[20oC (68°F)] distilled water of distilled water
Q (US pt, Imp pt) Q (US pt, Imp pt)

1.200 0.22 (1/2, 3/8) 0.72 (1.1/2,1-1/4)

1.210 0.23 (1/2, 3/8) 0.88 (1-7/8,1-1/2)
1.220 0.25 (1/2, 1/2) 1.04 (2-1/4,1-7/8)
1.230 0.26 (1/2, 1/2) 1.20 (2-1/2, 2-1/8)
1.240 0.28 (5/8, 1/2) 1.36 (2-7/8,2-3/8)
1.250 0.29 (5/8, 1/2) 1.52 (3-1/4, 2-5/8)
1.260 0.31 (5/~, 1/2) 1.68 (3-1/2, 3)
1.280 0.34 (3/4, 5/8) 2.00 (4-1/4,3-1/2)
1.300 0.38 (3/4, 5/8) 2.32 (4-7/8,4-1/8)
1.400 0.62 (1-3/8,1-1/8)

FBE583

BATTERY FREEZING
Freezing
Specific gravity
4. Install battery in the reverse order Electrolyte freezes at low temper- temperature
15°C (59°F) 0C (OF)
of removal. atures. Freezing will ruin a battery.
Always place battery in a warm, dry
place when not in use for an extended 1.000 0(32)
period of time. 1.050 -3.3 (26)
CHECKING 1.100 -7.7 (18)
ELECTROLYTE lEVEL 1.150 -15.0 (5)
Open upper panel and check elec- 1.200 -27.0(-17)
trolyte level. 1.250 -52.0 (-62)
Refer to battery manufacturer in- 1.300 -70.0(-94)
structions for inspection procedures.
1.350 -49.0 (-56)
1.400 -36.0 (-33)
1.450 -29.0 (-20)
1.500 -29.0 (-20)
1.600 ~14.0 (-7)
1.835 -34.0 (-29)

BE-13
 BATTERY

RELATIONSHIP BETWEEN ELECTROLYTE TEMPERATURE AND SPECIFIC GRAVITY

Specific gravity conversion table

Specific gravity (fully charged battery)

Conversion graph (S.G. vs temperature)
..............
Electrolyte Electrolyte
1.320 1.280 1.280
""'-... ....... ....... temperature temperature
20°C (68°F) 20°C (68°F)
""'-... .............. ............. °C eF) °C eF)
1.300 ...........,
.............. .........
....... ...........
""'-... ......... ....... ""'-... ........ 50 (122) 1.259 14 (57) 1.284
1.2S0 ............. .......
en ""'-... ........ ............. .......... ....... r---....... 1.;]00 48(118) 1.260 12 (54) 1.286
e .............. ....... ....... ..........
31.260 .............. ....... .......
.............
........... .........
........
.......
r---.......
r--.........
-
LL 46 (115) 1.261 10 (50) 1.287
~ ....... .......
1.?80 c
00
8-
E 1.240
""'-... ........... ............ ........ r---....... ~ 44 (Ill) 1.263 8 (46) 1.288
.............. ....... ............. ..........
...
CIl

""'-...
.......
.........
........ .............
..........., .......
........ r--.........
........ i'.......
1.260 U
c
0 42 (108) 1.264 4 (39) 1.290
~ 1.220
.Q
... ..............
....... .......
....... .......
........... ............ .......
....... r---....... 1.240 ...
N
CO 40 (104) 1.266 4 (39) 1.291
CO
~ 1.200
""'-... ........... ............ ....... r---....... ~
""'-... .............. .......... .:;: 38 (100) 2 (36)
CO ............. ........ r---....... 1.220 1.267 1.293
> ..........., .............. .......... ~
............. ........ r--......... 0>
.; 1.1S0
......... 36 (97) 1.268 0(32) 1.294
'"... .............. ........ ............. ............ ........ i'....... 1.200 ~
.u
0> ....... .......
.............. ........... ............ ....... r---....... Q) 34 (93) 1.270 -2 (28) 1.295
~ 1.160 ..........., ....... ....... Co
............. .......... ........ r---....... en
.u
8- 1.140 ..........., ............... .........
'.'e.
-.....::!! 32 (90) 1.271 -4 (25) 1.297
en
............. ........ r--.........
.........
.............. ....... ............. ............ ....... i'....... 1. 30 (86) 1.273 -6 (21) 1.298
....... ....... ........... ............ '60
1.120
....... r---.......
............. .......... ........ r---....... 28 (82) 1.274 -8 (18) 1.300
'.'40
......... ........ r---.......
1.100 26 (79) 1.275 -10 (14) 1.301
........ i'....... '.'20
r---....... 24 (75) 1.277 -12 (10) 1.303
1.0S0
-20 -10 0 10 20 30 40 50 60 22 (72) 1.278 -14 (7) 1.304
(-4) (14) (32) (50) (68) (S6}(104}(122)(140)
Electrolyte temperature °C (0 F) 20 (68) 1.280 -16 (3) 1.305
18 (64) 1.281 -18 (0) 1.307
16(61) 1.283 -20 (-4) 1.308

RELATIONSHIP BETWEEN SUPPLY OF DISTILLED WATER PRECAUTIONS WHEN

SPECIFIC GRAVITY AND
If electrolyte level is below prescribed CHARGING
DISCHARGING
level, add distilled (purified) water If battery falls below 80% [Specific
Changes in specific gravity of elec- only. Distilled water is available at gravity: 1.152 at 20°C (68°F)] of
trolyte are proportional to rate of dis- gas stations. It is, however, recom- rated capacity [Specific gravity: 1.280
charge and recharge. It is therefore mended to keep your own distilled at 20°C (68°F)] or the voltmeter
possible to estimate charging and dis- water available for use. reading is 41 volts (at this value, lift
charging rates by finding out specific can be raised with no load) during
gravity at any time. operation, be sure to charge battery.
STORAGE AND INSPECTION
OF BATTERY
...>
CIl

Be sure battery is fully charged be- BEFORE CHARGING

etl
CIl _
1.280
1260
1.240
Specific gravity of electrolyte
(fully-charged battery) I fore placing it in storage. 1. Charging should be performed in
"i)LL I .220
_ 0
Before charging, add distilled water so a warm and well ventilated plate. [Pre-
o 00 1200 -- ---- - - - --- Specific gravity
>~ I 180 : of electrolyte that electrolyte is a little higher than ferably with outdoor or indoor tem-
.'= U I 160
I
I the prescribed level. perature higher than 15°C (59°F)]
~~ I 140 I Fully- When not in use, battery should be
O>N
u
2. Make sure that battery filler cap
I 120 :disCharged state
~
.u I 100 stored in a warm and dry place free holes are not clogged.
o 10 20 30 40 50 60 70 80 90 100
8- - Discharge rate (%) from dust. Check specific gravity from 3. Leave fl11ercaps loose.
en 100 90 80 70 60 50 40 30 20 10 0
time to time and, when it is below 4. Add distilled water up to the pre-
Charging rate (%)-
1.200, charge the battery. scribed level if needed.

BE-14
 BATTERY

DURING CHARGING 2. When electrolyte temperature ex- AFTER CHARGING

ceeds sooe (122°F), stop charging
1. Keep battery away from any 1. Securely tighten filler caps.
until it is between 400e (104°F) and
inflammable object. (Make sure bat- 2. Wipe clean the top face of each
1Soe (S9°F). cell and surrounding area with a dry
tery is well ventilated.)
cloth.

BE-15
 WIRING DIAGRAM

WIRING DIAGRAM

PARKING BRAKE BULB FUSE BLOCK

TURN BRAKE FLU ID CHECK HORN
HEAD SI GNAL --em T ~.?

~~mm
OR F'-'
LAMP LAMP BR-

~ Y --og M ~I
HORN PARKING
_ G --a L 0lLJ. B CONTROLLER

B~c1
IM1BRAKE
0
w

~'~ Ltr-&-J BU%TR - p --a

REAR
COMBINATION
LAMP R. H.
--em oleo
K w -DD
t?l 9 t?l
.--- G Y B

~[J ~Q QQ [J [J W1 W1
V)
:::>
u. P -D
STOP

CD Cl: CD a:: a. - ....

:!:
R-{]::J

U r7ll~~~~MAN
mSWITCH
:::>
a.
TURN
REV
GY -(J

0: '" 0: [J Q ~ ~ OR -{]::J

gOIJ 0. 0: -' TAIL

[J~Q I
.-- R -D<lD- R
~ CD a:
- B -DDD B

~R:~
----'
I 111r
GY
OR
GY-
OR
-

I--- ORiP
BACK
OPERATION
LAMP

JYI
~

OgO
III ...J
'--
~
pu

B
Y
P
OR I0 PU

B
Y
P
OR
!Y

'--
GY-(J

LiP
p

B
-D
-DD
REV
TURN

STOP
[Jij REAR
COMB INA TI ON
0: '" 0: LAMP L. H.
WIRE COL R DING
I I

I-
a:: CI m >- Black BR = Brown
B
-
l tH~0 W
R
White
Red
OR = Orange
P Pink

[l
::>0:>- G Green PU = Purple
m 0:: CD 0:.
0."'''' >-0. '"
L Blue GY = Gray
gO 'DO ~ ~ ~
Y
LG =
Yellow
Light Green
SB = Sky blue

~ ~ ~

In caseof color coding using a Stripe.

~~
HEAD TURN
~~@i BATTERY
CAPACITY
METER
0-
:I:
0-
u.
BACK
BUZZER
:t
.J
ll::
W
Z
:t
.J
ll::
W
0-
:t
a: a:
ll::
W
Z
:t

ll::
W
0-
REACTOR
POWER
STEERING
RELAY
STEERING
MOTOR
BaseColor is given first, followed by
the Stripe Color:

Example: L/W = Blue with White Stri

LAMP SIGNAL KEY egE5R~RATOR (:J w Z :::> z :::>
L. H. LAMP >-< .J
L. H. SWI TCH CONTROL ll:: ~ LIGHT
SWITCH
>-< 0 >-< 0 CONNECTORS
FORWARD-
TURN
SIGNAL
REVERSE
CONTROL IE Pin.type connector (Male)
SWITCH SWITCH
WARNING LAMP UNIT tffi Pin-type connector (Female)

EE3 Plain-type connector (Male)

This wiring diagram has been prepared according

tffI Plain-type connector (Female)

to the assumption that the lift truck is fully equipped -0 ao- Bullet connector
(oncludongall factory optional equipment). (Female and male)

Plain connector

FBE584

BE-16